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BACKGROUND OF THE INVENTION
This invention relates generally to devices which are employed for positioning the limbs of a patient for medical procedures. More particularly, this invention relates devices which are employed for positioning the shoulder and arm of a patient.
A number of devices have been advanced to provide for the proper positioning of limbs for therapeutic or medical purposes. In this regard, complex traction systems employing cords and pulleys have conventionally been employed to obtain and maintain the proper positioning. In surgical procedures to which the invention relates, a positioning apparatus is required to "open" the joint to allow for insertion of surgical instruments while immobilizing the associated joint and limb at a fixed position for a given time and readily permitting repositioning to subsequent succeeding fixed positions. In arthroscopic surgical procedures performed on the shoulder of a patient, the optimum abduction position of the shoulder/arm ordinarily ranges between a 25° and 45° angle of abduction relative to a horizontal axis. The present invention has particular applicability in connection with maintaining the proper shoulder abduction angle for arthroscopic surgery procedures or for any surgical procedures performed on the shoulder and proximal regions.
SUMMARY OF THE INVENTION
Briefly stated, the invention in a preferred form is an apparatus which is adapted for positioning the shoulder of a patient for arthroscopic surgery or other surgical procedures. The apparatus includes a pair of laterally spaced support members which are mounted in parallel upright disposition. Table clamps mount the members to the rails of the operating table. A crossbar extends laterally relative to the support members. A manually operable drive mechanism is mounted to the crossbar for variably displacing a positioning shaft. A second crossbar laterally extends relative to the support members to mount a boom. The boom generally transversely extends from a forward end to a rear end. A pivotal linkage connects the rear end with the positioning shaft. An abduction sling assembly is suspended from the boom for supporting the upper arm and for abducting the upper arm to provide a separating or abducting force on the shoulder. The forearm is provided with longitudinal traction by attaching a well padded forearm holder and applying a tensional force to the forearm. Upon placing the arm of a patient in the abduction sling assembly, the forward end of the boom may be selectively raised and lowered by manual operation of the drive mechanism to abduct the shoulder of the patient.
In one apparatus embodiment, the drive assembly comprises a crank which is manually angularly displaceable for displacing the positioning shaft. The sling assembly includes a collar which is suspended from the forward end of the boom by means of a cord. A tension indicating device connects the cord at the forward end of the boom for indicating the tension exerted against the collar. The abductor sling also comprises an arm extender of padded flexible form which is attachable to the arm of the patient for extension of the arm. The extender includes a cord which is mounted to two pulleys and connected to a weight train. The support members may be generally L-shaped members. The boom may be variably laterally positionable relative to the second crossbar.
An object of the invention is to provide a new and improved shoulder positioning apparatus for obtaining and maintaining the proper angle of abduction of the shoulder and the arm.
Another object of the invention is to provide a new and improved surgical shoulder positioning apparatus having an efficient construction wherein the abduction and longitudinal traction of an arm/shoulder may be obtained and maintained in an efficient manner which does not unduly interfere with the surgical procedure.
A further object of the invention is to provide a new and improved shoulder positioning apparatus which is easily adaptable for use on an operating table to obtain the proper abduction and separation of a patient's arm/shoulder for arthroscopic surgery and other medical procedures.
Other objects and advantages of the invention will become apparent from the drawings and the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a surgical shoulder positioning apparatus of the present invention illustrated in conjunction with a patient; and
FIG. 2 is a fragmentary perspective view of the shoulder positioning apparatus of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the drawings wherein like numerals represent like parts throughout the figures, a surgical shoulder positioning apparatus in accordance with the present invention is generally designated by the numeral 10. The shoulder positioning apparatus 10, in its preferred application, is adapted for mounting to an operating table 12 for maintaining the proper abduction and separation of a shoulder/arm for purposes of arthroscopic surgery or other surgical procedures. For purposes of illustration in FIG. 1, the shoulder positioning apparatus is connected to a patient P in a fixed operative position for performing surgery on the shoulder of the patient.
The optimal abduction angle ordinarily lies in the range of between 25° and 45° to the horizontal axis. The proper abduction position will vary in accordance with a given patient and the procedure to be performed and may also change during the course of the operation. While apparatus 10 has other applications, the shoulder positioning apparatus 10 is especially adapted for efficiently obtaining and maintaining the proper abduction of the shoulder for arthroscopic surgical procedures.
The apparatus 10 is adapted for mounting to an operating table 12 for disposition generally above the patient P. The apparatus connects to separate locations of the lower and upper arm of patient P so as to abduct the shoulder and thereby separate the shoulder joint, as will be detailed below. The operating table 12 includes rails 14 of conventional form and function which are preferably used to mount the shoulder positioning apparatus.
A pair of substantially identical upright support members 20 and 22 are secured to the operating table by means of table clamps 24. Support members 20 and 22 may be manufactured from rectangular or rounded tubular steel or similar materials. The support members have a generally L-shaped configuration, including a diagonal brace. The legs of the support members are received in slides of the table clamps 24 and secured in fixed position to the table clamps by means of a knob operable clamp screw 26. A second set of manually operable clamp screws 28 secure the table clamps to the operating table rails 14 at a fixed position along the rails. The upright support members 20 and 22 project above the operating table in a generally parallel vertical orientation. The apparatus is longitudinally positionable along the rails 14 of the operating table, as required. During usage, the longitudinal position is securely fixed by the clamp screws 26 and 28.
A pair of substantially identical bracket connectors 40 are slidably mounted to the support members. The connectors 40 form a slot which is dimensioned to be approximately commensurate with the section of the support members 20 and 22 so that the connectors are engageable slidable along the supports. The connectors are secured in a rigid, fixed intermediate position by means of a clamp screw 42. The screw 42 is threadable through the side of the connector and receivable in one of a vertical series of apertures 44 of the support member for securely locking each bracket connector in the fixed vertical position.
A pair of corresponding connector bosses 46 extend rearwardly from the bracket connectors 40 for receiving a crossbar 50. Crossbar 50 extends in a generally horizontal orientation through the bosses 46. A connector block 54 is slidably received on the crossbar 50. A clamp screw 56 threaded to block 54 tightens against the crossbar to secure the block 54 at a fixed lateral position along the crossbar 50.
The top of the connector block 54 has an opening (not illustrated) which receives a stud (not illustrated) projecting downwardly from a crank housing 60 for mounting the crank housing to the connector block. A crank 62 extends rearwardly from the crank housing 60. Manual rotatable movement of the crank 62 results in a longitudinal displacement of a positioning shaft 64 which essentially reciprocates relative to the housing 60. The crank housing encloses a screw and a threaded interior end portion of the positioning shaft 64. For example, a clockwise rotation to the crank threadably displaces the positioning shaft 64 from the housing. A counter-clockwise rotation threadably retracts the positioning shaft into the housing. The position of the shaft 64 determines the abduction angle.
A swivel connector 68 is rigidly connected at the end of the positioning shaft 64. A lower end of a rod-like arm 70 is pivotally connected to the swivel connector 68. The upper end of the arm 70 is pivotally connected to a second swivel connector 72. A pulley 78 is mounted to the arm 70 at a fixed intermediate location.
A pair of substantially identical yokes 74 mount over the top portion of the upright support members 20 and 22. A crossbar 80 similar to crossbar 50 extends between the yokes in a generally horizontal orientation. Crossbar 80 is also parallel to crossbar 50. A connector block 82 having two orthogonal through bores is slidably received by the crossbar 80. The connector block 82 is secured in adjustably fixed lateral position by means of elastomeric collars 84. The collars 84 are positioned against lateral sides of the connector block and resiliently, frictionally engage against the crossbar 80 to prevent movement of the connector block 82 along the crossbar. The collars 84 may be laterally displaced to change the lateral position of the connector block.
An elongated abductor boom 90 of bent or angled configuration extends through the block 82 to connect in a fixed transverse relationship to the connector block. The rear portion of the abductor boom 90 rigidly connects with the swivel connector 72. A longitudinally positionable pulley 92 is mounted to the abductor boom 90. A loop 94 at the end of the boom secures a tension scale 96. The tension scale may assume a wide variety of forms. In one embodiment, the tension scale 96 is capable of readings from 0 to 30 pounds.
With reference to FIG. 1, a cervical collar 100 is adapted to be secured to patient P under the upper arm biceps portion. The collar 100 connects via a cord 102 fastened to a hook at the end of the tension scale 96 for suspension from the front end of the abductor boom. The upward tension exerted by the collar functions to abduct the patient's shoulder. The tension scale 96 provides an indicator for monitoring the abduction tension during the medical procedure.
A padded arm holder 106 of flexible material is wrapped around the lower portion of the arm and hand. A tension cord 108 leads from the outer end portion of the arm holder 106 upward through boom pulley 92 and pulley 78 which is mounted to the fulcrum arm. The end of the cord is secured to a weight tray 110. The tension exerted through the cord to the arm holder functions to extend the arm. Pulley 92 may also be attached to crossbar 80 or 50 or arm 70.
The shoulder positioning apparatus 10 provides an efficient means for correctly positioning the shoulder of a patient for arthroscopic surgery or other surgery and other related procedures. The cervical collar 100 is positioned under the upper arm of the patient. The holder 106 is wrapped around the lower arm/hand portion. The abductor boom 90 is manually raised or lowered through crank 62 to the proper height for abducting the upper arm and shoulder. The tension of the cord 108 functions to extend the arm straight out from the shoulder.
The correct positioning and/or repositioning of the shoulder is obtained by the crank handle. Upon rotary movement of the crank handle, the positioning shaft 64 connects via the arm 70 linkage for raising and lowering, as desired, the abductor boom. The extension of the arm is maintained during the raising and lowering process. In one embodiment of the invention, the end of the boom has a vertical displacement of approximately 40 inches from the maximum to the minimum position of the crank drive fulcrum 64.
The lateral position of the abductor boom 90 relative to the patient may be suitably obtained by sliding the connector blocks 54 and 82 along the respective crossbars. The blocks 54 and 82 are secured in position by the respective set screw 56 and locating collars 84. The shoulder abduction is obtained without causing undo interference with the surgical procedure.
While a preferred embodiment of the invention has been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations, and alternatives may occur to one skilled in the art without departing from the spirit and the scope of the present invention.
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A surgical shoulder positioning apparatus comprises a pivotally positionable abductor boom. An abductor collar and an arm extender may be suspended from the boom. The boom is variably positionable to obtain the proper abduction orientation of a shoulder for shoulder surgery. The abductor boom is mounted on a crossbar extending between a pair of upright support frames which are mounted to the operating table.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application incorporates by reference U.S. patent application Ser. No. 10/337,896, now U.S. Pat. No. 6,774,098, filed Oct. 10, 2002, entitled “Methods For Removing Stains From Fabrics Using Tetrapotassium EDTA,” which claims priority to U.S. Provisional Application Ser. No. 60/423,978, filed Nov. 6, 2002, entitled “A Subclass of Aqueous, Hard Surface Cleaners Used in A New and Unobvious Soft Surface Cleaning Application.” The present application also incorporates by reference U.S. patent application Ser. No. 10/612,016, filed Jul. 3, 2003, and U.S. patent application Ser. No. 10/373,787, filed Feb. 27, 2003, both of which are entitled “Methods and Equipment for Removing Stains from Fabrics.”
TECHNICAL FIELD
This invention relates to a fabric having a pattern of fades and a methodology for their creation. The fades are made by exposing selected areas of the fabric to a hypochlorite salt-containing composition.
BACKGROUND
Fades on garments and other apparel are popular among all age groups, both female and male. Due to its popularity to the consumers, jean manufacturers have developed various methods to produce fades on jeans or denims to achieve a faded look. One method employs washing denims with a cellulase enzyme to release the denim's color, which produces light or white areas and lightens the dark areas (see U.S. Pat. Nos. 4,832,864, 4,912,056, 5,006,126 and 5,122,159). However, the use of enzymes to create a faded appearance can also at the same time be used to desize or shrink a fabric or garment. Thus, extra care and precision are needed if one were to employ an enzymatic approach.
Another method, as disclosed in U.S. Pat. No. 4,740,213, uses pumice stones impregnated with fluid having powerful bleaching properties to create a random faded effect on the fabric when the stones and fabric are tossed together, such as in a dryer or other tumbling apparatus. However, this process, commonly known as “stone-washing,” produces uneven faded patches that vary in color shades and intensity, which, due to the random admixture, spread out in a non-uniform manner over the entire fabric being treated. These whole-fabric techniques do not permit treating specific areas of the fabric individually. Moreover, the use of strong bleaching agents is inherently harmful to the fabric.
Another technique to produce fades on fabric employs lasers. A laser method to mark and fade textiles, as disclosed in U.S. Pat. No. 5,567,207, involves exposing a textile or fabric to laser radiation of sufficient intensity. Such exposure photo-decomposes the coloring agent within the material without causing damage to the underlying textile or fabric. The pre-dyed material is scanned by a laser beam to produce uniform fading and patterns of photo-bleached marks on the textile material. Despite the possibility of great precision and potential for print-like art quality, this method is more expensive, time-consuming, and generally unavailable to consumers.
Unlike the above-mentioned methods, the present invention is simple, safe and readily available to consumers. The present invention can be done at home and allows the end users to selectively choose an area of the fabric where he or she wants to impart a customized and desired faded appearance, with a hand-art quality, either uniformly or non-uniformly. Additionally, there is a need for fabric having a pattern of fades thereon that can be customized by the consumers in a cost-effective manner and is a product of the consumers' artistic creation.
SUMMARY OF THE INVENTION
The present invention is directed to a fabric that comprises a pattern of fades produced by a method that includes (i) contacting a hypochlorite salt-containing composition on at least one portion of the fabric, wherein the hypochlorite salt-containing composition comprises an alkali metal hydroxide and a hypochlorite salt, and (ii) inactivating or removing the hypochlorite salt-containing composition from said at least one portion of the fabric to obtain a desired pattern of fades on the fabric. In one embodiment, the application of the hypochlorite salt-containing composition is performed at room temperature and the removal or inactivation of the hypochlorite salt-containing composition is achieved by a cold water wash.
In another embodiment, the hypochlorite salt-containing composition comprises an alkali metal hydroxide and a hypochlorite salt. In a preferred embodiment, the alkali metal hydroxide is sodium hydroxide and the hypochlorite salt is sodium hypochlorite. The weight concentration ratio of sodium hydroxide over sodium hypochlorite is no less than 1:12.5. In another embodiment, the weight concentration ratio of sodium hydroxide over sodium hypochlorite ranges from about 1:5 to about 5:1. In yet another embodiment, the weight concentration ratio of sodium hypochlorite over sodium hydroxide is about 2:1. In a further embodiment, the pH of the hypochlorite salt-containing composition is at least 11.8. It can also be, for example, at least 12, 12.5, or 13.
In yet another embodiment, the hypochlorite salt containing composition includes at least 0.2, 0.3, 0.5, 1, 2, 3 or higher weight percent of sodium hydroxide. In a non-limiting example, the concentration of sodium hydroxide ranges from 0.5-5.5 weight percent.
In a further embodiment, the hypochlorite salt is sodium hypochlorite whose concentration ranges from 0.1-11.0 weight percent or 1.0-2.5 weight percent. In a non-limiting example, the hypochlorite salt containing composition contains about 2.5% weight percent of sodium hypochlorite and 0.5. to 1.25 weight percent of sodium hydroxide. In another embodiment, the hypochlorite salt containing composition includes about 6 weight percent of sodium hypochlorite and 1.2 to 3 weight percent of sodium hydroxide. In yet another embodiment, the hypochlorite salt containing composition contains about 8 weight percent of sodium hypochlorite and 1.2 to 4 weight percent of sodium hydroxide. In still another embodiment, the hypochlorite salt containing composition includes about 11 weight percent of sodium hypochlorite and up to 5.5 weight percent of sodium hydroxide.
The hypochlorite salt-containing composition can be applied for successive intervals to produce successive faded hues. It can be applied as a liquid or a gel. In addition, it can be applied by means of a gel stick, microspray jet, fabric dye brush or any other appropriate applicators for generating artwork on a canvass. The duration of the application may depend on the formation of faded hues, as pre-determined by the end user. In a non-limiting example, the duration of application ranges from at least 1 minute to 30 minutes.
The hypochlorite salt-containing composition can be employed in various concentrations on a given fabric. The duration of application to achieve the formation of a variety of faded hues on a fabric can be standardized, such as in a commercial usage of the present invention. Instead of multiple, time-spaced passes over the fabric applying the full strength composition, one application from multiple sources of varying concentrations to achieve the desired variegated effect can be put down, thereby minimizing handling of the fabric and simplifying the production process. At the end of a predetermined treatment time, the treated fabric can be inactivated, such as by cold water immersion.
In one embodiment, the formation of the fades pattern on the fabric is dyed with another color or left as the fabric base color. It can be formed by means of free hand, template guide or machine operation. A preferred fabric is cotton and preferred garments are denim jeans or trousers.
In another embodiment, a method and a kit for the production of fabric having a pattern of fades are also provided in the present invention.
In a further embodiment, a device to manufacture the fabric having a pattern of fades is also contemplated. The device of the present invention includes a surface where the fabric is placed upon and at least one dispenser disposed adjacent to the surface. To produce a pattern of fades on the fabric, at least one dispenser relatively moves to the fabric and applies the hypochlorite salt-containing composition to the fabric. In addition, at least one dispenser may include a plurality of dispensers that relatively moves to the fabric and applies a hypochlorite salt-containing composition to the fabric. The device may further include at least one template that is placed atop the fabric. The hypochlorite salt-containing composition is applied through the template to form the pattern of fades on the fabric. The device may still further include a vat that is adjacent to the surface. After being in contact with the hypochlorite salt-containing composition, the treated fabric is inactivated, such as by cold water immersion in the vat.
Other features, objects, and advantages of the present invention are apparent in the detailed description that follows. It should be understood, however, that the detailed description, while indicating embodiments of the present invention, is given by way of illustration only, not limitation. Various changes and modifications within the scope of the invention will become apparent to those skilled in the art from the detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawings ( FIGS. 1-5 ) will be provided by the Office upon request and payment of the necessary fee. The drawings are provided for illustration, not limitation.
FIG. 1 is frontal view of a denim patch that has been treated with a 6% hypochlorite salt-containing composition for 1.5 to 30 minutes, pursuant to the present invention. Reference numerals 10 and 70 show dark blue and white patches, respectively;
FIG. 2 is a frontal view of a faded denim patch of a first fade artwork labeled as “The Comic;”
FIG. 3 is a frontal view of a faded denim patch of a second fade artwork labeled as the “Eye of the Hurricane;”
FIG. 4 is a frontal view of a faded denim patch showing of a third fade artwork labeled as the “Blossom and Bow;”
FIG. 5 is a frontal view of the fade artwork of FIG. 4 , wherein another dye color (red) is applied to a bleached-out section of the fabric portraying the flower blossom;
FIGS. 6A and 6B are side and top views, respectively, of a device used to produce pattern of faded hues in a fabric according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is based on the surprising discovery that a hypochlorite salt-containing composition, which contains a metallic salt of hypochlorous acid and an appropriate amount of alkali metal, can not only be used as a cleaning composition but can also be used to non-destructively and conveniently create a pattern of fades on a fabric. The fades are formed by the application of the hypochlorite salt-containing composition on one or more selected portion(s) of the fabric. The fades action can be stopped by removal, dilution, or otherwise inactivation of the hypochlorite salt-containing composition when a desired fades formation is produced.
Without limiting the present invention to any particular mechanism, Applicant has found that alkali metal hydroxide (such as sodium hydroxide) adds significantly to the cleaning power of sodium hypochlorite to remove stains, such as menstrual fluid or underarm perspiration stains, from clothes and other soft fabric articles, while significantly increasing the compatibility of sodium hypochlorite with soft fabric, such as cotton fabric, thereby preventing sodium hypochlorite from damaging the fabric. The discovery of the hypochlorite salt-containing composition as an effective cleaning composition is disclosed in co-pending U.S. patent application Ser. Nos. 10/373,787 and 10/612,016, incorporated by reference herein.
The metallic salt of hypochlorous acid preferably is sodium hypochlorite. The alkali metal hydroxide preferably is sodium hydroxide. It should, of course, be understood that other hypochlorous salts and/or alkali metal hydroxides can also be used in the present invention.
Sodium hypochlorite (NaOCl) dissolves in water to sodium and hypochlorite ions. The hypochlorite ion is a strong oxidant which can react with numerous materials. The stability of the sodium hypochlorite composition is affected by the pH of the composition. It has been reported that sodium hypochlorite is the most stable when the pH of the composition is between 11 to 13. Such a high pH can be created by adding excess alkali metal hydroxide, such as sodium hydroxide, to the sodium hypochlorite composition. Thus, the pH of the hypochlorite salt-containing composition preferably is at least about 11.8. For instance, the pH of the hypochlorite salt-containing composition can be at least 12, 12.5 or 13. In one embodiment, the pH of the hypochlorite salt-containing composition is about 13.
The decomposition rate of the hypochlorite ion increases when the pH of the composition falls below 11. This is because of the rapid acid-catalyzed decomposition pathway of the hypochlorite ion. The rate of decomposition also increases when the pH of the composition is over 13. This is due to the increase in the ionic strength of the composition caused by the increased level of excess alkali metal hydroxide added to the composition. The present invention finds, however, that even with a high ionic strength, the sodium hypochlorite/sodium hydroxide composition is effective in imparting a faded appearance on the fabric without any significant damaging effects. In addition, Applicant has found that addition of appropriate amounts of alkali metal hydroxide to a hypochlorite composition retards the damaging effect of the hypochlorite composition on soft fabric (such as cotton fabric).
The concentration of sodium hypochlorite in the hypochlorite salt-containing composition of the present invention is preferably at least 0.1% by weight, based on the total weight of the hypochlorite salt-containing composition. For instance, the concentration of sodium hypochlorite can be at least 0.5, 1, 2, 3, 4, 5, 6, 7 or 8% by weight. In one embodiment, the concentration of sodium hypochlorite ranges from 0.1 to 11% by weight. In another embodiment, the concentration of sodium hypochlorite is about 0.5 to 5% by weight. In yet another embodiment, the concentration of sodium hypochlorite is about 1 to 2.5% by weight. In still another embodiment, the concentration of sodium hypochlorite is about 1.5 to 2% by weight.
The concentration of sodium hydroxide in the hypochlorite salt-containing composition preferably is at least 0.2% by weight, based on the total weight of the hypochlorite salt-containing composition. For instance, the concentration of sodium hydroxide can be at least about 0.3, 0.4, 0.5, 1, 1.5, 2, 2.5, 3, 4 or 5% by weight. In one embodiment, the concentration of sodium hydroxide ranges from about 0.5 to about 5.5% by weight. In another embodiment, the concentration of sodium hydroxide ranges from about 1 to 2% by weight. It is generally known that an appropriate amount of alkali metal hydroxide (such as sodium hydroxide) increases the stability of sodium hypochlorite in the hypochlorite salt-containing composition.
Applicant has discovered that the weight concentration ratio of sodium hydroxide over sodium hypochlorite may vary substantially without affecting the ability of the hypochlorite salt-containing composition to form pattern of fades on fabrics. Preferably, the weight concentration ratio of sodium hydroxide over sodium hypochlorite is no less than 1:12.5. For instance, the weight concentration ratio of sodium hydroxide over sodium hypochlorite can be no less than 1:10, 1:5, 1:2.5 or 1:1.
In one embodiment, the weight concentration ratio of sodium hydroxide over sodium hypochlorite can range from about 1:5 to about 5:1. In another embodiment, the weight concentration ratio of sodium hydroxide over sodium hypochlorite is about 1:3 to about 1:1. For instance, the weight concentration ratio of sodium hydroxide over sodium hypochlorite can be about 1:2.
In another embodiment, the hypochlorite salt-containing composition includes about 6 weight percent of sodium hypochlorite and 1.2 to 3 weight percent of sodium hydroxide. In another embodiment, the hypochlorite salt-containing composition includes about 2.5 weight percent of sodium hypochlorite and 0.5 to 1.25 weight percent of sodium hydroxide. In still another embodiment, the hypochlorite salt containing composition contains about 8 weight percent of sodium hypochlorite and 1.2 to 4 weight percent of sodium hydroxide. In yet another embodiment, the hypochlorite salt containing composition includes about 11 weight percent of sodium hypochlorite and up to 5.5 weight percent of sodium hydroxide.
Other ingredients or additives can be added in the hypochlorite salt-containing composition. These ingredients or additives include, for example, chelating agents, phosphorous-containing salts, surfactants, or abrasive agents. These ingredients or additives, however, are not necessary for the fading formation function of the hypochlorite salt-containing composition. In one embodiment, the hypochlorite salt-containing composition is substantially free of chelating agents, phosphorous-containing salts, surfactants, and abrasive agents.
The hypochlorite salt-containing composition can be applied for successive intervals to produce successive hues of fades. In one embodiment, the application of the hypochlorite salt-containing composition is performed at room temperature (e.g., 68-72° F. or 21-23° C.) and the inactivation process can be achieved by a cold water wash.
The composition of the present invention can be applied on the fabric as a liquid or gel by means of a fabric dye brush, gel stick, spray jet, e.g., microspray jet, or any other appropriate applicators for generating artwork on a canvass. In a non-limiting example, the duration of the application ranges from at least 1 min-30 min. In another example, an application time of less than 15 minutes produces partially bleached-out (dark) fades while an application time of approximately 30 minutes produces totally bleached-out (white) fades. In another embodiment, the faded pattern is dyed with another color or left as the fabric base color, typically white.
The fabric patterns formed by the hypochlorite salt-containing composition can be applied onto the fabric in a uniform and non-uniform faded manner to achieve a variety of effects. For example, contacting the fabric at certain duration with the hypochlorite salt-containing composition in a non-uniform manner produces an uneven faded appearance. Also, one can spot treat the pockets or certain sections of the denim jeans with the hypochlorite salt-containing composition at a certain time frame, while leaving the remainder of the fabric untreated, to produce an overall uneven or targeted faded look. Alternatively, one can evenly expose the entire fabric to a hypochlorite salt-containing composition to create a homogeneous faded appearance over the entire fabric.
In another embodiment, the present invention includes a method to produce a fabric having a pattern of faded hues. This method includes, for example, the steps of (i) contacting a hypochlorite salt-containing composition on at least one portion of the fabric, wherein the hypochlorite salt-containing composition comprises an alkali metal hydroxide. and a hypochlorite salt, and (ii) inactivating or removing the hypochlorite salt-containing composition from at least one portion of the fabric to obtain a desired pattern of fades on the fabric. The step of contacting the fabric with the hypochlorite salt-containing composition is performed at either a fixed concentration or varying concentrations of the hypochlorite salt-containing composition. The present invention can also further comprise contacting the fabric with the hypochlorite salt-containing composition by means of free hand, a template guide or machine operation.
The hypochlorite salt-containing composition of the present invention is available to consumers as a kit. The kit preferably includes a container of the hypochlorite salt-containing composition (e.g., in a spray bottle, gel stick, spray jet, e.g., a microspray jet, or any other appropriate applicators for generating artwork on a canvass), a flat fabric dye brush made of synthetic fiber, a labeled container box and an instruction sheet.
Sodium hypochlorite and sodium hydroxide can be separately stored prior to use. For instance, they can be stored in two separate compartments of a common container. The first compartment encloses a sodium hypochlorite composition, which preferably has a pH of between 11 and 13. The second compartment encloses a concentrated sodium hydroxide composition. The two compositions are mixed together upon use. An exemplary device suitable for this purpose is illustrated in U.S. Pat. No. 6,398,077, which is incorporated herein by reference. The two compositions may also, of course, be stored separately and mixed together in one of the containers or admixed into a third container.
In a further embodiment, the present invention contemplates a device for producing a pattern of fades on the fabric. The device comprises a surface where the fabric rests upon and at least one dispenser disposed adjacent to the surface. To form the pattern of fades according to the present invention, at least one dispenser relatively moves to the fabric and applies the hypochlorite salt-containing composition to the fabric. It should be understood that a plurality of dispensers that relatively moves to the fabric may be employed to apply a hypochlorite salt-containing composition to the fabric. The device may further include at least one template that is placed atop the fabric. The hypochlorite salt-containing composition is applied through the template to form the pattern of fades on the fabric. The device may still further include a vat that is adjacent to the surface. After being in contact with the hypochlorite salt-containing composition, the treated fabric is inactivated, such as by cold water immersion in the vat.
Fabrics suitable for the present invention can be made of a variety of materials, such as cotton, cotton/polyester, corduroy, rayon, canvas, linen, nylon, acrylic, flax, hemp, jute, ramie, polyester, polyamide, acrylic, polyvinyl chloride and polyolefin. A preferred fabric is cotton. In addition, the fabric can be a garment or other apparel, carpet, tote bags, curtains, towels, bed clothing, indoor or outdoor protective covers or various wall-covering fabrics to name but a few of the potential fabrics. The garment or apparel items can be a dress, work wear, coveralls, denim or jeans, jacket, pants, gloves, undergarments, socks, hats, skirts, aprons, head coverings, and T-shirts. A preferred garment or apparel is a denim or jeans.
The gradation of hues or fades is best illustrated with respect to FIG. 1 , where the dark blue denim fabric is dyed using the hypochlorite salt-containing composition of the present invention. The dark hue of the untreated fabric, generally indicated by the reference numeral 10 , is the untreated state of the color, which in this example is dark blue, as indicated in the color version of the Drawings submitted herewith. As noted above, treatment of the fabric with the hypochlorite salt-containing composition of the present invention at varying time intervals or treatment strengths results in patches of treated fabric of varying hues, such as also depicted in FIGS. 2-5 described hereinbelow.
As indicated in FIG. 1 , applying the composition to the fabric for a short period or at reduced concentration strength results in a patch having a lighter hue, generally indicated by the reference numeral 20 , which is a lighter shade of blue in this example. Further application of the composition, either for longer times, greater concentration strengths or both, results in additional patches of increasingly lighter hues, generally indicated by the reference numerals 30 , 40 , 50 , and 60 , respectively, until the color is substantially or entirely removed, as is designated by the reference numeral 70 .
With reference to FIGS. 2-5 , the varying application of the hypochlorite salt-containing composition of the present invention onto the untreated fabric results in a variety of patterns of varying hues. As indicated, the patterns can be enhanced by use of a template guide or applique to better control the treatment process and standardize the production process.
In one embodiment of the present invention, a consumer can purchase a kit containing the aforedescribed hypochlorite salt-containing composition along with instructions for use. Templates of patterns may also be purchased or constructed by the user. It should be understood that the user may employ the instant invention in a wide variety of artistic expression, creating patterns on fabrics of all types. As discussed, the principles of the present invention can be employed on apparel or any other fabric to create patterns, messages or other expression thereon. Designs can include purely ornamental works of expression as well as practical uses, e.g., camouflage or other functional usages. Indeed, the full measure of consumer use of the instant invention is subject only to the imagination of the user, and the instant invention provides the means for this new form of expression.
In another aspect of the present invention, the fabric or apparel items can be treated in a commercial fashion, such as on an assembly line or in an automated factory. Patterns can be coded into a program and the hypochlorite salt-containing composition can be directed on the subject fabric, e.g., sprayed or otherwise applied. As discussed, a uniform strength composition can be applied in a time-delayed fashion through multiple applications at staggered times, thereby obtaining varied hues, as noted above and as discussed in more detail hereinbelow. Another approach is a single application of the composition from multiple sources and in varying strengths to the entire fabric to achieve the desired pattern, and immerse the entire fabric at the end, thereby simplifying the process for throughput, as also discussed hereinbelow. It should be understood that various percentages of the composition can be formulated, each having a particular strength to fade the fabric over a common fixed time. Additionally, it should be understood that commercial manufacturing techniques could employ multiple treatments, differing compositional strengths and timed applications in a variety of ways to achieve a desired pattern, and deactivation can also be performed by a single or multiple partial or full immersions of the treated fabric.
For example, in FIG. 1 , as well as the remaining FIGURES, untreated fabric 10 can be passed through a device, as shown in FIG. 6A and generally designated by the reference number 600 , that dispenses a weak concentration of the hypochlorite salt-containing composition to slightly dye or bleach a portion, for example, patch 20 , and discrete increasing concentrations from respective dispensers to effectuate the remaining patches 30 , 40 , 50 , 60 , and the completely bleached patch 70 , which has the strongest concentration composition. Instead of multiple stagings and application over time, this one-step of substantially simultaneous dyeing of the fabric 10 handles the entire fabric once, i.e., in one pass of the apparatus.
With reference now to FIGS. 6A AND 6B , device 600 employs one or more dispensers 610 that dispense the aforementioned hypochlorite salt-containing composition of the present invention in either a uniform or varying concentrations. The dispensers 610 are disposed above a surface, designated by the reference numeral 620 in FIG. 6B , and a belt or other conveyor 630 , e.g., moving atop rollers 640 on surface 620 . A fabric for treatment, designated by the reference numeral 650 , e.g., a pair of pants as depicted in FIG. 6B , are placed atop conveyor 630 and transported adjacent the dispensers 610 , preferably vertically beneath them. It should be understood that the dispensers 610 can deliver the composition of the present invention in a variety of manners, e.g., simple dripping or spraying such as from jets, as discussed hereinabove. It should also be understood that the dispensers 610 preferably move relative to the fabric for treatment. For example, the dispensers 610 can move transversely and longitudinally with respect to the fabric to position the chemical treatment thereon. The dispensers 610 may also rotate about a position to direct the composition, for example, under pressure, to the fabric at an angle, thereby covering a radial area of the subject fabric for treatment. In this manner, transverse and longitudinal movement of the dispensers 610 can be minimized or eliminated. It should also be understood that the fabric 650 can be positioned under fixed dispensers 610 and moved relative thereto, transversely and/or longitudinally, to effectuate the same treatment.
Patterns can be created on the fabric being treated using a template, designated by the reference numeral 660 in FIG. 6B . Template 660 is disposed between dispensers 610 and the fabric for treatment 650 to control the application of the composition on the fabric, as discussed hereinabove. Thus, items placed on the belt or conveyor 630 move longitudinally under the dispensers 610 , which apply the composition, possibly through the template 660 to the fabric 650 . After this treatment, the conveyor 630 continues to transport the fabric 650 to an adjacent vat 670 . As illustrated in FIG. 6A , conveyor 630 immerses the treated fabric 650 , e.g., a rinse in cold water. The conveyor 630 then transports the dyed fabric 650 for pickup. It should, of course, be understood, however, that fabrics 650 can be passed through multiple devices 600 or reprocessed through the same device 600 to effectuate creation of a desired pattern.
As shown in FIG. 6A , the dispensers 610 can employ a number of discrete dispensers to deliver the composition of the present invention in a variety of ways. For example, by time offsetting a uniform concentration solution can be employed and a dispenser 610 A applies the composition to sections of the fabric 650 that are to be bleached-out or lightest. Subsequent dispensers 610 would apply the same uniform concentration composition to other sections at succeeding times, and a last dispenser 610 B would apply the composition to sections that would ultimately be slightly faded and have almost the original fabric color. In this fashion, the progression of the fabrics 650 for treatment can employ a plurality of templates 660 , each for directing a staged pattern portion until the last template completes the overall pattern.
It should also be understood that a plurality of fabrics 650 can be processed simultaneously, e.g., transversely in parallel across the conveyor 630 or having multiple longitudinal staging areas under the dispenser 610 , where multiple identical operations proceed simultaneously or substantially simultaneously, handling a batch of fabrics 650 at once.
With reference again to FIG. 6A , the dispensers 610 can employ varying concentrations of the composition of the present invention, e.g., dispenser 610 A has a full-strength concentration for application to sections of the pattern to be bleached-out or lightest. Subsequent nozzles or dispensers 610 apply weaker strength compositions to shade sections darker, i.e., less light, and the last dispenser 610 B would have the weakest strength composition. A variety of templates 660 could also be employed, as discussed hereinabove. It should be understood that ordering of the dispensers 610 in this scheme is not necessarily based upon composition concentration. In this fashion, there is no need for any time delay in application of the composition, as there is in the uniform composition embodiment, and the time for fabric 650 processing in the device 600 is minimized, speeding up processing. As with the previous embodiment, multiple fabrics 650 can be handled at once in parallel and through multiple staging areas.
It should, of course, be understood that a computer software program coded to implement the aforementioned applications can be operated by a controller computer that is coupled to the device 600 . The computer software program would allow the user to perform the aforementioned techniques and coordinate the various steps, e.g., setting the appropriate template 660 in place prior to application of the composition thereon, and then advancing the process accordingly. As discussed hereinabove, different design patterns to be applied to the fabric 650 , as illustrated in FIGS. 2-5 , can also be coded into the software program for the above-mentioned applications.
It should be understood that the above-described embodiments and the following examples are given by way of illustration, not limitation. Various changes and modifications within the scope of the present invention will become apparent to those skilled in the art from the present description.
EXAMPLES
Example 1
Creation of Jeans Fades Art to Denim Jeans Fabric
A flat dye brush (approximately 0.125×0.375×0.375 in) was used to apply the bleach in broad strokes and to make fine lines. The brush was dipped in a hypochlorite salt-containing composition, shaken to remove excess liquid and then applied to the fabric. Excessive liquid may diffuse into the adjoining areas of the pattern and may cause the loss of detail. On the other hand, insufficient liquid may require additional passes of the brush over the same area. Applications to a test fabric can be tried first to develop speed and skill. A template may be used as a guide for the application. After each section of artwork is completed, the template may be removed temporarily, if desired, to observe how the art is developing—being careful, of course, to replace the pattern exactly in the original location before continuing and be mindful of the treatment time.
Examples of the representative artwork are shown in FIGS. 2-5 . Each of the artistic patterns is transferred to the fabric in any manner of orientation or depiction. With care, the delicate renderings set forth in FIGS. 2-5 can be duplicated, improved upon or otherwise altered. Representative steps to achieve the patterns of FIGS. 2-5 or any other pattern are set forth below.
T = 0 min
Apply the hypochlorite salt-containing composition to
sections of the pattern that are to be bleached-out, i.e.,
to the base color of the fabric (usually white). These
sections will be allowed to bleach for 30 minutes.
T = 15 min
Bleach sections that are to be light but not white, if any.
T = 20 min
Bleach sections that are to be a shade darker, if any.
T = 25 min
Bleach sections that are to be a next darker shade, if any.
T = 27 min
Bleach sections that are to be relatively darker, if any.
T = 28½ min
Bleach sections that are almost the original jeans color, if
any.
T = 30 min
Immerse treated area of jeans or entire jeans in cold
water, thoroughly rinsing out the bleach. This stops
the bleach action and fixes the artwork.
It should be understood that the above steps for forming the fade artwork or other fade pattern employ a uniform concentration of the hypochlorite salt containing composition that is applied at offset time intervals and inactivated by water immersion. Steps for forming the same fade artwork shown in FIGS. 2-5 employing multiple dispensers of varying strength concentrations of the composition are set forth below.
T = 0 min
Apply the hypochlorite salt-containing composition to
sections of the pattern to be treated. A first nozzle applies a
full-strength composition to those sections of the pattern to
be bleached out, i.e., to the base color of the fabric (usually
white). A second nozzle applies a weaker strength
composition, e.g., half strength, to those sections that are to
be light but not white, if any. A third nozzle applies a still
weaker strength composition, e.g., one third, to form a
shade darker area, if any. A fourth nozzle applies a still
weaker strength composition, e.g., one sixth, to form a next
darker shade, if any. A fifth nozzle applies a still weaker
strength composition, e.g., a tenth. Finally, a sixth nozzle
applies the weakest strength composition, e.g., one
twentieth.
T = 30 min
Immerse treated area of jeans or entire jeans in cold water,
thoroughly rinsing out the bleach. This stops the bleach
action and fixes the artwork.
It should be understood that the number of discrete nozzles and the percentage strength compositions are variable and dependent upon the fade effect desired. For example, to minimize the entire processing time of a particular fabric, more powerful strength compositions may be employed to shorten the treatment time. Conversely, finer fade artwork or fade effects may be obtained using weaker concentrations, which would be useful on delicate fabrics. The techniques of the present invention may be employed in a variety of ways to achieve the creative results envisioned by the artists.
If desired, the artist can apply another color dye of choice to bleached-out or other sections of the artwork, such as a flower blossom. For example, in FIG. 5 , a red flower blossom is applied to a flower-shaped, bleached-out portion of the artwork, designated by the reference numeral 80 . After completing the application, the jeans can be handled in a customary manner, e.g., washed, dried or ironed. The artwork becomes part of the jeans color. With reference again to FIGS. 6A and 6B , it should be understood that the application of a different color can be accomplished by running the treated fabric 650 through the device 600 . The different color, e.g., red, can be applied to a section, e.g., a bleached-out portion, of the fabric 650 through an appropriately configured template 660 .
It should be understood that many modifications and variations of the present inventions are possible in light of the above teachings. While the invention has been described in its preferred embodiments, it is understood that the invention shall not be limited by thus description alone but in combination with the appended claims.
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This invention relates to a fabric having a pattern of fades and a methodology for their creation, both industrial and artistic. The fades are created by contacting at least one portion of the fabric with a hypochlorite salt-containing composition. The resulting fabric has a faded appearance either uniformly or non-uniformly. Methods, kits and a device for making a fabric having a pattern of fades are also disclosed.
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This application claims the benefit of U.S. Provisional Application No. 60/050,136, filed Jun. 18, 1997.
FIELD OF THE INVENTION
This invention relates to certain novel compounds and derivatives thereof, their synthesis, and their use as alpha 1a adrenoceptor antagonists. More particularly, the compounds of the present invention are useful for treating benign prostatic hyperplasia (BPH).
BACKGROUND OF THE INVENTION
Human adrenergic receptors are integral membrane proteins which have been classified into two broad classes, the alpha and the beta adrenergic receptors. Both types mediate the action of the peripheral sympathetic nervous system upon binding of catecholamines, norepinephrine and epinephrine.
Norepinephrine is produced by adrenergic nerve endings, while epinephrine is produced by the adrenal medulla. The binding affinity of adrenergic receptors for these compounds forms one basis of the classification: alpha receptors bind norepinephrine more strongly than epinephrine and much more strongly than the synthetic compound isoproterenol. The binding affinity of these hormones is reversed for the beta receptors. In many tissues, the functional responses, such as smooth muscle contraction, induced by alpha receptor activation are opposed to responses induced by beta receptor binding.
Subsequently, the functional distinction between alpha and beta receptors was further highlighted and refined by the pharmacological characterization of these receptors from various animal and tissue sources. As a result, alpha and beta adrenergic receptors were further subdivided into alpha 1, alpha 2, β1, and β2 subtypes. Functional differences between alpha 1 and alpha 2 receptors have been recognized, and compounds which exhibit selective binding between these two subtypes have been developed.
For a general background on the alpha adrenergic receptors, the reader's attention is directed to Robert R. Ruffolo, Jr., α-Adrenoreceptors: Molecular Biology, Biochemistry and Pharmacology, (Progress in Basic and Clinical Pharmacology series, Karger, 1991), wherein the basis of alpha 1/alpha 2 subclassification, the molecular biology, signal transduction (G-protein interaction and location of the significant site for this and ligand binding activity away from the 3'-terminus of alpha adrenergic receptors), agonist structure-activity relationships, receptor functions, and therapeutic applications for compounds exhibiting alpha-adrenergic receptor affinity was explored.
The cloning, sequencing and expression of alpha receptor subtypes from animal tissues has led to the subclassification of the alpha 1 receptors into alpha 1d (formerly known as alpha 1a or 1a/1d), alpha 1b and alpha 1a (formerly known as alpha 1c) subtypes. Each alpha 1 receptor subtype exhibits its own pharmacologic and tissue specificities. The designation "alpha 1a" is the appellation recently approved by the IUPHAR Nomenclature Committee for the previously designated "alpha 1c" cloned subtype as outlined in the 1995 Receptor and Ion Channel Nomenclature Supplement (Watson and Girdlestone, 1995). The designation alpha 1a is used throughout this application to refer to this subtype. At the same time, the receptor formerly designated alpha 1a was renamed alpha 1d. The new nomenclature is used throughout this application. Stable cell lines expressing these alpha 1 receptor subtypes are referred to herein; however, these cell lines were deposited with the American Type Culture Collection (ATCC) under the old nomenclature. For a review of the classification of alpha 1 adrenoceptor subtypes, see, Martin C. Michel, et al., Naunyn-Schmiedeberg's Arch. Pharmacol. (1995) 352:1-10.
The differences in the alpha adrenergic receptor subtypes have relevance in pathophysiologic conditions. Benign prostatic hyperplasia, also known as benign prostatic hypertrophy or BPH, is an illness typically affecting men over fifty years of age, increasing in severity with increasing age. The symptoms of the condition include, but are not limited to, increased difficulty in urination and sexual dysfunction. These symptoms are induced by enlargement, or hyperplasia, of the prostate gland. As the prostate increases in size, it impinges on free-flow of fluids through the male urethra. Concommitantly, the increased noradrenergic innervation of the enlarged prostate leads to an increased adrenergic tone of the bladder neck and urethra, further restricting the flow of urine through the urethra.
In benign prostatic hyperplasia, the male hormone 5alpha-dihydrotestosterone has been identified as the principal culprit. The continual production of 5α-dihydrotestosterone by the male testes induces incremental growth of the prostate gland throughout the life of the male. Beyond the age of about fifty years, in many men, this enlarged gland begins to obstruct the urethra with the pathologic symptoms noted above.
The elucidation of the mechanism summarized above has resulted in the recent development of effective agents to control, and in many cases reverse, the pernicious advance of BPH. In the forefront of these agents is Merck & Co., Inc.s' product PROSCAR® (finasteride). The effect of this compound is to inhibit the enzyme testosterone 5α-reductase, which converts testosterone into 5α-dihydrotesterone, resulting in a reduced rate of prostatic enlargement, and often reduction in prostatic mass.
The development of such agents as PROSCAR® bodes well for the long-term control of BPH. However, as may be appreciated from the lengthy development of the syndrome, its reversal also is not immediate. In the interim, those males suffering with BPH continue to suffer, and may in fact lose hope that the agents are working sufficiently rapidly.
In response to this problem, one solution is to identify pharmaceutically active compounds which complement slower-acting therapeutics by providing acute relief. Agents which induce relaxation of the lower urinary tract tissue, by binding to alpha 1 adrenergic receptors, thus reducing the increased adrenergic tone due to the disease, would be good candidates for this activity. Thus, one such agent is alfuzosin, which is reported in EP 0 204597 to induce urination in cases of prostatic hyperplasia. Likewise, in WO 92/0073, the selective ability of the R(+) enantiomer of terazosin to bind to adrenergic receptors of the alpha 1 subtype was reported. In addition, in WO 92/161213, combinations of 5α-reductase inhibitory compounds and alpha1-adrenergic receptor blockers (terazosin, doxazosin, prazosin, bunazosin, indoramin, alfuzosin) were disclosed. However, no information as to the alpha 1d, alpha 1b, or alpha 1a subtype specificity of these compounds was provided as this data and its relevancy to the treatment of BPH was not known. Current therapy for BPH uses existing non-selective alpha 1 antagonists such as prazosin (Minipress, Pfizer), Terazosin (Hytrin, Abbott) or doxazosin mesylate (Cardura, Pfizer). These non-selective antagonists suffer from side effects related to antagonism of the alpha 1d and alpha 1b receptors in the peripheral vasculature, e.g., hypotension and syncope.
The recent cloning of the human alpha 1a adrenergic receptor (ATCC CRL 11140) and the use of a screening assay utilizing the cloned human alpha 1a receptor enables identification of compounds which specifically interact with the human alpha 1a adrenergic receptor. [PCT International Application Publication Nos. WO94/08040, published Apr. 14, 1994 and WO94/10989, published May 26, 1994] As disclosed in the instant patent disclosure, a cloned human alpha 1a adrenergic receptor and a method for identifying compounds which bind the human alpha 1a receptor has now made possible the identification of selective human alpha 1a adrenergic receptor antagonists useful for treating BPH. The instant patent disclosure discloses novel compounds which selectively bind to the human alpha 1a receptor. These compounds are further tested for binding to other human alpha 1 receptor subtypes, as well as counterscreened against other types of receptors (e.g., alpha 2), thus defining the specificity of the compounds of the present invention for the human alpha 1a adrenergic receptor.
It is an object of the present invention to identify compounds which bind to the alpha 1a adrenergic receptor. It is a further object of the invention to identify compounds which act as antagonists of the alpha 1a adrenergic receptor. It is another object of the invention to identify alpha 1a adrenergic receptor antagonist compounds which are useful agents for treating BPH in animals, preferably mammals, especially humans. Still another object of the invention is to identify alpha 1a adrenergic receptor antagonists which are useful for relaxing lower urinary tract tissue in animals, preferably mammals, especially humans.
It has now been found that the compounds of the present invention are alpha 1a adrenergic receptor antagonists. Thus, the compounds of the present invention are useful for treating BPH in mammals. Additionally, it has been found that the alpha 1a adrenergic receptor antagonists of the present invention are also useful for relaxing lower urinary tract tissue in mammals.
SUMMARY OF THE INVENTION
The present invention provides compounds for the treatment of urinary obstruction caused by benign prostatic hyperplasia (BPH). The compounds antagonize the human alpha 1a adrenergic receptor at nanomolar and subnanomolar concentrations while exhibiting at least ten fold lower affinity for the alpha 1d and alpha 1b human adrenergic receptors and many other G-protein coupled receptors. This invention has the advantage over non-selective alpha 1 adrenoceptor antagonists of reduced side effects related to peripheral adrenergic blockade. Such side effects include hypotension, syncope, lethargy, etc. The compounds of the present invention have the structure: ##STR1## wherein Q is selected from ##STR2## E, G, L and M are each independently selected from hydrogen, C 1-8 alkyl, C 3-8 cycloalkyl, (CH 2 ) 0-4 OR 15 , (CH 2 ) 0-4 N(R 16 ) 2 , (CH 2 ) 0-4 CN, (CH 2 ) 0-4 CF 3 , (CH 2 ) 0-4 CO 2 R 16 , (CH 2 ) 0-4 CON(R 16 ) 2 , (CH 2 ) 0-4 SO 2 R 15 or (CH 2 ) 0-4 SO 2 N(R 16 ) 2;
J is selected from hydrogen, C 1-8 alkyl, C 3-8 cycloalkyl, (CH 2 ) 1-4 OR 15 , (CH 2 ) 1-4 N(R 16 ) 2 , (CH 2 ) 1-4 CN, (CH 2 ) 0-4 CF 3 , (CH 2 ) 0-4 CO 2 R 16 , (CH 2 ) 0-4 CON(R 16 ) 2 , (CH 2 ) 0-4 SO 2 R 15 or (CH 2 ) 0-4 SO 2 N(R 16 ) 2 ;
R 1 is selected from unsubstituted, mono- or poly-substituted phenyl wherein the substitutents on the phenyl are independently selected from halogen, CF 3 , cyano, nitro, N(R 16 ) 2 , NR 16 COR 18 , NR 16 CON(R 18 ) 2 , NR 16 SO 2 R 18 , NR 16 SO 2 N(R 18 ) 2 , OR 15 , (CH 2 ) 0-4 CO 2 R 16 , (CH 2 ) 0-4 CON(R 16 ) 2 , (CH 2 ) 0-4 SO 2 N(R 16 ) 2 , (CH 2 ) 0-4 SO 2 R 15 or C 1-4 alkyl; or unsubstituted, mono- or poly-substituted pyridyl, pyrazinyl, thienyl, thiazolyl, furanyl, quinazolinyl or naphthyl wherein the substituents on the pyridyl, pyrazinyl, thienyl, thiazolyl, furanyl, quinazolinyl or naphthyl are independently selected from CF 3 , cyano, nitro, N(R 16 ) 2 , (CH 2 ) 0-4 CO 2 R 16 , (CH 2 ) 0-4 CON(R 16 ) 2 , (CH 2 ) 0-4 SO 2 N(R 16 ) 2 , (CH 2 ) 0-4 SO 2 R 15 , phenyl, OR 15 , halogen, C 1-4 alkyl or 3-8 cycloalkyl;
R is selected from hydrogen, cyano, OR 15 , CO 2 R 15 , CON(R 16 ) 2 , SO 2 R 15 , SO 2 N(R 16 ) 2 , tetrazole, isooxadiazole, unsubstituted, mono- or poly-substitued phenyl wherein the substitutents on the phenyl are independently selected from halogen, cyano, OR 15 , (CH 2 ) 0-4 CO 2 R 16 , (CH 2 ) 0-4 CON(R 16 ) 2 , N(R 16 ) 2 , NR 16 COR 15 , NR 16 CON(R 18 ) 2 , NR 16 SO 2 R 15 , NR 16 SO 2 N(R 18 ) 2 , (CH 2 ) 0-4 SO 2 N(R 16 ) 2 , (CH 2 ) 0-4 SO 2 R 15 or C 1-4 alkyl; or unsubstituted, mono- or poly-substituted pyridyl, thienyl, furanyl or naphthyl wherein the substituents on the pyridyl, thienyl, furanyl or naphthyl are independently selected from CF 3 , (CH 2 ) 0-4 CO 2 R 16 , (CH 2 ) 0-4 CON(R 16 ) 2 , (CH 2 ) 0-4 SO 2 N(R 16 ) 2 , (CH 2 ) 0-4 SO 2 R 15 , phenyl, OR 15 , halogen, C 1-4 alkyl or C 3-8 cycloalkyl;
R 2 and R 7 are each independently selected from hydrogen, C 1-8 alkyl, C 4-8 cycloalkyl, (CH 2 ) 0-4 CO 2 R 16 , (CH 2 ) 0-4 CON(R 16 ) 2 , (CH 2 ) 0-4 COR 15 , (CH 2 ) 2-4 OR 15 , (CH 2 ) 1-4 CF 3 , (CH 2 ) 0-4 SO 2 R 15 , (CH 2 ) 0-4 SO 2 N(R 16 ) 2 or (CH 2 ) 1-4 CN;
R 3 , R 6 , R 8 , R 9 and R 10 are each independently selected from hydrogen, C 1-8 alkyl, C 3-8 cycloalkyl, (CH 2 ) 1-4 OR 15 or (CH 2 ) 0-4 CF 3 ;
R 11 and R 12 are each independently selected from hydrogen, C 1-8 alkyl or C 3-8 cycloalkyl;
R 13 and R 14 are each independently selected from hydrogen, C 1-8 alkyl, C 3-8 cycloalkyl, (CH 2 ) 0-4 OR 15 , (CH 2 ) 0-4 CF 3 , unsubstituted, mono- or independently selected from halogen, CF3, cyano, nitro, CO 2 R 16 , OR 15 , independently selected from halogen, CF 3 , cyano, nitro, CO 2 R 16 , OR 15 , (CH 2 ) 0-4 CON(R 16 ) 2 , (CH 2 ) 0-4 CO 2 R 16 or C 1-4 alkyl; or unsubstituted, mono- or poly-substituted: pyridyl, thienyl, furanyl or naphthyl are independently selected from CF 3 , phenyl, OR 15 , furanyl or naphthyl are independently selected from CF 3 , phenyl, OR 15 , halogen, C 1-4 alkyl or C 3-8 cycloalkyl;
R 15 is selected from hydrogen, C 1-8 alkyl, C 3-8 cycloalkyl or (CH 2 ) 0-4 CF 3 ;
R 16 and R 18 are each independently selected from hydrogen, C 1-8 alkyl, C 3-8 cycloalkyl or (CH 2 ) 1-4 CF 3 ;
R 19 is selected from hydrogen, C 1-8 alkyl, C 3-8 cycloalkyl, (CH 2 ) 0-4 OR 15 or (CH 2 ) 0-4 CF 3 ;
W is O or NR 11 ;
each X is independently selected from halogen, cyano, nitro, C 1-8 alkyl, C 3-8 cycloalkyl, (CH 2 ) 0-4 OR 24 or (CH 2 ) 0-4 CF 3 ;
R 24 is selected from hydrogen, C 1-8 alkyl, C 3-8 cycloalkyl or (CH 2 ) 0-4 CF 3 ;
Y is C--R 15 or N;
Z is hydrogen, oxygen or sulphur;
m, n, p and q are each independently an integer from zero to four;
o is an integer from one to four;
r is zero or one;
and the pharmaceutically acceptable salts thereof.
In one embodiment of the invention is the compound of the formula ##STR3## wherein E, G, L, M and J are each independently selected from hydrogen, C 1-8 alkyl, C 3-8 cycloalkyl, (CH 2 ) 0-4 CO 2 R 16 or (CH 2 ) 0-4 CF 3 ;
R 1 is selected from unsubstituted, mono-, di- or tri-substituted phenyl wherein the substitutents on the phenyl are independently selected from halogen, CF 3 , cyano, nitro, N(R 16 ) 2 , NR 16 COR 18 , NR 16 CON(R 18 ) 2 , NR 16 SO 2 R 18 , NR 16 SO 2 N(R 18 ) 2 , OR 15 , (CH 2 ) 0-4 CO 2 R 16 , (CH 2 ) 0-4 CON(R 16 ) 2 , (CH 2 ) 0-4 SO 2 N(R 16 ) 2 , (CH 2 ) 0-4 SO 2 (R 15 ) 2 or C 1-4 alkyl; or unsubstituted, mono-, di- or tri-substituted pyridyl, pyrazinyl, thienyl, thiazolyl, furanyl, quinazolinyl or naphthyl wherein the substituents on the pyridyl, pyrazinyl, thienyl, thiazolyl, furanyl, quinazolinyl or naphthyl are independently selected from CF 3 , cyano, nitro, N(R 16 ) 2 , (CH 2 ) 0-4 CO 2 R 16 , (CH 2 ) 0-4 CON(R 16 ) 2 , (CH 2 ) 0-4 SO 2 N(R 16 ) 2 , (CH 2 ) 0-4 SO 2 (R 15 ) 2 , phenyl, OR 15 , halogen, C 1-4 alkyl or C 3-8 cycloalkyl;
R is selected from hydrogen, cyano, OR 15 , CO 2 R 15 , CON(R 16 ) 2 , SO 2 R 15 , SO 2 N(R 16 ) 2 or unsubstituted, mono- or di-substituted phenyl wherein the substitutents on the phenyl are independently selected from halogen, cyano, OR 15 , (CH 2 ) 0-4 CO 2 R 16 , (CH 2 ) 0-4 CON(R 16 ) 2 , N(R 16 ) 2 , NR 16 COR 15 , NR 16 CON(R 18 ) 2 , NR 16 SO 2 R 15 , NR 16 SO 2 N(R 18 ) 2 , (CH 2 ) 0-4 SO 2 N(R 16 ) 2 , (CH 2 ) 0-4 SO 2 R 15 or
C 1-4 alkyl; or unsubstituted, mono- or di-substituted pyridyl, thienyl, furanyl or naphthyl wherein the substituents on the pyridyl, thienyl, furanyl or naphthyl are independently selected from CF 3 , (CH 2 ) 0-4 CO 2 R 16 , (CH 2 ) 0-4 CON(R 16 ) 2 , (CH 2 ) 0-4 SO 2 N(R 16 ) 2 , (CH 2 ) 0-4 SO 2 R 15 , phenyl, OR 15 , halogen, C 1-4 alkyl or C 3-8 cycloalkyl;
R 2 and R 7 are each independently selected from hydrogen, C 1-8 alkyl, C 4-8 cycloalkyl or (CH 2 ) 1-4 CF 3 ;
R 13 and R 14 are each independently selected from hydrogen, C 1-8 alkyl, C 3-8 cycloalkyl, (CH 2 ) 1-4 OR 15 , (CH 2 ) 0-4 CF 3 , unsubstituted, mono-, di- or tri-substituted phenyl wherein the substitutents on the phenyl are independently selected from halogen, CF 3 , cyano, nitro, CO 2 R 16 , OR 15 , (CH 2 ) 0-4 CON(R 16 ) 2 , (CH 2 ) 0-4 CO 2 R 16 or C 1-4 alkyl; or unsubstituted, mono-, di- or tri-substituted: pyridyl, thienyl, furanyl or naphthyl wherein the substituents on the pyridyl, thienyl, furanyl or naphthyl are independently selected from CF 3 , phenyl, OR 15 , halogen, C 1-4 alkyl or C 3-8 cycloalkyl;
n is an integer from zero to two;
o is an integer from one to four;
and all other variables are as defined previously;
and the pharmaceutically acceptable salts thereof
In a class of the invention is the compound of the formula ##STR4## wherein Q is selected from ##STR5## E and J are each independently selected from hydrogen or CO 2 --C 1-6 alkyl;
R 1 is selected from unsubstituted, mono-, di- or tri-substituted phenyl wherein the substitutents on the phenyl are independently selected from halogen, CF 3 , cyano, nitro, N(R 16 ) 2 , OR 15 , (CH 2 ) 0-2 CO 2 R 16 , (CH 2 ) 0-2 CON(R 16 ) 2 or C 1-4 alkyl; or unsubstituted, mono- or di-substituted pyridyl wherein the substitutents on the pyridyl are independently selected from halogen, CF 3 , cyano, nitro, N(R 16 ) 2 , OR 15 , (CH 2 ) 0-2 CO 2 R 16 , (CH 2 ) 0-2 CON(R 16 ) 2 or C 1-4 alkyl;
R is selected from hydrogen, cyano, OR 15 , CO 2 R 15 , CON(R 16 ) 2 , SO 2 R 15 or SO 2 N(R 16 ) 2 ;
R 2 and R 7 are each independently selected from hydrogen, C 1-6 alkyl, C 4-6 cycloalkyl or (CH 2 ) 1-4 CF 3 ;
R 8 , R 9 and R 10 are each independently selected from hydrogen, C 1-6 alkyl, C 3-6 cycloalkyl, (CH 2 ) 2-4 OR 15 or (CH 2 ) 0-2 CF 3 ;
R 13 is selected from hydrogen, C 1-6 alkyl, C 3-6 cycloalkyl,
(CH 2 ) 2-4 OR 15 , (CH 2 ) 0-2 CF 3 , or unsubstituted, mono-, or di-substituted phenyl wherein the substitutents on the phenyl are independently selected from halogen, CF 3 , cyano, CO 2 R 16 , OR 15 or C 1-4 alkyl;
R 15 is selected from hydrogen, C 1-6 alkyl, C 3-6 cycloalkyl or (CH 2 ) 0-2 CF 3 ;
R 16 is selected from hydrogen, C 1-6 alkyl, C 3-6 cycloalkyl or (CH 2 ) 1-2 CF 3 ;
R 19 is selected from hydrogen, C 1-6 alkyl, C 3-6 cycloalkyl, (CH 2 ) 0-4 OR 15 or (CH 2 ) 0-2 CF 3 ;
each X is independently selected from halogen or C 1-4 alkyl,
p is an integer from zero to two;
q is an integer from zero to three;
and all other variables are as defined above;
and the pharmaceutically acceptable salts thereof
In a subclass of the inention is the compound of the formula ##STR6## wherein Q is ##STR7## A is C--R 17 or N; R is selected from hydrogen, cyano, hydroxy, CO 2 R 15 , CON(R 16 ) 2 , SO 2 R 15 or SO 2 N(R 16 ) 2 ;
each R 17 is independently selected from hydrogen, halogen, CO 2 R 16 , cyano, nitro, CON(R 16 ) 2 , SO 2 R 15 , SO 2 N(R 16 ) 2 or OR 15 ;
each X is independently selected from flourine or methyl;
s is an integer from zero to two;
and all other variables are as defined above;
and the pharmaceutically acceptable salts thereof.
Illustrative of the invention is the compound selected from
(4-cyano-4-phenyl-cyclohexyl)-[3-(2,2-di-p-tolyl-acetylamino)-propyl]-methyl-ammonium chloride;
(4-cyano-4-phenyl-cyclohexyl)-methyl-[4-(1,1,3-trioxo-1,3-dihydro-1l6-benzo[d]isothiazol-2yl)-butyl]-ammonium chloride;
(4-cyano-4-phenyl-cyclohexyl)-methyl-[3-(1,1,3-trioxo-1,3-dihydro-1l6-benzo[d]isothiazol-2-yl)-propyl]-ammonium chloride;
(+)-2-Oxo-4-(3,4,5-trifluorophenyl)-oxazolidine-3-carboxylic acid [2-(4-cyano-4-phenyl-cyclohexylamino)-ethyl]amide;
(+)-2-Oxo-4-(3,4-difluorophenyl)-oxazolidine-3-carboxylic acid [2-(4-phenyl-4-methoxycarbonyl-cyclohexylamino)-ethyl]amide;
(+)-cis-2-Oxo-4-(3,4-difluorophenyl)-oxazolidine-3-carboxylic acid [2-(4-Cyano-4-(2-ethoxyphenyl)-cyclohexylamino)-ethyl]amide;
[4-cyano-4-(2-methoxy-phenyl)-cyclohexyl]-(2-{[4-(3,4-difluoro-phenyl)-2-oxo-oxazolidine-3-carbonyl]-amino}-ethyl)-ammonium chloride;
[4-cyano-4-(2-fluoro-phenyl)-cyclohexyl]-(2-{[4-(3,4-difluoro-phenyl)-2-oxo-oxazolidine-3-carbonyl]-amino}-ethyl)-ammonium chloride;
4-(3,4-difluoro-phenyl)-2-oxo-oxazolidine-3-carboxylic acid {2-[4-cyano-4-(2-trifluoromethoxy-phenyl)-cyclohexylamino]-ethyl}-amide;
4-(3,4-difluoro-phenyl)-2-oxo-oxazolidine-3-carboxylic acid {2-[4-cyano-4-(2-trifluoromethoxy-phenyl)-cyclohexylamino]-ethyl}-amide;
4-(3,4-difluoro-phenyl)-2-oxo-oxazolidine-3-carboxylic acid {2-[4-cyano-4-(2-trifluoromethyl-phenyl)-cyclohexylamino]-ethyl}-amide;
4-(3,4-difluoro-phenyl)-2-oxo-oxazolidine-3-carboxylic acid {2-[4-cyano-4-(2-trifluoromethyl-phenyl)-cyclohexylamino]-ethyl}-amide;
(2-{[4-(3,4-difluoro-phenyl)-2-oxo-oxazolidine-3-carbonyl]-amino}-ethyl)-(4-methanesulfonyl-4-phenyl-cyclohexyl)-ammonium chloride; or
(2-{[4-(3,4-difluoro-phenyl)-2-oxo-oxazolidine-3-carbonyl]-amino}-ethyl)-(4-methanesulfonyl-4-phenyl-cyclohexyl)-ammonium chloride
and the pharmaceutically acceptable salts thereof.
An illustration of the invention is a pharmaceutical composition comprising a therapeutically effective amount of any of the compounds described above and a pharmaceutically acceptable carrier. An example of the invention is a pharmaceutical composition made by combining any of the compounds described above and a pharmaceutically acceptable carrier. Another illustration of the invention is a process for making a pharmaceutical composition comprising combining any of the compounds described above and a pharmaceutically acceptable carrier.
Exemplifying the invention is the composition further comprising a therapeutically effective amount of a testosterone 5-alpha reductase inhibitor. Preferably, the testosterone 5-alpha reductase inhibitor is a type 1, a type 2, both a type 1 and a type 2 (i.e., a three component combination comprising any of the compounds described above combined with both a type 1 testosterone 5-alpha reductase inhibitor and a type 2 testosterone 5-alpha reductase inhibitor) or a dual type 1 and type 2 testosterone 5-alpha reductase inhibitor. More preferably, the testosterone 5-alpha reductase inhibitor is a type 2 testosterone 5-alpha reductase inhibitor. Most preferably, the testosterone 5-alpha reductase inhibitor is finasteride.
More specifically illustrating the invention is a method of treating benign prostatic hyperplasia in a subject in need thereof which comprises administering to the subject a therapeutically effective amount of any of the compounds (or any of the compositions) described above.
Further exemplifying the invention is the method of treating BPH wherein the compound (or composition) additionally does not cause a fall in blood pressure at dosages effective to alleviate BPH.
Another example of the invention is the method of treating benign prostatic hyperplasia wherein the compound is administered in combination with a testosterone 5-alpha reductase inhibitor. Preferably, the testosterone 5-alpha reductase inhibitor is finasteride.
Further illustrating the invention is a method of inhibiting contraction of prostate tissue or relaxing lower urinary tract tissue in a subject in need thereof which comprises administering to the subject a therapeutically effective amount of any of the compounds (or any of the compositions) described above.
More specifically exemplifying the invention is the method of inhibiting contraction of prostate tissue or relaxing lower urinary tract tissue wherein the compound (or composition) additionally does not cause a fall in blood pressures at dosages effective to inhibit contraction of prostate tissue.
More particularly illustrating the invention is the method of inhibiting contraction of prostate tissue or relaxing lower urinary tract tissue wherein the compound (or composition) is administered in combination with a testosterone 5-alpha reductase inhibitor; preferably, the testosterone 5-alpha reductase inhibitor is finasteride.
More particularly exemplifying the invention is a method of treating a disease which is susceptible to treatment by antagonism of the alpha 1a receptor which comprises administering to a subject in need thereof an amount of any of the compounds described above effective to treat the disease. Diseases which are susceptible to treatment by antagonism of the alpha 1a receptor include, but are not limited to, BPH, high intraocular pressure, high cholesterol, impotency, sympathetically mediated pain, migraine (see, K. A. Vatz, Headache 1997:37: 107-108) and cardiac arrhythmia.
An additional illustration of the invention is the use of any of the compounds described above in the preparation of a medicament for: a) the treatment of benign prostatic hyperplasia; b) relaxing lower urinary tract tissue; or c) inhibiting contraction of prostate tissue; in a subject in need thereof.
An additional example of the invention is the use of any of the alpha 1a antagonist compounds described above and a 5-alpha reductase inhibitor for the manufacture of a medicament for: a) treating benign prostatic hyperplasia; b) relaxing lower urinary tract tissue; or c) inhibiting contraction of prostate tissue which comprises an effective amount of the alpha 1a antagonist compound and an effective amount of 5-alpha reductase inhibitor, together or separately.
DETAILED DESCRIPTION OF THE INVENTION
Representative compounds of the present invention exhibit high selectivity for the human alpha 1a adrenergic receptor. One implication of this selectivity is that these compounds display selectivity for lowering intraurethral pressure without substantially affecting diastolic blood pressure.
Representative compounds of this invention display submicromolar affinity for the human alpha 1a adrenergic receptor subtype while displaying at least ten-fold lower affinity for the human alpha 1d and alpha 1b adrenergic receptor subtypes, and many other G-protein coupled human receptors. Particular representative compounds of this invention exhibit nanomolar and subnanomolar affinity for the human alpha 1a adrenergic receptor subtype while displaying at least 30 fold lower affinity for the human alpha 1d and alpha 1b adrenergic receptor subtypes, and many other G-protein coupled human receptors (e.g., serotonin, dopamine, alpha 2 adrenergic, beta adrenergic or muscarinic receptors).
These compounds are administered in dosages effective to antagonize the alpha 1a receptor where such treatment is needed, as in BPH. For use in medicine, the salts of the compounds of this invention refer to non-toxic "pharmaceutically acceptable salts." Other salts may, however, be useful in the preparation of the compounds according to the invention or of their pharmaceutically acceptable salts. Suitable pharmaceutically acceptable salts of the compounds of this invention include acid addition salts which may, for example, be formed by mixing a solution of the compound according to the invention with a solution of a pharmaceutically acceptable acid such as hydrochloric acid, sulphuric acid, fumaric acid, maleic acid, succinic acid, acetic acid, benzoic acid, citric acid, tartaric acid, carbonic acid or phosphoric acid. Furthermore, where the compounds of the invention carry an acidic moiety, suitable pharmaceutically acceptable salts thereof may include alkali metal salts, e.g. sodium or potassium salts; alkaline earth metal salts, e.g. calcium or magnesium salts; and salts formed with suitable organic ligands, e.g. quaternary ammonium salts. Thus, representative pharmaceutically acceptable salts include the following:
Acetate, Benzenesulfonate, Benzoate, Bicarbonate, Bisulfate, Bitartrate, Borate, Bromide, Calcium, Camsylate, Carbonate, Chloride, Clavulanate, Citrate, Dihydrochloride, Edetate, Edisylate, Estolate, Esylate, Fumarate, Gluceptate, Gluconate, Glutamate, Glycollylarsanilate, Hexylresorcinate, Hydrabamine, Hydrobromide, Hydrochloride, Hydroxynaphthoate, Iodide, Isothionate, Lactate, Lactobionate, Laurate, Malate, Maleate, Mandelate, Mesylate, Methylbromide, Methylnitrate, Methylsulfate, Mucate, Napsylate, Nitrate, N-methylglucamine ammonium salt, Oleate, Pamoate (Embonate), Palmitate, Pantothenate, Phosphate/diphosphate, Polygalacturonate, Salicylate, Stearate, Sulfate, Subacetate, Succinate, Tannate, Tartrate, Teoclate, Tosylate, Triethiodide and Valerate.
Compounds of this invention are used to reduce the acute symptoms of BPH. Thus, compounds of this invention may be used alone or in conjunction with a more long-term anti-BPH therapeutics, such as testosterone 5α-reductase inhibitors, including PROSCAR® (finasteride). Aside from their utility as anti-BPH agents, these compounds may be used to induce highly tissue-specific, localized alpha 1a adrenergic receptor blockade whenever this is desired. Effects of this blockade include reduction of intra-ocular pressure, control of cardiac arrhythmias, and possibly a host of alpha 1a receptor mediated central nervous system events.
The present invention includes within its scope prodrugs of the compounds of this invention. In general, such prodrugs will be functional derivatives of the compounds of this invention which are readily convertible in vivo into the required compound. Thus, in the methods of treatment of the present invention, the term "administering" shall encompass the treatment of the various conditions described with the compound specifically disclosed or with a compound which may not be specifically disclosed, but which converts to the specified compound in vivo after administration to the patient Conventional procedures for the selection and preparation of suitable prodrug derivatives are described, for example, in "Design of Prodrugs," ed. H. Bundgaard, Elsevier, 1985. Metabolites of these compounds include active species produced upon introduction of compounds of this invention into the biological milieu.
Where the compounds according to the invention have at least one chiral center, they may accordingly exist as enantiomers. Where the compounds according to the invention possess two or more chiral centers, they may additionally exist as diastereoisomers. It is to be understood that all such isomers and mixtures thereof are encompassed within the scope of the present invention. Furthermore, some of the crystalline forms for compounds of the present invention may exist as polymorphs and as such are intended to be included in the present invention. In addition, some of the compounds of the present invention may form solvates with water (i.e., hydrates) or common organic solvents. Such solvates are also encompassed within the scope of this invention.
The term "alkyl" shall mean straight or branched chain alkanes of one to ten total carbon atoms, or any number within this range (i.e., methyl, ethyl, 1-propyl, 2-propyl, n-butyl, s-butyl, t-butyl, etc.).
The term "alkenyl" shall mean straight or branched chain alkenes of two to ten total carbon atoms, or any number within this range.
The term "aryl" as used herein, except where otherwise specifically defined, refers to unsubstituted, mono- or poly-substituted aromatic groups such as phenyl or naphthyl.
The term "cycloalkyl" shall mean cyclic rings of alkanes of three to eight total carbon atoms (i.e., cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl or cyclooctyl).
Whenever the term "alkyl" or "aryl" or either of their prefix roots appear in a name of a substituent (e.g., aralkoxyaryloxy) it shall be interpreted as including those limitations given above for "alkyl" and "aryl." Designated numbers of carbon atoms (e.g., C 1-10 ) shall refer independently to the number of carbon atoms in an alkyl or cyclic alkyl moiety or to the alkyl portion of a larger substituent in which alkyl appears as its prefix root.
The term "halogen" shall include iodine, bromine, chlorine and fluorine.
The term "substituted" shall be deemed to include multiple degrees of substitution by a named substitutent. The term "poly-substituted" as used herein shall include di-, tri-, tetra- and penta-substitution by a named substituent.
It is intended that the definition of any substituent or variable (e.g., X, R 16 , R 18 ) at a particular location in a molecule be independent of its definitions elsewhere in that molecule. Thus, --understood N(R 16 ) 2 represents --NH 2 , --NHCH 3 , --NHC 2 H 5 , --N(CH 3 )C 2 H 5 , etc. It is understood that substituents and substitution patterns on the compounds of the instant invention can be selected by one of ordinary skill in the art to provide compounds that are chemically stable and that can be readily synthesized by techniques known in the art as well as those methods set forth below.
Where multiple substituent moieties are disclosed or claimed, the substituted compound can be independently substituted by one or more of the disclosed or claimed substituent moieties, singly or plurally.
The term "Z is hydrogen," when refering to the "Q" group ##STR8## refers to the moiety ##STR9##
The term heterocycle or heterocyclic ring, as used herein, represents an unsubstituted or substituted stable 5- to 7-membered monocyclic ring system which may be saturated or unsaturated, and which consists of carbon atoms and from one to three heteroatoms selected from N, O or S, and wherein the nitrogen and sulfur heteroatoms may optionally be oxidized, and the nitrogen heteroatom may optionally be quaternized. The heterocyclic ring may be attached at any heteroatom or carbon atom which results in the creation of a stable structure. Examples of such heterocyclic groups include, but is not limited to, piperidinyl, piperazinyl, oxopiperazinyl, oxopiperidinyl, oxopyrrolidinyl, oxoazepinyl, azepinyl, pyrrolyl, pyrrolidinyl, furanyl, thienyl, pyrazolyl, pyrazolidinyl, imidazolyl, imidazolinyl, imidazolidinyl, pyridyl, pyrazinyl, pyrimidinyl, pyridazinyl, oxazolyl, oxazolidinyl, isooxazolyl, isoxazolidinyl, morpholinyl, thiazolyl, thiazolidinyl, isothiazolyl, thiadiazolyl, tetrahydropyranyl, thiamorpholinyl, thiamorpholinyl sulfoxide, thiamorpholinyl sulfone, and oxadiazolyl. Morpholino is the same as morpholinyl.
The term "(S)-oxa" as used herein, refers to an oxazolidinone group of the formula ##STR10## for example, ##STR11##
The term "activated (S)-oxa" as used herein, refers to an N-(activated)carbamate of the desired oxazolidinone where the activating group is, for example, a p-nitrophenyloxy group. A specific example of an activated (S)-oxa group is 4-(3,4-difluorophenyl)-2-oxo-oxazolidine-3-carboxylic acid 4-nitrophenyl ester (i.e., compound 2).
The term "selective alpha 1a adrenergic receptor antagonist," as used herein, refers to an alpha 1a antagonist compound which is at least ten fold selective for the human alpha 1a adrenergic receptor as compared to the human alpha 1b, alpha 1d, alpha 2a, alpha 2b and alpha 2c adrenergic receptors.
The term "lower urinary tract tissue," as used herein, refers to and includes, but is not limited to, prostatic smooth muscle, the prostatic capsule, the urethra and the bladder neck.
The term "subject," as used herein refers to an animal, preferably a mammal, most preferably a human, who has been the object of treatment, observation or experiment.
The term "therapeutically effective amount" as used herein means that amount of active compound or pharmaceutical agent that elicits the biological or medicinal response in a tissue, system, animal or human that is being sought by a researcher, veterinarian, medical doctor or other clinician, which includes alleviation of the symptoms of the disease being treated.
The present invention also provides pharmaceutical compositions comprising one or more compounds of this invention in association with a pharmaceutically acceptable carrier. Preferably these compositions are in unit dosage forms such as tablets, pills, capsules, powders, granules, sterile parenteral solutions or suspensions, metered aerosol or liquid sprays, drops, ampoules, auto-injector devices or suppositories; for oral, parenteral, intranasal, sublingual or rectal administration, or for administration by inhalation or insufflation. Alternatively, the compositions may be presented in a form suitable for once-weekly or once-monthly administration; for example, an insoluble salt of the active compound, such as the decanoate salt, may be adapted to provide a depot preparation for intramuscular injection. For preparing solid compositions such as tablets, the principal active ingredient is mixed with a pharmaceutical carrier, e.g. conventional tableting ingredients such as corn starch, lactose, sucrose, sorbitol, talc, stearic acid, magnesium stearate, dicalcium phosphate or gums, and other pharmaceutical diluents, e.g. water, to form a solid preformulation composition containing a homogeneous mixture of a compound of the present invention, or a pharmaceutically acceptable salt thereof. When referring to these preformulation compositions as homogeneous, it is meant that the active ingredient is dispersed evenly throughout the composition so that the composition may be readily subdivided into equally effective unit dosage forms such as tablets, pills and capsules. This solid preformulation composition is then subdivided into unit dosage forms of the type described above containing from 0.1 to about 500 mg of the active ingredient of the present invention. The tablets or pills of the novel composition can be coated or otherwise compounded to provide a dosage form affording the advantage of prolonged action. For example, the tablet or pill can comprise an inner dosage and an outer dosage component, the latter being in the form of an envelope over the former. The two components can be separated by an enteric layer which serves to resist disintegration in the stomach and permits the inner component to pass intact into the duodenum or to be delayed in release. A variety of materials can be used for such enteric layers or coatings, such materials including a number of polymeric acids and mixtures of polymeric acids with such materials as shellac, cetyl alcohol and cellulose acetate.
As used herein, the term "composition" is intended to encompass a product comprising the specified ingredients in the specified amounts, as well as any product which results, directly or indirectly, from combination of the specified ingredients in the specified amounts.
The liquid forms in which the novel compositions of the present invention may be incorporated for administration orally or by injection include aqueous solutions, suitably flavoured syrups, aqueous or oil suspensions, and flavoured emulsions with edible oils such as cottonseed oil, sesame oil, coconut oil or peanut oil, as well as elixirs and similar pharmaceutical vehicles. Suitable dispersing or suspending agents for aqueous suspensions include synthetic and natural gums such as tragacanth, acacia, alginate, dextran, sodium carboxymethylcellulose, methylcellulose, polyvinyl-pyrrolidone or gelatin.
Where the processes for the preparation of the compounds according to the invention give rise to mixtures of stereoisomers, these isomers may be separated by conventional techniques such as preparative chromatography. The compounds may be prepared in racemic form, or individual enantiomers may be prepared either by enantiospecific synthesis or by resolution. The compounds may, for example, be resolved into their component enantiomers by standard techniques, such as the formation of diastereomeric pairs by salt formation with an optically active acid, such as (-)-di-p-toluoyl-d-tartaric acid and/or (+)-di-p-toluoyl-l-tartaric acid followed by fractional crystallization and regeneration of the free base. The compounds may also be resolved by formation of diastereomeric esters or amides, followed by chromatographic separation and removal of the chiral auxiliary. Alternatively, the compounds may be resolved using a chiral HPLC column.
During any of the processes for preparation of the compounds of the present invention, it may be necessary and/or desirable to protect sensitive or reactive groups on any of the molecules concerned. This may be achieved by means of conventional protecting groups, such as those described in Protective Groups in Organic Chemistry, ed. J. F. W. McOmie, Plenum Press, 1973; and T. W. Greene & P. G. M. Wuts, Protective Groups in Organic Synthesis, John Wiley & Sons, 1991. The protecting groups may be removed at a convenient subsequent stage using methods known from the art.
The specificity of binding of compounds showing affinity for the alpha 1a receptor is shown by comparing affinity to membranes obtained from tranfected cell lines that express the alpha 1a receptor and membranes from cell lines or tissues known to express other types of alpha (e.g., alpha 1d, alpha 1b) or beta adrenergic receptors. Expression of the cloned human alpha 1d, alpha 1b, and alpha 1a receptors and comparison of their binding properties with known selective antagonists provides a rational way for selection of compounds and discovery of new compounds with predictable pharmacological activities. Antagonism by these compounds of the human alpha 1a adrenergic receptor subtype may be functionally demonstrated in anesthetized animals. These compounds may be used to increase urine flow without exhibiting hypotensive effects.
The ability of compounds of the present invention to specifically bind to the alpha 1a receptor makes them useful for the treatment of BPH. The specificity of binding of compounds showing affinity for the alpha 1a receptor is compared against the binding affinities to other types of alpha or beta adrenergic receptors. The human alpha adrenergic receptor of the 1a subtype was recently identified, cloned and expressed as described in PCT International Application Publication Nos. WO94/08040, published Apr. 14, 1994 and WO 94/21660, published Sep. 29, 1994. The cloned human alpha 1a receptor, when expressed in mammalian cell lines, is used to discover ligands that bind to the receptor and alter its function. Expression of the cloned human alpha 1d, alpha 1b, and alpha 1a receptors and comparison of their binding properties with known selective antagonists provides a rational way for selection of compounds and discovery of new compounds with predictable pharmacological activities.
Compounds of this invention exhibiting human alpha 1a adrenergic receptor antagonism may further be defined by counterscreening. This is accomplished according to methods known in the art using other receptors responsible for mediating diverse biological functions. [See e.g., PCT International Application Publication No. W094/10989, published May 26, 1994; U.S. Pat. No. 5,403,847, issued Apr. 4, 1995]. Compounds which are both selective amongst the various human alpha1 adrenergic receptor subtypes and which have low affinity for other receptors, such as the alpha2 adrenergic receptors, the β-adrenergic receptors, the muscarinic receptors, the serotonin receptors, and others are particularly preferred. The absence of these non-specific activities may be confirmed by using cloned and expressed receptors in an analogous fashion to the method disclosed herein for identifying compounds which have high affinity for the various human alpha1 adrenergic receptors. Furthermore, functional biological tests are used to confirm the effects of identified compounds as alpha 1a adrenergic receptor antagonists.
The present invention also has the objective of providing suitable topical, oral, systemic and parenteral pharmaceutical formulations for use in the novel methods of treatment of the present invention. The compositions containing compounds of this invention as the active ingredient for use in the specific antagonism of human alpha 1a adrenergic receptors can be administered in a wide variety of therapeutic dosage forms in conventional vehicles for systemic administration. For example, the compounds can be administered in such oral dosage forms as tablets, capsules (each including timed release and sustained release formulations), pills, powders, granules, elixirs, tinctures, solutions, suspensions, syrups and emulsions, or by injection. Likewise, they may also be administered in intravenous (both bolus and infusion), intraperitoneal, subcutaneous, topical with or without occlusion, or intramuscular form, all using forms well known to those of ordinary skill in the pharmaceutical arts. An effective but non-toxic amount of the compound desired can be employed as an alpha 1a antagonistic agent.
Advantageously, compounds of the present invention may be administered in a single daily dose, or the total daily dosage may be administered in divided doses of two, three or four times daily. Furthermore, compounds for the present invention can be administered in intranasal form via topical use of suitable intranasal vehicles, or via transdermal routes, using those forms of transdermal skin patches well known to those of ordinary skill in that art. To be administered in the form of a transdermal delivery system, the dosage administration will, of course, be continuous rather than intermittent throughout the dosage regimen.
The dosage regimen utilizing the compounds of the present invention is selected in accordance with a variety of factors including type, species, age, weight, sex and medical condition of the patient; the severity of the condition to be treated; the route of administration; the renal and hepatic function of the patient; and the particular compound thereof employed. A physician or veterinarian of ordinary skill can readily determine and prescribe the effective amount of the drug required to prevent, counter or arrest the progress of the condition. Optimal precision in achieving concentration of drug within the range that yields efficacy without toxicity requires a regimen based on the kinetics of the drug's availability to target sites. This involves a consideration of the distribution, equilibrium, and elimination of a drug.
In the methods of the present invention, the compounds herein described in detail can form the active ingredient, and are typically administered in admixture with suitable pharmaceutical diluents, excipients or carriers (collectively referred to herein as "carrier" materials) suitably selected with respect to the intended form of administration, that is, oral tablets, capsules, elixirs, syrups and the like, and consistent with conventional pharmaceutical practices.
For instance, for oral administration in the form of a tablet or capsule, the active drug component can be combined with an oral, non-toxic pharmaceutically acceptable inert carrier such as ethanol, glycerol, water and the like. Moreover, when desired or necessary, suitable binders, lubricants, disintegrating agents and coloring agents can also be incorporated into the mixture. Suitable binders include, without limitation, starch, gelatin, natural sugars such as glucose or beta-lactose, corn sweeteners, natural and synthetic gums such as acacia, tragacanth or sodium alginate, carboxymethylcellulose, polyethylene glycol, waxes and the like. Lubricants used in these dosage forms include, without limitation, sodium oleate, sodium stearate, magnesium stearate, sodium benzoate, sodium acetate, sodium chloride and the like. Disintegrators include, without limitation, starch, methyl cellulose, agar, bentonite, xanthan gum and the like.
The liquid forms in suitably flavored suspending or dispersing agents such as the synthetic and natural gums, for example, tragacanth, acacia, methyl-cellulose and the like. Other dispersing agents which may be employed include glycerin and the like. For parenteral administration, sterile suspensions and solutions are desired. Isotonic preparations which generally contain suitable preservatives are employed when intravenous administration is desired.
The compounds of the present invention can also be administered in the form of liposome delivery systems, such as small unilamellar vesicles, large unilamellar vesicles and multilamellar vesicles. Liposomes can be formed from a variety of phospholipids, such as cholesterol, stearylamine or phosphatidylcholines.
Compounds of the present invention may also be delivered by the use of monoclonal antibodies as individual carriers to which the compound molecules are coupled. The compounds of the present invention may also be coupled with soluble polymers as targetable drug carriers. Such polymers can include polyvinyl-pyrrolidone, pyran copolymer, polyhydroxypropylmethacryl-amidephenol, polyhydroxy-ethylaspartamidephenol, or polyethyl-eneoxidepolylysine substituted with palmitoyl residues. Furthermore, the compounds of the present invention may be coupled to a class of biodegradable polymers useful in achieving controlled release of a drug, for example, polylactic acid, polyepsilon caprolactone, polyhydroxy butyric acid, polyorthoesters, polyacetals, polydihydro-pyrans, polycyanoacrylates and cross-linked or amphipathic block copolymers of hydrogels.
Compounds of this invention may be administered in any of the foregoing compositions and according to dosage regimens established in the art whenever specific blockade of the human alpha 1a adrenergic receptor is required.
The daily dosage of the products may be varied over a wide range from 0.01 to 1,000 mg per adult human per day. For oral administration, the compositions are preferably provided in the form of tablets containing 0.01, 0.05, 0.1, 0.5, 1.0, 2.5, 5.0, 10.0, 15.0, 25.0, 50.0 and 100 milligrams of the active ingredient for the symptomatic adjustment of the dosage to the patient to be treated. A medicament typically contains from about 0.01 mg to about 500 mg of the active ingredient, preferably, from about 1 mg to about 100 mg of active ingredient. An effective amount of the drug is ordinarily supplied at a dosage level of from about 0.0002 mg/kg to about 20 mg/kg of body weight per day. Preferably, the range is from about 0.001 to 10 mg/kg of body weight per day, and especially from about 0.001 mg/kg to 7 mg/kg of body weight per day. The compounds may be administered on a regimen of 1 to 4 times per day.
Compounds of this patent disclosure may be used alone at appropriate dosages defined by routine testing in order to obtain optimal antagonism of the human alpha 1a adrenergic receptor while minimizing any potential toxicity. In addition, co-administration or sequential administration of other agents which alleviate the effects of BPH is desirable. Thus, in one embodiment, this includes administration of compounds of this invention and a human testosterone 5α-reductase inhibitor. Included with this embodiment are inhibitors of 5-alpha reductase isoenzyme 2. Many such compounds are now well known in the art and include such compounds as PROSCAR®, (also known as finasteride, a 4-Aza-steroid; see U.S. Pat. Nos. 4,377,584 and 4,760,071, for example). In addition to PROSCAR®, which is principally active in prostatic tissue due to its selectivity for human 5α-reductase isozyme 2, combinations of compounds which are specifically active in inhibiting testosterone 5-alpha reductase isozyme 1 and compounds which act as dual inhibitors of both isozymes 1 and 2, are useful in combination with compounds of this invention. Compounds that are active as 5α-reductase inhibitors have been described in WO93/23420, EP 0572166; WO 93/23050; WO93/23038,; WO93/23048; WO93/23041; WO93/23040; WO93/23039; WO93/23376; WO93/123419, EP 0572165; WO93/23051.
The dosages of the alpha 1a adrenergic receptor and testosterone 5-alpha reductase inhibitors are adjusted when combined to achieve desired effects. As those skilled in the art will appreciate, dosages of the 5-alpha reductase inhibitor and the alpha 1a adrenergic receptor antagonist may be independently optimized and combined to achieve a synergistic result wherein the pathology is reduced more than it would be if either agent were used alone. In accordance with the method of the present invention, the individual components of the combination can be administered separately at different times during the course of therapy or concurrently in divided or single combination forms. The instant invention is therefore to be understood as embracing all such regimes of simultaneous or alternating treatment and the term "administering" is to be interpreted accordingly.
Thus, in one preferred embodiment of the present invention, a method of treating BPH is provided which comprises administering to a subject in need of treatment any of the compounds of the present invention in combination with finasteride effective to treat BPH. The dosage of finasteride administered to the subject is about 0.01 mg per subject per day to about 50 mg per subject per day in combination with an alpha 1a antagonist. Preferably, the dosage of finasteride in the combination is about 0.2 mg per subject per day to about 10 mg per subject per day, more preferably, about 1 to about 7 mg per subject to day, most preferably, about 5 mg per subject per day.
For the treatment of benign prostatic hyperplasia, compounds of this invention exhibiting alpha 1a adrenergic receptor blockade can be combined with a therapeutically effective amount of a 5α-reductase 2 inhibitor, such as finasteride, in addition to a 5α-reductase 1 inhibitor, such as 4,7β-dimethyl-4-aza-5α-cholestan-3-one, in a single oral, systemic, or parenteral pharmaceutical dosage formulation. Alternatively, a combined therapy can be employed wherein the alpha 1a adrenergic receptor antagonist and the 5α-reductase 1 or 2 inhibitor are administered in separate oral, systemic, or parenteral dosage formulations. See, e.g., U.S. Pat. No.'s 4,377,584 and 4,760,071 which describe dosages and formulations for 5α-reductase inhibitors.
Abbreviations used in the instant specification, particularly the Schemes and Examples, are as follows:
AcOH or HOAc=acetic acid
BCE=bromochloroethane
Boc or BOC=t-butyloxycarbonyl
Boc 2 O=di-tert-butyl dicarbonate
BOPCl=bis(2-oxo-3-oxazolidinyl)phosphinic chloride
Cbz-Cl=benzyloxycarbonyl chloride
DEAD=diethylazodicarboxylate
DMF=N,N-dimethylformamide
DMSO=dimethylsulfoxide
D-S=Dean Stark
EDCI=1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride
Et=ethyl
Et 3 N=triethylamine
EtOAc=ethyl acetate
EtOH=ethanol
FABLRMS=fast atom bombardment low resolution mass spectroscopy
HPLC=high performance liquid chromatography
HOBt=1-hydroxy benzotriazole hydrate
i-PrOH=2-propanol
i-Pr 2 NEt=diisopropylethylamine
LAH=lithium aluminum hydride
mCPBA=meta-chloroperbenzoic acid
Me=methyl
MeOH=methanol
NMR=nuclear magnetic resonance
PCTLC=preparative centrifugal thin layer chromatography
PEI=polyethylenimine
Ph=phenyl
RT=retention time
tBuOH=tert-butanol
TEBAC=benzyltriethylammonium chloride
TFA=trifluoroacetic acid
THF=tetrahydrofuran
TLC=thin layer chromatography
TMS=trimethylsilyl
Tos 2 O=p-toluenesulfonicanhydride
Triton B=N-benzyltrimethylammonium hydroxide
The compounds of the present invention can be prepared readily according to the following reaction schemes and examples, or modifications thereof, using readily available starting materials, reagents and conventional synthesis procedures. In these reactions, it is also possible to make use of variants which are themselves known to those of ordinary skill in this art, but are not mentioned in greater detail. Unless otherwise indicated, all variables are as defined above.
The general synthetic approach to analogs claimed within this application is outlined in Scheme 1. Starting from ketone A, reductive amination with a mono blocked diamino species provides an intermediate which can be alkylated on the newly generated secondary amine. Deprotection of the terminal blocked amine and acylation, alkylation, etc. provides the desired analogs.
For example, a substituted benzyl nitrile, sulphone, etc. can be added to methyl acrylate, submitted to Dieckman cyclization, hydrolyzed and decarboxylated providing appropriately substituted ketones A. Scheme 2 depicts a more specific series of compounds derived from Michael addition of substituted benzyl nitriles to methyl acrylate, Dieckman cyclization, providing the β-keto ester which can be either: (a) submitted to a reductive amination and carried on to final products, (b) enolized and alkylated then reductively aminated, deprotected and further manipulated providing further substituted analogs; or (c) hydrolyzed and decarboxylated and run through the above described conditions producing the desired antagonists.
Another strategy for the synthesis of some geminally disubstituted cyclic ketones, in particular, 4,4-disubstituted cyclohexanones was accomplished as outlined in Scheme 3 starting from benzophenone derivatives and substituted methyl vinyl ketones which under basic conditions lead to the 4,4-diaryl cyclohex-2-en-1-ones in good yield. Subsequent hydrogenation, reductive amination and deprotection provided the appropriate acylation/alkylation precursors.
Some examples were prepared by first assembling the appropriately substituted amino bearing cycloalkyl, then allylating the amino moiety. This approach is described in Scheme 4. Starting with a cycloalkanone, for instance, 4-cyano 4-phenyl piperidone, reductive amination with ammonium acetate and sodium cyanoborohydride provides both the cis and trans 1-amino cyclohexanes. The ratio of these isomers is modulated by the choice of an appropriate reducing reagent. The incipient amino group could be protected, alkylated, deprotected and alkylated again providing more funtionalized analogs.
Antagonists with alkyl (straight or branched chain) can be assembled by reductive amination of the prerequisite aminoalcohol and a cycloketone, for example, 4-cyano 4-phenylcyclohexanone, Scheme 5. Boc protection of the amine, followed by tosylation of the hydroxy and displacement by the lithium or sodium salt of the desired Q group completes the synthesis of the targeted antagonists.
The selective acylation of the primary amines was accomplished by treatment with nearly equimolar quantities of the activated termini species (i.e., the "Q" groups). The activated termini species comprising the "Q" groups are readily prepared by one of ordinary skill in the art. For example, oxazolidinones are prepared and activated in general by published and well developed chemistry, in particular, of Evans. [Evans, D. A. ; Nelson, J. V. ; Taber, T. R. Top. Stereochem. 13, 1 (1982)] The starting materials, in general, are natural and unnatural amino acids. For instance, some of the preferred compounds are prepared from substituted phenyl glycine derivatives, which after reduction of the carboxylate and a phosgene equivalent mediated cyclization provides the substituted oxazolidinone ring system. Deprotonation with n-butyl lithium and addition to a THF solution of p-nitrophenylchloroformate produces the stable, isolable "activated" oxazolidinone (oxa).
Hydantoins and cycloimide were prepared in two chemical steps from ketones as outlined in the literature. More specifically, hydantoins were prepared according to known methodology, e.g., J. J. Edmunds et al., J. Med. Chem. 1995, 38, pp. 3759-3771; J. H. Poupart et al., J. Chem. Res. 1979, pp. 174-175. Saccharins were prepared according to known methods, e.g., page 40 and Examples 21 and 22 of PCT International Application Publication No. WO96/25934, published Aug. 29, 1996.
The oxazolidinones were synthesized independently in racemic form, and then separated utilizing preparative chiral HPLC. Their optical rotations were recorded. Then they were activated and reacted with prerequisite amines. From the receptor binding studies, a preferred isomer was identified, the (+) rotational isomer. The absolute configurations were determined to be (S) for the oxazolidinones by correlating their optical rotations with x-ray crystal structures obtained of fragments involved in the production of the antagonists. ##STR12##
The following examples are provided to further define the invention without, however, limiting the invention to the particulars of these examples.
EXAMPLE 1 ##STR13##
cis 1-amino 4-cyano 4-phenylcyclohexane and trans 1-amino 4-cyano 4-phenylcyclohexane
A solution of 4-cyano 4-phenylcyclohexanone (6.0 g, 30 mmol), 8.0 g 4 Å molecular sieves and ammonium acetate (23.2 g, 300 mmol) in methanol (200 mL) (1.5 h premixed) was treated with sodium cyanoborohydride (1.9 g, 30 mmol) at room temperature. The resulting mixture was stirred at room temperature (60 min), then concentrated in vacuo and the residue dissolved in EtOAc and sodium bicarbonate solution. The aqueous layer was extracted with one additional portion of EtOAc, the combined organic extracts were washed with brine, dried over Na 2 SO 4 , and concentrated under reduced pressure. PCTLC (SiO 2 , 6 mm, 0-10% MeOH--CHCl 3 ) provided the two title compounds. The cis (more polar isomer) and trans isomer (less polar isomer). cis isomer: 1 H NMR (CDCl 3 , 300 MHz) 7.49 (br d, 2 H, ArH), 7.39 (br t, 2 H, ArH), 7.33 (br m, 1 H, ArH), 2.76 (br m, 1 H, CHNH 2 ), 2.21 (br d, 2 H), 2.03 (br dd, 2 H), 1.88 (br ddd, 2 H), 1.73 (br ddd, 2 H)
Anal. Calcd for C 13 H 16 N 2 : C=77.96, H=8.05, N=13.99. Found: C=78.00, H=7.94, N=13.82.
HPLC (Vydac; C18; diameter=4.6 mm; length=150 mm; gradient=H 2 O [0.1% H 3 PO 4 ]--CH 3 CN, 95%-5%, 5%-95%, over 16 minutes, 2 ml/min flow rate) RT=5.87 min; focus=215 nm; 97.4% pure. trans isomer: 1 H NMR (CDCl 3 , 300 MHz) 7.53 (br m, 2 H, ArH), 7.38 (br m, 2 H, ArH), 7.34 (br m, 1 H, ArH), 3.37 (dd, 1 H, CHNH 2 ), 2.36 (ddd, 2 H), 2.08 (br ddd, 2 H), 1.91 (br dd, 2 H), 1.67 (br dd, 2 H)
Anal. Calcd for C 13 H 16 N 2 .0.15 H 2 O C=77.96, H=8.05, N=13.99. Found: C=76.85, H=7.87, N=13.82.
HPLC (Vydac; C18; diameter=4.6 mm; length=150 mm; gradient=H 2 O [0.1% H 3 PO 4 ]--CH 3 CN, 95%-5%, 5%-95%, over 16 minutes, 2 ml/min flow rate) RT=5.68 min; focus=215 nm; 98.4% pure.
EXAMPLE 2 ##STR14##
cis 1-N-(1,1-dimethylethoxycarbonyl)amino-4-cyano 4-phenylcyclohexane
A solution of the amine (3.0 g, 15 mmol) and BOC 2 O (3.3 g, 15 mmol) in THF (40 mL) was mixed at room temperature for 1 h. The resulting mixture was concentrated in vacuo to afford the title compound.
cis isomer: 1 H NMR (CDCl 3 , 300 MHz) 7.47 (br m, 2 H, ArH), 7.40 (br m, 2 H, ArH), 7.35 (br m, 1 H, ArH), 4.52 (br d, 1 H, NHC═O), 3.52 (br s, 1 H, CHNH), 2.40 (br m, 4 H), 1.92 (br ddd, 2 H), 1.71 (br ddd, 2 H), 1.46 (br s, 9 H)
EXAMPLE 3 ##STR15##
cis 1-N-[(1,1-dimethylethoxycarbonyl)methyl]amino-4-cyano 4-phenylcyclohexane
A solution of the BOC carbamate (2.0 g, 15 mmol) in DMF (10 mL) was treated with NaH (290 mg, 7.33 mmol) and iodomethane at 0° C. for 4 h. The resulting mixture was diluted with water (50 mL), extracted with EtOAc (3×50 mL), washed with brine (1×75 mL), dried (Na 2 SO 4 ), filtered and concentrated in vacuo. PCTLC 0-50% EtOAc/hexane afforded the title compound.
cis isomer: 1 H NMR (CDCl 3 , 300 MHz) 7.48 (br m, 2 H, ArH), 7.43 (br m, 2 H, ArH), 7.34 (br m, 1 H, ArH), 4.16 (br d, 1 H, CHNH), 2.83 (br s, 3 H, NCH 3 ), 2.25 (br d, 2 H), 1.80-2.10 (br m, 6 H), 1.49 (br s, 9 H)
EXAMPLE 4 ##STR16##
cis 1-N-methylamino-4-cyano 4-phenylcyclohexane
A solution of the BOC carbamate (1.5 g, 4.8 mmol) was treated saturated HCl-EtOAc at 0° C. The resulting mixture was allowed to warm to room temperature (1 h) then concentrated in vacuo affording the title compound.
Anal. Calcd for C 14 H 18 N 2 .HCl: C=67.05, H=7.64, N=11.17. Found: C=66.92, H=7.51, N=11.20.
HPLC (Vydac; C18; diameter=4.6 mm; length=150 mm; gradient=H 2 O [0.1% H 3 PO 4 ]--CH 3 CN, 95%-5%, 5%-95%, over 16 minutes, 2 ml/min flow rate) RT=5.91 min; focus=215 nm; 100% pure.
EXAMPLE 5 ##STR17##
(4-cyano-4-phenyl-cyclohexyl)-[3-(2,2-di-p-tolyl-acetylamino)-propyl]-methyl-ammonium chloride
A solution of the amine (75.0 mg, 0.35 mmol), Br(CH2) 3 NHCOCH(p-tolyl) 2 (140 mg, 0.385 mmol) and iPr 2 NEt (54.3 mg, 0.42 mmol) was stirred in DMF (1 mL) at room temperature (12 h). The solvent was removed in vacuo and submitted to PCTLC (SiO 2 , 2 mm, CHCl 3 -90:10:1 CHCl 3 :CH 3 OH:NH 4 OH providing the title compound which was converted to the hydrochloride salt by treatment with HCl-EtOAc.
cis isomer: 1 H NMR (DMSO-d 6 , 400 MHz) 8.44 (br t, 1 H, NH), 7.53 (br d, 2 H, ArH), 7.47 (br t, 2 H, ArH), 7.39 (br m, 1 H, ArH), 7.18 (br dd, 4 H, ArH), 7.1 (br d, 4 H, ArH), 4.83 (br s, 1 H, CHC═O), 3.19 (br m, 2 H), 3.04 (br m, 2 H), 2.50 (br s, 7 H, CHNCH 3 and ArCH 3 ), 2.24 (br s, 3 H, NCH 3 ), 2.21 (br m, 2 H), 2.10 (br d, 2 H), 1.95 (br m, 2 H), 1.82 (br m, 2 H), 1.72 (br m, 2H)
Anal. Calcd for C 33 H 39 N 3 O. 2H 2 O: C=70.00, H=7.83, N=7.42. Found: C=69.92, H=7.51, N=7.08.
HPLC (Vydac; C18; diameter=4.6 mm; length=150 mm; gradient=H 2 O [0.1% H 3 PO 4 ]--CH 3 CN, 95%-5%, 5%-95%, over 16 minutes, 2 ml/min flow rate) RT=10.66 min; focus=215 nm; 96.7% pure.
EXAMPLE 6 ##STR18##
(4-cyano-4-phenyl-cyclohexyl)-methyl-[4-(1,1,3-trioxo-1,3-dihydro-1l6-benzo[d]isothiazol-2-yl)-butyl]-ammonium chloride
A solution of the amine (99.6 mg, 0.465 mmol), Br(CH2) 4 -N(saccharin) (178 mg, 0.558 mmol) and iPr 2 NEt (72 mg, 0.558 mmol) was stirred in DMF (1 mL) at room temperature (12 h). The solvent was removed in vacuo and submitted to PCTLC (SiO 2 , 2 mm, CHCl 3 -95:5 CHCl 3 :CH 3 OH providing the title compound (193.2 mg, 210 mg theoretical, 92%) which was converted to the hydrochloride salt by treatment with HCl-EtOAc.
cis isomer: 1 H NMR (CDCl 3 , 300 MHz) 8.07 (dd, 1 H, ArH), 7.90 (br dd, 1 H, ArH), 7.87 (br m, 2 H, ArH), 7.48 (br d, 2 H, ArH), 7.28-7.42 (br m, 3 H, ArH), 3.83 (t, 2 H, J=7.5 Hz), 2.56 (br m, 3 H), 2.32 (br 2, 3 H, NCH 3 ), 2.24 (br d, 2 H), 1.80-2.00 (br m, 8 H), 1.60 (br m, 2 H).
Anal. Calcd for C 25 H 29 N 3 O 3 S.1 HCl & 0.25 H 2 O: C=60.96, H=6.24, N=8.53. Found: C=60.97, H=6.08, N=8.57.
HPLC (Vydac; C18; diameter=4.6 mm; length=150 mm; gradient=H 2 O [0.1% H 3 PO 4 ]--CH 3 CN, 95%-5%, 5%-95%, over 16 minutes, 2 ml/min flow rate) RT=8.53 min; focus=215 nm; 100% pure.
EXAMPLE 7 ##STR19##
(4-cyano-4-phenyl-cyclohexyl)-methyl-[3-(1,1,3-trioxo-1,3-dihydro-1l6-benzo[d]isothiazol-2-yl)-propyl]-ammonium chloride
A solution of the amine (80.0 mg, 0.3733 mmol), Br(CH2) 3 -N(saccharin) (119.2 mg, 0.392 mmol) and iPr 2 NEt (53 mg, 0.411 mmol) was stirred in DMF (1 mL) at room temperature (12 h). The solvent was removed in vacuo and submitted to PCTLC (SiO 2 , 2 mm, CHCl 3 -95:5 CHCl 3 :CH 3 OH providing the title compound.
cis isomer: 1 H NMR (CDCl 3 , 300 MHz) 8.04 (dd, 1 H, ArH), 7.90 (br dd, 1 H, ArH), 7.87 (br m, 2 H, ArH), 7.49 (br d, 2 H, ArH), 7.28-7.42 (br m, 3 H, ArH), 3.83 (t, 2 H, J=7.5 Hz), 2.64 (br t, 2 H), 2.56 (br m, 1 H), 2.32 (br 2, 3 H, NCH 3 ), 2.24 (br d, 2 H), 1.80-2.00 (br m, 8 H).
Anal. Calcd for C 24 H 27 N 3 O 3 S. 0.25 CHCl 3 : C=65.12, H=6.15, N=9.47. Found: C=65.19, H=5.76, N =9.34.
EXAMPLE 8 ##STR20##
A: 5-nitrilo-4-o-tolyl-pentanoic acid methyl ester
B: 4-cyano-4-o-tolyl-heptanedioic acid dimethyl ester
A solution of 2-methylbenzyl nitrile (25.0 g), methyl acrylate (75 mL) and Triton-B (40 μmL) in t-butanol (90 mL) was refluxed (12 h). The solvent was removed in vacuo and submitted to SGC (SiO 2 , 10 cm×30 cm, 0-15% EtOAc-hexane) affording the mono addition product and the desired bis addition compound (5).
A: 1 H NMR (CDCl 3 , 300 MHz) 7.42 (m, 1 H, ArH), 7.20 (m, 3 H, ArH), 4.34 (dd, 1 H, CHCN), 3.69 (s, 3 H, OMe), 2.57 (m, 2 H), 2.37 (s, 3 H, Me), 2.16 (m, 2 H).
B: 1 H NMR (CDCl 3 , 300 MHz) 7.42 (m, 1 H, ArH), 7.20 (m, 3 H, ArH), 3.62 (s, 6 H, OMe), 2.57 (m, 4 H), 2.54 (s, 3 H, Me), 2.31 (m, 2 H).
EXAMPLE 9 ##STR21##
5-cyano-2-oxo-5-o-tolyl-cyclohexanecarboxylic acid methyl ester
A solution of the diester (9.38 g, 29.4 mmol) in THF (200 mL) was treated with KOt-Bu (6.6 g, 58.74 mmol) at 0° C. then heated to reflux (20 min). The solvent was removed in vacuo and submitted to SGC (SiO 2 , 6 cm×20 cm, 15% EtOAc-hexane) affording desired product and some decarboxylated material.
1 H NMR (CDCl 3 , 300 MHz) consistent with assigned structure.
FABLRMS m/e 272.22 g/mole (M + +H, C 16 H 17 NO 3 =272 g/mole.)
EXAMPLE 10 ##STR22##
4-cyano(2-methylphenyl)-cyclohexan-1-one
A solution of the ketoester (5.0 g, 18.4 mmol) in AcOH (100 mL) was treated with 10% aqueous H 2 SO 4 (10 mL) at 0° C. then heated to reflux (24 h). The solvent was removed in vacuo, diluted with EtOAc (100 mL) and water (100 mL), partitioned, washed with brine (75 mL), dried (Na 2 SO 4 ), filtered and concentrated in vacuo and submitted to SGC (SiO 2 , 5 cm×20 cm, 0-15% EtOAc-hexane) affording the ketone.
1 H NMR (CDCl 3 , 300 MHz) 7.24 (m, 4H, ArH), 2.95 (ddd, 1 H, CHCN), 2.70 (s, 3 H, Me), 2.60 (m, 4 H), 2.20 (ddd, 2 H).
EXAMPLE 11 ##STR23##
2-(2-tert-butoxycarbonylamino-ethylamino)-5-cyano-5-o-tolyl-cyclohexanecarboxylic acid methyl ester
A solution of the ketoester (0.8 g, 3.75 mmol), amine (0.601 g, 3.75) and acetic acid (0.236 g, 18.75 mmol) in MeOH (10 mL) was treated with NaBH 3 CN (0.236 g, 3.75 mmol) at room temperature (12 h). The solvent was removed in vacuo, diluted with DCM (25 mL) and saturated aqueous sodium bicarbonate (25 mL), partitioned, extracted with DCM (2×25 mL), washed with saturated aqueous sodium bicarbonate (2×25 mL) and brine (50 mL), dried (Na 2 SO 4 ), filtered and concentrated in vacuo and submitted to PCTLC (SiO 2 , 4 mm, 90/10/1 CHCl 3 --MeOH--NH 4 OH) the titled trans (A) and cis (B) amines.
B 1 H NMR (CDCl 3 , 400 MHz) 7.24 (m, 4 H, ArH), 4.98 (br s, 1 H, NHBOC), 3.75 (s, 3 H, OMe), 3.18 (br d, 2 H, 2.89 (br ddd, 2 H), 2.80 (ddd,1 H), 2.68 (m, 1 H), 2.64 (s, 3 H, Me), 2.54 (ddd, 1 H), 2.45 (ddd, 1 H), 2.29 (ddd, 1 H), 2.01 (dd, 1 H), 1.84 (ddd, 1 H), 1.75 (ddd, 1H), 1.45 (s, 9 H, C(Me) 3 )
EXAMPLE 12 ##STR24##
[2-(4-cyano-4-o-tolyl-cyclohexylamino)-ethyl]-carbamic acid tert-butyl ester
A solution of the ketone (0.6 g, 2.813 mmol), ethylene diamine (0.845 g, 14.1 mmol) and p-toluene sulphonic acid (0.026 g, 0.141 mmol) in benzene (10 mL) was refluxed under a Dean-Stark trap until cessation of water azeotrope. The solvent was removed in vacuo, diluted with MeOH (25 mL) and treated with NaBH 3 CN (0.159 g, 2.55 mmol) at room temperature (1 h). The solvent was removed in vacuo, diluted with DCM 25 mL) and saturated aqueous sodium bicarbonate (25 mL), partitioned, extracted with DCM (2×25 mL), washed with saturated aqueous sodium bicarbonate (2×25 mL) and brine (50 mL), dried (Na 2 SO 4 ), filtered and concentrated in vacuo and submitted to PCTLC (SiO 2 , 2 cm, 80/20/2 CHCl 3 --MeOH--NH 4 OH) the titled trans (minor) (A) and cis (major) (B) amines.
A trans: 1 H NMR (CDCl 3 , 300 MHz) 7.38 (m, 1 H), 7.20 (m, 3 H, ArH), 2.98 (br m, 1 H, CHNH), 2.80 (br t, 2 H), 2.65 (s, 3 H, Me), 2.64 (br m, 2 H), 2.38 (br dd, 2 H) 2.09 (br m, 4 H), 1.83 (br d, 2 H).
B cis: 1 H NMR (CDCl 3 ,300 MHz) 7.24 (m, 4 H, ArH), 2.83 (br dd, 2 H), 2.75 (br dd, 2 H), 2.65 (s, 3 H, Me), 2.55 (br m, 1 H, CHNH), 2.43 (br m, 2 H), 2.16 (br d, 2 H), 1.67 (br d, 4 H).
EXAMPLE 13 ##STR25##
(+)-2-Oxo-4-(3,4,5-trifluorophenyl)-oxazolidine-3-carboxylic acid [2-(4-cyano-4-phenyl-cyclohexylamino)-ethyl]amide
To a solution of 1-[(2-amino-ethyl)-amino]-4-cyano-4-phenylhexane (25 mg, 0.103 mmol) in 10 mL of THF, 4-(3,4,5-trifluorophenyl)-2-oxo-oxazolidine-3-carboxylic acid-4-nitro-phenyl ester (30 mg, 0.079 mmol) was added and the resulting yellow solution was stirred under argon atmosphere for 2 h at room temperature. The solvent was removed in vacuo and the residue was purified by column chromatography over silica gel with 1:1 hexane/EtOAc followed by MeOH:EtOAc=1:9 (R f =0.60, MeOH:EtOAc=1:3) to obtain the title compound. The compound was dissolved in CH 2 Cl 2 (3 mL) and was treated with 1N HCl in ether (1 mL). The solvent was removed in vacuo to give the corresponding hydrochloride salt as a pale yellow solid. M. P. 130-134° C.; [α] D =+43.5, (c=0.25, MeOH); Anal. Calcd. For C 25 H 26 N 4 O 3 F 3 Cl 1.10 C 3 H 6 O: C, 57.92; H, 5.60; N, 8.55. Found: C, 58.33; H, 5.90; N, 8.52.
EXAMPLES 14 AND 15 ##STR26##
(+)-2-Oxo-4-(3,4-difluorophenyl)-oxazolidine-3-carboxylic acid [2-(4-phenyl-4-methoxycarbonyl-cyclohexylamino)-ethyl]amide (cis isomer) and
(+)-2-Oxo-4-(3,4-difluorophenyl)-oxazolidine-3-carboxylic acid [2-(4-phenyl-4-methoxycarbonyl-cyclohexylamino)-ethyl]amide (trans isomer)
a. 2-[4-Cyano-4-phenylcyclohex-1-yl]aminoethylamine
A mixture of 4-cyano-4-phenylcyclohexanone (48.7 mmol) and ethylenediamine (8.78 g, 146 mmol) and p-toluenesulfonic acid (92 mg) in benzene (200 mL) was refluxed for 4 h in Dean-Stark trap to remove the water that formed. Solvent was evaporated and the residue was redissolved in methanol (60 mL) and cooled to 0 C. To this, sodium borohydride (6.4 5 g) was added in portions and the mixture was stirred at room temperature for 3 h. Solvent was evaporated, the residue was dissolved in dichloromethane (300 mL), washed with brine (3×500 mL), dried (potassium carbonate), and the solvent evaporated to leave the product as a pale yellow viscous oil (90-95%). The 1 H-NMR showed the product to be pure and found to contain the cis/trans isomers in the ratio of about 9:1. A careful chromatography of this mixture with chloroform/methanol/2M ammonia in methanol (100/10/5 to 100/20/10) gave some earlier fractions enriched in the trans isomer relative to the amino and cyano groups. The fractions eluted at the end were almost pure cis isomer relative to the amino and cyano groups.
b. 2-[4-Methoxycarbonyl-4-phenylcyclohex-1-yl]aminoethylamine
A mixture of 2-[4-cyano-4-phenylcyclohex-1-yl]aminoethylamine (2.34 g, 10 mmol) and concentrated sulfuric acid (20 mL) was heated at 80-85° C. for 10 h. It was cooled to room temperature, mixed with anhydrous methanol (200 mL), and refluxed for 20 h. Solvent was evaporated and the residue was poured onto ice (200 g) and basified to pH 11 by addition 6N NaOH. It was extracted with dichloromethane (4×125 mL), dried (potassium carbonate) and solvent evaporated to leave the product as an oil (2.1 g, 76%). 1 H-NMR showed this product to be pure and a mixture of cis and trans isomers. It was used in the next step without any further purification.
c. (+)-2-Oxo-4-(3,4-difluorophenyl)-oxazolidine-3-carboxylic acid [2-(4-phenyl-4-methoxycarbonyl-cyclohexylamino)-ethyl]amide (cis isomer) and
(+)-2-Oxo-4-(3,4-difluorophenyl)-oxazolidine-3-carboxylic acid [2-(4-phenyl-4-methoxycarbonyl-cyclohexylamino)-ethyl]amide (trans isomer).
A mixture of 4-(3,4-difluorophenyl)-3-(4-nitrophenyloxy-carbonyl)-2-oxo-oxazolidine (50 mg, 0.123 mmol) and 2-[4-methoxy-carbonyl-4-phenylcyclohex-1-yl]aminoethylamine (75 mg) in dichloromethane (6 mL) was stirred at room temperature and the product formed was purified by preparative TLC on silica gel using ethyl acetate as the eluent. There were two bands for the two isomers, the higher band was the minor product ( 1 H-NMR confirmed it to be the cis isomer with respect to methoxycarbonyl and amine groups) and the lower band was the major product ( 1 H-NMR confirmed it to be the trans isomer with respect to methoxycarbonyl and amine groups). The HCl salt was made by treatment with 1N HCl in ether.
(+)-2-Oxo-4-(3,4-difluorophenyl)-oxazolidine-3-carboxylic acid [2-(4-phenyl-4-methoxycarbonyl-cyclohexylamino)-ethyl]amide (cis isomer). [α] D =65.8 (c=0.50 g, methanol);
m.p. 146-148 C; Anal. Calcd. For: C 26 H 29 F 2 N 3 O 5 .HCl: C, 58.05; H, 5.62; N, 7.81. Found: C, 58.45; H, 5.51; N, 7.89.
(+)-2-Oxo-4-(3,4-difluorophenyl)-oxazolidine-3-carboxylic acid [2-(4-phenyl-4-methoxycarbonyl-cyclohexylamino)-ethyl]amide (trans isomer). [α]D =+66 (c=0.48 g, methanol); m.p. 140-142 C; Anal. Calcd. For: C26H 29 F 2 N 3O 5 . HCl.0.4H 2 O: C, 57.16; H, 5.39; N, 7.61. Found: C, 57.28; H, 5.69; N, 7.79.
EXAMPLE 16 ##STR27##
(+)-cis-2-Oxo-4-(3,4-difluorophenyl)-oxazolidine-3-carboxylic acid [2-(4-cyano-4-(2-ethoxyphenyl)-cyclohexylamino)-ethyl]amide
a. 4-Cyano-4-(2-ethoxy)phenyl-2-methoxycarbonylcyclohexanone
A solution of 40% methanolic triton-B (1.8 mL) in t-butyl alcohol (3.7 mL) was slowly added to a solution of 2-ethoxybenzyl cyanide (3.0 g, 18.6 mmol) and methyl acrylate (5.4 mL, 60.0 mmol) in refluxing t-butyl alcohol (5.4 mL). The mixture, after having been heated at reflux overnight, was concentrated. The residue was dissolved in chloroform (50 mL) and washed with 2N HCl (40 mL) and water (40 mL), dried (Na 2 SO 4 ), filtered and concentrated to give a colorless oil (5.98 g, 96%). This oil (5.98 g, 17.9 mmol) was dissolved in dry toluene (50 mL), cooled by an ice water bath and treated with NaH (60% oil dispersion, 804 mg, 20.1 mmol). The mixture was heated at reflux for 4 h. A solution of 2N acetic acid (21 mL) was added. The organic layer was separated, washed with NaHCO 3 solution, dried (Na 2 SO 4 ), filtered and concentrated to give a light brown liquid (4.76 g). It was dissolved in CH 2 Cl 2 and flash chromatographed over silica gel (320 g) eluting with EtOAc/hexane (1:10) to afford a white solid (2.09 g, 39%): mp 82-88 C.; ESMS m/e=302 (MH + ).
b. 4-Cyano-4-(2-ethoxy)phenylcyclohexanone
4-Cyano-4-(2-ethoxy)phenyl-2-methoxycarbonylcyclohexanone (1.06 g, 3.5 mmol) was heated at reflux in acetic acid (24 mL) and 10% H 2 SO 4 (13 mL) for 6 h. Extraction with benzene (3×10 mL), which was washed with K 2 CO 3 solution, dried (Na 2 SO 4 ), filtered and concentrated, gave a white solid (0.755 g, 88%): mp 116-121 C.
c. cis-4-Cyano-4-(2-ethoxy)phenylcyclohexyl-aminoethylamine
4-Cyano-4-(2-ethoxy)phenylcyclohexanone (300 mg, 1.23 mmol) was mixed with ethylenediamine (420 mL, 6.28 mmol) and a catalytic amount of tosic acid monohydrate in benzene (10 mL) and heated at reflux for 6 h. The solvent was evaporated off and the residue dissolved in dry EtOH (10 mL). After treatment with NaBH 4 (47 mg, 1.24 mmol), the mixture was stirred at room temperature for 3 h. The solvent was evaporated off and the residue triturated with CH 2 Cl 2 , treated with anhydrous Na 2 SO 4 and filtered to afford a pale yellow oil (320 mg, 90%).
d. (+)-cis-2-Oxo-4-(3,4-difluorophenyl)-oxazolidine-3-carboxylic acid [2-(4-cyano-4-(2-ethoxyphenyl)-cyclohexylamino)-ethyl]amide
To cis-4-cyano-4-(2-ethoxy)phenylcyclohexylaminoethylamine (43 mg, 0.15 mmol) in dry THF (5 mL) was added (+)-4-(3,4-difluoro)phenyl-3-(4-nitro)phenoxycarbonyl-2-oxazolidone (50 mg, 0.14 mmol). The yellow solution was stirred at room temperature for 5 h before it was concentrated. The residue was dissolved in CHCl 3 and flash chromatographed over silica gel (18 g) eluting with EtOAc/hexane (1:1) and then EtOAc/2M NH 3 in MeOH (20:1) to give a colorless oil (41 mg, 58%). It was dissolved in CHCl 3 /CH 2 Cl 2 and treated with 1M HCl in ether (120 μL) to afford a white solid: mp 125 C. (dec.); [α] D =71.4 (2.1 mg/mL MeOH); ESMS m/e=513 (MH + ). Anal. Calcd. for C 27 H 30 F 2 N 4 O 4 .HCl.0.5CHCl 3 : C, 54.26; H, 5.22; N, 9.20. Found: C, 53.98; H, 5.04; N, 8.89.
EXAMPLE 17 ##STR28##
[4-cyano-4-(2-methoxy-phenyl)-cyclohexyl]-(2-{[4-(3,4-difluoro-phenyl)-2-oxo-oxazolidine-3-carbonyl]-amino}-ethyl)-ammonium chloride
To a solution of dry tetrahydrofuran (2 mL) containing 120 mg (0.33 mmole) of (+)-4-(3,4-difluorophenyl)-2-oxo-oxazolidine-3-carboxylic acid 4-nitrophenyl ester was added 87 mg (0.32 mmole) of 2-{[4-cyano-4-(2-methoxy)phenyl]cyclohexylamino}ethyl amine at ambient temperature under argon. The reaction mixture was stirred for 15 minutes and then was treated with 5 mL of 10% potassium carbonate solution. The reaction mixture was extracted with ethyl acetate (2×). The combined organic extracts were washed with brine, dried (sodium sulfate) and concentrated to give the crude product as an oil. Column chromatography of the reaction product on silica gel (methanol/methylene chloride gradient elution (1 to 4%)) afforded the title compound which was converted to its salt form with HCl in dioxane: m.p. 140° C. (d);
HPLC=>99% pure at 215 nm
NMR(CDCl 3 , 400 MHz): Consistent with structure assignment and confirms presence of solvent.
FAB MS: 499 (M + +1).
Analysis for C 26 H 28 F 2 N 4 O 4 .HCl.0.3H 2 O: Calculated: C, 57.79; H, 5.52; N, 10.37. Found: C, 57.76; H, 5.80; N, 10.47.
EXAMPLE 18 ##STR29##
[4-cyano-4-(2-fluoro-phenyl)-cyclohexyl]-(2-{[4-(3,4-difluoro-phenyl)-2-oxo-oxazolidine-3-carbonyl]-amino}-ethyl)-ammonium chloride
Using reaction conditions identical to those described in Example 19,139 mg (0.38 mmole) of (+)-4-(3,4-difluorophenyl)-2-oxo-oxazolidine-3-carboxylic acid 4-nitrophenyl ester in 2 mL of tetrahydrofuran was converted to the title compound by reacting it with 100 mg (0.38 mmole) of 2-{[4-cyano-4-(2-fluoro)phenyl]cyclohexylamino}ethyl. The chromatographed product was converted to the HCl salt and lyophilized:
HPLC=>99% pure at 215 nm
NMR(CDCl 3 , 400 MHz): Consistent with structure assignment and confirms presence of solvent.
FAB MS: 487 (M + +1).
Analysis for C 25 H 25 F 3 N 4 O 2 .HCl.0.6H 2 O: Calculated: C, 56.25; H, 5.14; N, 10.50. Found: C, 56.21; H, 4.74; N, 10.27.
EXAMPLE 19 ##STR30##
4-(3,4-difluoro-phenyl)-2-oxo-oxazolidine-3-carboxylic acid {2-[4-cyano-4-(2-trifluoromethoxy-phenyl)-cyclohexylamino]-ethyl{-amide
To a solution of dry N,N-dimethylformamide (5 mL) containing 137 mg (0.34 mmole) of 2-{[4-cyano-4-(2-trifluoromethoxy)phenyl]cyclohexylamino}ethyl amine hydrochloride was added 124 mg (0.34 mmole) of (+)-4-(3,4-difluorophenyl)-2-oxo-oxazolidine-3-carboxylic acid 4-nitrophenyl ester and 124 μL (1.2 mmole) of diisopropylethylamine at ambient temperature. The homogeneous reaction mixture was stirred for 30 minutes, concentrated in vacuo and and residue was dissolved in ethyl acetate. The ethyl acetate solution was washed with 10% potassium carbonate solution (6×), dried (magnesium sulfate) and concentrated to give the crude product as an oil. Flash column chromatography of the reaction product on silica gel (methanol/methylene chloride/ammonium hydroxide, gradient elution (0.5 to 2%)) afforded the title compound in analytically pure form:
HPLC=96% pure at 215 nm
NMR(CDCl 3 , 400 MHz): Consistent with structure assignment and confirms presence of solvent.
FAB MS: 553 (M + +1).
Analysis for C 26 H 25 F 5 N 4 O 4 .0.55H 2 O: Calculated: C, 55.52; H, 4.68; N, 9.96. Found: C, 55.54; H, 4.64; N, 10.01.
EXAMPLE 20 ##STR31##
4-(3,4-difluoro-phenyl)-2-oxo-oxazolidine-3-carboxylic acid {2-[4-cyano-4-(2-trifluoromethoxy-phenyl)-cyclohexylamino]-ethyl}-amide
Using reaction conditions identical to those described in Example 21, 126 mg (0.35 mmole) of (+)-4-(3,4-difluorophenyl)-2-oxo-oxazolidine-3-carboxylic acid 4-nitrophenyl ester in 5 mL of N,N-dimethylformamide was converted to the title compound with 139 mg (0.35 mmole) of 2-{[4-cyano-4-(2-trifluoromethoxy)phenyl]cyclohexylamino}ethyl amine hydrochloride and 211 μL (1.2 mmole) of diisopropylethylamine. Extractive workup, followed by flash chromatography of the crude reaction product, and lyophilization gave a white solid:
HPLC=>99% pure at 215 nm
NMR(CDCl 3 , 400 MHz): Consistent with structure assignment.
FAB MS: 553 (M + +1).
Analysis for C 26 H 25 F 5 N 4 O 4 : Calculated: C, 56.52; H, 4.56; N, 10.14. Found: C, 56.76; H, 4.72; N, 10.18.
EXAMPLE 21 ##STR32##
4-(3,4-difluoro-phenyl)-2-oxo-oxazolidine-3-carboxylic acid (2-[4-cyano-4-(2-trifluoromethyl-phenyl)-cyclohexylamino]-ethyl}-amide
Using reaction conditions identical to those described in Example 21, 122 mg (0.34 mmole) of (+)-4-(3,4-difluorophenyl)-2-oxo-oxazolidine-3-carboxylic acid 4-nitrophenyl ester in 5 mL of N,N-dimethylformamide was converted to the title compound by reacting it with 129 mg (0.34 mmole) of 2-{[4-cyano-4-(2-trifluoromethyl)phenyl]cyclohexylamino}ethyl amine hydrochloride and 204 μL (1.2 mmole) of diisopropylethylamine. Extractive workup, followed by flash chromatography of the crude reaction product, and lyophilization gave the title compound as a white powder:
HPLC=99% pure at 215 nm
NMR(CDCl 3 , 400 MHz): Consistent with structure assignment.
FAB MS: 537 (M + +1).
Analysis for C 26 H 25 F 5 N 4 O 3 : Calculated: C, 58.21; H, 4.70; N, 10.44. Found: C, 57.70; H, 4.55; N, 10.32.
EXAMPLE 22 ##STR33##
4-(3,4-difluoro-phenyl)-2-oxo-oxazolidine-3-carboxylic acid {2-[4-cyano-4-(2-trifluoromethyl-phenyl)-cyclohexylamino]-ethyl}-amide
Using reaction conditions identical to those described in Example 21, 130 mg (0.36 mmole) of (+)-4-(3,4-difluorophenyl)-2-oxo-oxazolidine-3-carboxylic acid 4-nitrophenyl ester in 5 mL of N,N-dimethylformamide was converted to the title compound by reacting it with 138 mg (0.36 mmole) of 2-{[4-cyano-4-(2-trifluoromethyl)phenyl]cyclohexylamino}ethyl amine hydrochloride and 219 μL (1.26 mmole) of diisopropylethylamine. Extractive workup, followed by flash chromatography of the crude reaction product, and lyophilization gave the title compound as a white powder:
HPLC=97% pure at 215 nm
NMR(CDCl 3 , 400 MHz): Consistent with structure assignment.
FAB MS: 537 (M + +1).
Analysis for C 26 H 25 F 5 N 4 O 3 : Calculated: C, 58.21; H, 4.70; N, 10.44. Found: C, 57.80; H, 4.61; N, 10.42.
EXAMPLE 23 ##STR34##
(2-{[4-(3,4-difluoro-phenyl)-2-oxo-oxazolidine-3-carbonyl]-amino}-ethyl)-(4-methanesulfonyl-4-phenyl-cyclohexyl)-ammonium chloride
Using reaction conditions identical to those described in Example 21, 172 mg (0.47 mmole) of (+)-4-(3,4-difluorophenyl)-2-oxo-oxazolidine-3-carboxylic acid 4-nitrophenyl ester in a solvent mix of 8 mL of N,N-dimethylformamide and 2 mL of tetrahydrofuran was converted to the title compound by reacting it with 175 mg (0.47 mmole) of 2-[(4-methansulfonyl-4-phenyl) cyclohexylamino]ethyl amine hydrochloride and 288 μL (1.66 mmole) of diisopropylethylamine. Extractive workup, followed by flash chromatography of the crude reaction product (silica gel; methanol/methylene chloride elution, 1:1), and lyophilization gave the title compound which was converted to its HCl salt with HCl in dioxane:
HPLC=>93% pure at 215 nm
NMR(CDCl 3 , 400 MHz): Consistent with structure assignment and confirms presence of solvent.
FAB MS: 522 (M + +1).
Analysis for C 25 H 29 F 2 N 3 O 5 S.0.95 H 2 O: Calculated: C, 52.20; H, 5.59; N, 7.31. Found: C, 52.19; H, 5.28; N, 7.22.
EXAMPLE 24 ##STR35##
(2-{[4-(3,4-difluoro-phenyl)-2-oxo-oxazolidine-3-carbonyl]-amino}-ethyl)-(4-methanesulfonyl-4-phenyl-cyclohexyl)-ammonium chloride
Using reaction conditions identical to those described in Example 21, 153 mg (0.42 mmole) of (+)-4-(3,4-difluorophenyl)-2-oxo-oxazolidine-3-carboxylic acid 4-nitrophenyl ester in 2 mL of N,N-dimethylformamide was converted to the title compound by reacting it with 155 mg (0.42 mmole) of 2-[(4-methansulfonyl-4-phenyl)cyclohexylamino]ethyl amine hydrochloride and 256 μL (1.47 mmole) of diisopropylethylamine. Extractive workup, followed by flash chromatography of the crude reaction product (silica gel; methanol/methylene chloride/ammonium hydroxide gradient elution), and lyophilization gave the title compound which was converted to its 4HCl salt with HCl in dioxane:
HPLC=>93% pure at 215 nm
NMR(CDCl 3 , 400 MHz): Consistent with structure assignment and confirms presence of solvent.
FAB MS: 522 (M + +1).
Analysis for C 25 H 29 F 2 N 3 O 5 S.0.5 H 2 O: Calculated: C, 52.95; H, 5.51; N, 7.41. Found: C, 53.14; H, 5.80; N, 7.02.
Utilizing the methodology described in detail in the Examples and schemes above, the following compounds shown in Table 1 were made.
TABLE 1__________________________________________________________________________ #STR36## - cis/ HPLC Elemental R.sup.2 Q trans FABLRMS R.T. Analysis__________________________________________________________________________ CBZ.sup.4 cis 574.27 g/mole 14.19 min. Calc. for 0.95 H.sub.2 O; 0.25 EtOAc Solvate mol. wt. = 612.83 g/mole Calc: C = 68.60% H = 6.73% N = 6.86% Obs: C = 69.52% H = 6.31% N = 6.95% - #STR38## cis 598.32 g/mole 12.49 min. N/A - H cis (±) 440.30 g/mole 9.72 min. N/A - #STR41## cis 482.41 g/mole 10.44 min. N/A - #STR43## cis 498.31 g/mole 10.21 min. Calc. for 0.10 H.sub.2 O; 0.60 CHCl.sub.3 Solvate mol. wt. = 571.06 g/mole Calc.: C = 62.26% H = 6.67% N = 7.36% Obs.: C = 62.22% H = 6.54% N = 7.08% - H cis 398.28 g/mole 8.00 min. Calc. for 0.30 H.sub.2 O; 1.0 HCl Solvate mol. wt. = 487.08 g/mole Calc.: C = 62.26% H = 6.67% N = 7.36% Obs.: C = 62.22% H = 6.54% N = 7.08% - #STR46## cis 598.23 g/mole 12.49 min. N/A - H cis (±) 440.30 g/mole 9.72 min. N/A - #STR49## cis 482.41 g/mole 10.44 min. N/A - H cis 384.21 g/mole 8.08 min. Calc. for 0.20 MeOH; 1.0 HCl Solvate mol. wt. = 426.32 g/mole Calc.: C = 62.55% H = 5.86% N = 9.86% Obs.: C = 62.53% H = 5.83% N = 9.62% - H cis 366.27 g/mole 8.17 min. Calc. for 0.85 H.sub.2 O; 1.0 HCl; 0.25 EtOAc Solvate mol. wt. = 439.82 g/mole Calc.: C = 65.54% H = 8.19% N = 9.56% Obs.: C = 65.54% H = 7.86% N = 9.58% - H cis 452.23 g/mole 8.23 min. Calc. for 0.20 H.sub.2 O; Solvate mol. wt. = 456.09 g/mole Calc.: C = 76.53% H = 6.51% N = 9.23% Obs.: C = 76.64% H = 6.51% N = 9.31% - H --NH.sub.2 cis N/A 5.54 min. Calc. for 0.40 H.sub.2 O; 2.0 HCl; 0.30 MeOH Solvate mol. wt. = 333.10 g/mole Calc.: C = 55.17% H = 7.57% N = 12.62% Obs.: C = 55.27% H = 7.36% N = 12.63% - #STR54## cis 328.35 g/mole 7.33 min. Calc.: C = 69.48% H = 7.98% N = 12.79% Obs.: C = 69.40% H = 7.53% N = 12.61% - H cis 286.29 g/mole 5.85 min. Calc. for 0.65 H.sub.2 O; 0.95 EtOAc Solvate mol. wt. = 417.26 g/mole Calc.: C = 59.87% H = 7.95% N = 10.07% Obs.: C = 59.90% H = 8.04% N = 10.10% - H cis (-) 440.25 g/mole 9.81 min. Calc. for 0.30 H.sub.2 O; 1.0 HCl Solvate mol. wt. = 501.49 g/mole Calc.: C = 62.99% H = 6.55% N = 8.38% Obs.: C = 63.16% H = 6.28% N = 8.83% - H cis (+) 440.24 g/mole 9.81 min. Calc. for 0.50 H.sub.2 O; 0.85 CHCl.sub.3 ; 1.0 HCl Solvate mol. wt. = 549.10 g/mole Calc.: C = 58.73% H = 6.20% N = 7.64% Obs.: C = 58.72% H = 6.15% N = 7.48% - CBZ.sup.4 cis 378.25 g/mole 8.89 min. N/A__________________________________________________________________________ .sup.4 ##STR60##
EXAMPLE 25
As a specific embodiment of an oral composition, 100 mg of the compound of Example 5 is formulated with sufficient finely divided lactose to provide a total amount of 580 to 590 mg to fill a size O hard gel capsule.
EXAMPLE 26 Screening Assay: Alpha 1a Adrenergic Receptor Binding
Membranes prepared from the stably transfected human alpha 1a cell line (ATCC CRL 11140) were used to identify compounds that bind to the human alpha 1a adrenergic receptor. These competition binding reactions (total volume=200 μl) contained 50 mM Tris-HCl pH. 7.4, 5 mM EDTA, 150 mM NaCl, 100 pM [ 125 I]-HEAT, membranes prepared from the alpha 1a cell line and increasing amounts of unlabeled ligand. Reactions were incubated at room temperature for one hour with shaking. Reactions were filtered onto Whatman GF/C glass fiber filters with a Inotec 96 well cell harvester. Filters were washed three times with ice cold buffer and bound radioactivity was determined (Ki). Representative compounds of the present invention were found to have Ki values≦50 nM.
EXAMPLE 27
Selective Binding Assays
Membranes prepared from stably transfected human alpha 1d and alpha 1b cell lines (ATCC CRL 11138 and CRL 11139, respectively) were used to identify compounds that selectively bind to the human alpha 1a adrenergic receptor. These competition binding reactions (total volume=200 μl) contained 50 mM Tris-HCl pH. 7.4, 5 mM EDTA, 150 mM NaCl, 100 pM [ 125 I]-HEAT, membranes prepared from cell lines transfected with the respective alpha 1 subtype expression plasmid and increasing amounts of unlabeled ligand. Reactions were incubated at room temperature for one hour with shaking. Reactions were filtered onto Whatman GF/C glass fiber filters with a Inotec 96 well cell harvester. Filters were washed three times with ice cold buffer and bound radioactivity was determined (Ki).
EXAMPLE 28
Exemplary Counterscreens
1. Assay Title: Dopamine D2, D3, D4 in vitro screen
Objective of the Assay
The objective of this assay is to eliminate agents which specifically affect binding of [3H] spiperone to cells expressing human dopamine receptors D2, D3 or D4.
Method
Modified from VanTol et al (1991); Nature (Vol 350) Pg 610-613.
Frozen pellets containing specific dopamine receptor subtypes stably expressed in clonal cell lines are lysed in 2 ml lysing buffer (10 mM Tris-HCl/5 mM Mg, pH 7.4). Pellets obtained after centrifuging these membranes (15' at 24,450 rpm) are resuspended in 50 mM Tris-HCl pH 7.4 containing EDTA, MgCl[2], KCl, NaCl, CaCl[2] and ascorbate to give a 1 Mg/mL suspension. The assay is initiated by adding 50-75 μg membranes in a total volume of 500 μl containing 0.2 nM [3H]-spiperone. Non-specific binding is defined using 10 μM apomorphine. The assay is terminated after a 2 hour incubation at room temperature by rapid filtration over GF/B filters presoaked in 0.3% PEI, using 50 mM Tris-HCl pH 7.4.
2. Assay Title Serotonin 5HT1a
Objective of the Assay
The objective of this assay is to eliminate agents which specifically affect binding to cloned human 5HT1a receptor
Method
Modified from Schelegel and Peroutka Biochemical Phamacology 35:1943-1949 (1986).
Mammalian cells expressing cloned human 5HT1a receptors are lysed in ice-cold 5 mM Tris-HCl, 2 mM EDTA (pH 7.4) and homogenized with a polytron homogenizer. The homogenate is centrifuged at 1000×g for 30', and then the supernatant is centrifuged again at 38,000×g for 30'. The binding assay contains 0.25 nM [3H]8-OH-DPAT (8-hydroxy-2-dipropylamino-1,2,3,4-tetrahydronaphthalene) in 50 mM Tris-HCl, 4 mM CaCl2 and 1 mg/ml ascorbate. Non-specific binding is defined using 10 μM propranolol. The assay is terminated after a 1 hour incubation at room temperature by rapid filtration over GF/Cfilters
EXAMPLE 29
Exemplary Functional Assays
In order to confirm the specificity of compounds for the human alpha 1a adrenergic receptor and to define the biological activity of the compounds, the following functional tests may be performed:
1. In vitro Rat, Dog and Human Prostate and Dog Urethra
Taconic Farms Sprague-Dawley male rats, weighing 250-400 grams are sacrificed by cervical dislocation under anesthesia (methohexital; 50 mg/kg, i.p.). An incision is made into the lower abdomen to remove the ventral lobes of the prostate. Each prostate removed from a mongrel dog is cut into 6-8 pieces longitudinally along the urethra opening and stored in ice-cold oxygenated Krebs solution overnight before use if necessary. Dog urethra proximal to prostate is cut into approximately 5 mm rings, the rings are then cut open for contractile measurement of circular muscles. Human prostate chips from transurethral surgery of benign prostate hyperplasia are also stored overnight in ice-cold Krebs solution if needed.
The tissue is placed in a Petri dish containing oxygenated Krebs solution [NaCl, 118 mM; KCl, 4.7 mM; CaCl 2 , 2.5 mM; KH 2 PO 4 , 1.2 mM; MgSO 4 , 1.2 mM; NaHCO 3 , 2.0 mM; dextrose, 11 mM] warmed to 37° C. Excess lipid material and connective tissue are carefully removed. Tissue segments are attached to glass tissue holders with 4-0 surgical silk and placed in a 5 ml jacketed tissue bath containing Krebs buffer at 37° C., bubbled with 5% CO 2 /95% O 2 . The tissues are connected to a Statham-Gould force transducer; 1 gram (rat, human) or 1.5 gram (dog) of tension is applied and the tissues are allowed to equilibrate for one hour. Contractions are recorded on a Hewlett-Packard 7700 series strip chart recorder.
After a single priming dose of 3 μM (for rat), 10 μM (for dog) and 20 μM (for human) of phenylephrine, a cumulative concentration response curve to an agonist is generated; the tissues are washed every 10 minutes for one hour. Vehicle or antagonist is added to the bath and allowed to incubate for one hour, then another cumulative concentration response curve to the agonist is generated.
EC 50 values are calculated for each group using GraphPad Inplot software. pA 2 (-log K b ) values were obtained from Schild plot when three or more concentrations were tested. When less than three concentrations of antagonist are tested, K b values are calculated according to the following formula K b =[B],
x-1
where x is the ratio of EC 50 of agonist in the presence and absence of antagonist and [B] is the antagonist concentration.
2. Measurement of Intra-Urethral Pressure in Anesthetized Dogs
Purpose: Benign prostatic hyperplasia causes a decreased urine flow rate that may be produced by both passive physical obstruction of the prostatic urethra from increased prostate mass as well as active obstruction due to prostatic contraction. Alpha adrenergic receptor antagonists such as prazosin and terazosin prevent active prostatic contraction, thus improve urine flow rate and provide symptomatic relief in man. However, these are non-selective alpha 1 receptor antagonists which also have pronounced vascular effects. Because we have identified the alpha 1a receptor subtype as the predominent subtype in the human prostate, it is now possible to specifically target this receptor to inhibit prostatic contraction without concomitant changes in the vasculature. The following model is used to measure adrenergically mediated changes in intra-urethral pressure and arterial pressure in anesthetized dogs in order to evaluate the efficacy and potency of selective alpha adrenergic receptor antagonists. The goals are to: 1) identify the alpha 1 receptor subtypes responsible for prostatic/urethral contraction and vascular responses, and 2) use this model to evaluate novel selective alpha adrenergic antagonists. Novel and standard alpha adrenergic antagonists may be evaluated in this manner.
Methods: Male mongrel dogs (7-12 kg) are used in this study. The dogs are anesthetized with pentobarbital sodium (35 mg/kg, i.v. plus 4 mg/kg/hr iv infusion). An endotracheal tube is inserted and the animal ventilated with room air using a Harvard instruments positive displacement large animal ventilator. Catheters (PE 240 or 260) are placed in the aorta via the femoral artery and vena cava via the femoral veins (2 catheters, one in each vein) for the measurement of arterial pressure and the administration of drugs, respectively. A supra-pubic incision ˜1/2 inch lateral to the penis is made to expose the urethers, bladder and urethra. The urethers are ligated and cannulated so that urine flows freely into beakers. The dome of the bladder is retracted to facilitate dissection of the proximal and distal urethra. Umbilical tape is passed beneath the urethra at the bladder neck and another piece of umbilical tape is placed under the distal urethra approximately 1-2 cm distal to the prostate. The bladder is incised and a Millar micro-tip pressure transducer is advanced into the urethra. The bladder incision is sutured with 2-0 or 3-0 silk (purse-string suture) to hold the transducer. The tip of the transducer is placed in the prostatic urethra and the position of the Millar catheter is verified by gently squeezing the prostate and noting the large change in urethral pressure.
Phenylephrine, an alpha 1 adrenergic agonist, is administered (0.1-100 ug/kg, iv; 0.05 ml/kg volume) in order to construct dose response curves for changes in intra-urethral and arterial pressure. Following administration of increasing doses of an alpha adrenergic antagonist (or vehicle), the effects of phenylephrine on arterial pressure and intra-urethral pressure are re-evaluated. Four or five phenylephrine dose-response curves are generated in each animal (one control, three or four doses of antagonist or vehicle). The relative antagonist potency on phenylephrine induced changes in arterial and intra-urethral pressure are determined by Schild analysis. The family of averaged curves are fit simultaneously (using ALLFIT software package) with a four paramenter logistic equation constraining the slope, minimum response, and maximum response to be constant among curves. The dose ratios for the antagonist doses (rightward shift in the dose-response curves from control) are calculated as the ratio of the ED 50 's for the respective curves. These dose-ratios are then used to construct a Schild plot and the Kb (expressed as ug/kg, iv) determined. The Kb (dose of antagonist causing a 2-fold rightward shift of the phenylephrine dose-response curve) is used to compare the relative potency of the antagonists on inhibiting phenylephrine responses for intra-urethral and arterial pressure. The relative selectivity is calculated as the ratio of arterial pressure and intra-urethral pressure Kb's. Effects of the alpha 1 antagonists on baseline arterial pressure are also monitored. Comparison of the relative antagonist potency on changes in arterial pressure and intra-urethral pressure provide insight as to whether the alpha receptor subtype responsible for increasing intra-urethral pressure is also present in the systemic vasculature. According to this method, one is able to confirm the selectivity of alpha 1a adrenergic receptor antagonists that prevent the increase in intra-urethral pressure to phenylephrine without any activity at the vasculature.
While the foregoing specification teaches the principles of the present invention, with examples provided for the purpose of illustration, it will be understood that the practice of the invention encompasses all of the usual variations, adaptations and/or modifications as come within the scope of the following claims and their equivalents.
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This invention relates to certain novel compounds and derivatives thereof, their synthesis, and their use as alpha 1a adrenergic receptor antagonists. One application of these compounds is in the treatment of benign prostatic hyperplasia. These compounds are selective in their ability to relax smooth muscle tissue enriched in the alpha 1a receptor subtype without at the same time inducing hypotension. One such tissue is found surrounding the urethral lining. Therefore, one utility of the instant compounds is to provide acute relief to males suffering from benign prostatic hyperplasia, by permitting less hindered urine flow. Another utility of the instant compounds is provided by combination with a human 5-alpha reductase inhibitory compound, such that both acute and chronic relief from the effects of benign prostatic hyperplasia are achieved.
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[0001] This application claims priority from U.S. Provisional Application Serial No. 60/304,424 filed Jul. 12, 2001. The entirety of that provisional application is incorporated herein by reference.
[0002] This invention was made with Government support under 19-94-111 and 19-94-112 awarded by the U.S. Department of Agriculture/Forest Service. The Government may have certain rights in this invention.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates to the field of termite control technology and more specifically to a novel method of controlling termite activity by the use of radio waves. More particularly, this invention provides a method of attracting termites to a desired location by the use of radio waves within a certain frequency range.
[0005] 2. Background of the Technology
[0006] Untreated termite infestation in homes leads to irreversible structural damage in buildings throughout the world. As a result, a myriad of treatments to control or destroy termite populations have been developed. Because of the potential negative environmental impact of insecticides, environmentally friendly alternatives have been the primary focus of the latest research.
[0007] A significant amount of prior art focuses on the use of electromagnetic fields to control (repel and/or negatively affect) termites. U.S. Pat. No. 5,473,836, issued to Liu discloses a method for removing insects from “hidden places” by inducing an electromagnetic field to create physical vibrations. U.S. Pat. No. 5,930,946 issued to Mah discloses a method for creating an electromagnetic field to which pests react adversely. U.S. Pat. No. 5,442,876 issued to Pederson discloses a method for controlling termites by heating the area where termites are located to temperatures which are lethal to living organisms by means of electromagnetic energy. U.S. Pat. No. 4,870,779 issued to Bergerioux et al. discloses a method in which a low frequency, randomly varying magnetic field is generated by a device such that it interacts with the earth's geomagnetic field to eliminate (repel) rodents and similar pests located above and below ground level in the area surrounding the device.
[0008] The use of electrical energy has also been employed in efforts to eliminate (repel and/or negatively affect) termites. U.S. Pat. No. 5,210,719 issued to Lawrence discloses an apparatus and method which uses a sweep-frequency, high voltage generator coupled to an applicator gun for feeding electric power into pest-infested dielectrics, for example termite-infested wood. U.S. Pat. No. 4,366,644 issued to Lawrence discloses a method that involves the application of broad band radio frequency or multifrequency high-voltage electrical energy to termite shelter tubes, galleries and nests and to the bodies of termites in those areas. Lawrence '644 teaches that by that method termites are killed directly by electroshock or indirectly by creating interference with the digestive processes of termites. U.S. Pat. No. 4,782,623 issued to Lawrence discloses an apparatus and method, which uses a phase-locked high voltage, high frequency pulse generator capable of “quasiunlimited” power output and an applicator gun for feeding electric power into pest-infested dielectrics, for example termite infested wood. U.S. Pat. No. 4,223,468 issued to Lawrence discloses a method that involves killing termites by the application of broad band, high voltage electrical energy to habitats of termites.
[0009] The application of microwave energy has also been employed in the attempt to control (repel and /or negatively affect) termites. U.S. Pat. No. 5,575,106 issued to Martin et al. discloses a method of using low voltage “microwave horns” to kill termite populations. U.S. Pat. No. 5,896,696 issued to Stokes et al. discloses an apparatus and method for generating and radiating energy at specific wavelengths for the purpose of adversely affecting the nervous systems of “small insects.”
[0010] While recent efforts to discover environmentally friendly methods of controlling termites have sought to avoid the use of conventional pesticides; they have failed to adequately protect termite-susceptible structures from infestation. Both conventional chemical and more modem methods alike seek to deal with the problem of termite infestation by killing termites in the area that is infested rather than providing a method by which termite infestation and subsequent structural damage can be prevented. The inventors have discovered a novel method by which the application of radio waves to a selected area can attract termites to that area and thereby provide protection from termites for other adjacent areas.
SUMMARY OF THE INVENTION
[0011] This invention relates to a method of controlling termite activity by emitting radio waves that attract termites to toxic baits, light traps, etc. or directing their movements away from susceptible structures.
[0012] It is therefore an object of the present invention to provide a system for transmitting radio waves of specific frequencies to an area where termite activity is desired.
[0013] It is also an object of this invention to use detection devices that monitor radio waves and/or energy levels of specific frequencies as a means to determine which structures are likely to attract termites.
[0014] It is also an object of the present invention to provide a radio wave transmitting system that is associated with proximately positioned termite bait stations, wooden stakes, wooden posts, or other termite-degradable materials to augment the termite attraction features of the radio wave transmitting system.
[0015] It is also an object of the present invention to provide a method of protecting termite-degradable materials of a natural or man-made character in a protected area by providing a radio wave transmitting system in an adjacent radio transmission area so as to attract termites to the transmission area and away from the protected area.
BRIEF DESCRIPTION OF THE FIGURES
[0016] FIGS. 1 A-D show diagram representations of different example embodiments of the radio wave transmitting system of the present invention.
[0017] FIGS. 2 A-C provide diagrammatic representations of the test area for the transmitting system of the present invention having both active and inactive transmission areas. FIG. 2A shows the disposition of antenna arrays within the test area. FIG. 2B shows the location of termite activity within the test area that were identified in 1998. FIG. 2C shows the location of termite activity within the test area that were identified in 2002.
[0018] [0018]FIG. 3 shows a diagram of antenna arrays associated with a radio transmitter and the location of wooden poles, which served as termite attractants in the area of the antenna arrays. The shaded areas indicate termite activity.
[0019] FIGS. 4 A-G show diagrams of different antenna arrays and circumferentially positioned wooden poles for antenna arrays. The absence of shaded areas in the diagram indicates no new termite activity.
[0020] FIGS. 5 A-H show diagrams of antenna arrays and circumferentially located wooden poles for active antenna arrays. The presence of shaded areas in the diagram indicate wooden poles having evidence of termite activity.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The present invention as described below and shown in the accompanying figures is a novel method of attracting termites that is employed to provide a method of controlling termite activity by emitting radio waves of a certain frequency.
[0022] As best shown in FIGS. 1 A-D the radio wave transmitting system of the present invention, generally shown at 10 , can be configured to position at least one transmitting device 12 in a transmission area 14 where termite activity is desired. A radio transmitter 16 is designed to provide a broadcast radio signal of a certain wave length within a transmission area 14 . As shown in FIGS. 1A and 1C the transmitter 16 can be operationally connected to more than one transmitting device 12 .
[0023] As shown in FIGS. 1 A-D, the radio wave transmitting system of the present invention can have varied configurations where the transmitting devices 12 can be positioned adjacent to or circumferentially disposed around a natural or man-made termite-degradable structure 18 for which protection from termite damage is desired. The structure 18 can have a degradable component and therefore be susceptible to termite damage. The different transmitting system configurations depicted in FIGS. 1 A-D are non-limiting examples, the pattern of which can be widely varied without departing from the concept of the present invention.
[0024] Within the effective range of the transmission area 14 natural or man-made termite-degradable materials can be positioned so as to provide an attractant 20 for termites that is localized within the transmission area 14 . Inclusion of the attractant 20 , in addition to increasing the effectiveness of the termite-attraction of the transmitting device 12 , also provides foci for termite infestation in the transmission area 14 . By focusing the relocation of the termites to the attractant 20 , subsequent containment, collection, or elimination of the termites by conventional means can be facilitated.
[0025] The transmitter 16 of the present invention can be any conventional radio wave transmitter capable of transmitting radio waves having a frequency range of about 1 to 100 megahertz and preferably 1 to 30 megahertz. The intensity of the radio wave transmission can be about 1 to 100 kilowatts and preferably 1 to 10 kilowatts.
[0026] After conducting tests over a 10-year period, the inventors discovered that termites are attracted to radio waves within a certain frequency range and broadcast intensity. The inventors discovered that termites such as Coptotermes formosanus are attracted to radio waves such as those employed in the present invention. Species such as Coptotermes, Reticulitermes and other termite genera can be susceptible to the attraction qualities of the present invention. Unlike conventional remedial termite control methods, the present invention provides a method to control subterranean, surface, and dispersal flight movement of termites before infestation of an area in need of protection. The inclusion of attraction augmentation in the transmitting system 10 of the present invention further permits the localization of the termites within the transmission area. The optional attractant 20 used in the transmitting system 10 can be any material to which termites can be attracted, to include, for example natural or man-made wooden items, bait stations, or any object with a termite-degradable component.
[0027] The present invention can be used to attract termites to the transmission area 14 for containment, collection and study, or elimination. By properly positioning the transmitting system 10 relative to a natural or man-made structure 18 for which termite protection is desired, the termites can be attracted away from the material or structure 18 that is to be protected and drawn towards the transmitting system 10 . Non-limiting examples of transmitting system configurations which can be used to provide protection for a material or object, such as a house, fence, utility pole, or any material subject to termite infestation are shown in FIGS. 1 A-D.
EXAMPLES
[0028] Field observations of the natural populations of the termite Coptotermes formosanus on the Lualualei Naval facility, Oahu, Hi. were conducted over a 10-year test period. These field observations indicated that movements of this subterranean termite are affected by radio waves of a frequency about 1-100 megahertz, preferably about 1-30 megahertz, and more preferably about 2-20 megahertz. The intensity of the radio transmission can be about 1-100 kilowatts; preferably about 1-10 kilowatts. Antenna arrays were formed of wires supported by large pressure-treated Douglas-fir wooden poles and were located over a large portion of the facility. The frequency of the radio waves ranged from about 1-100 megahertz at transmission intensities from about 1-100 kilowatts.
[0029] [0029]FIG. 2A is a diagrammatic representation of the disposition of antenna arrays within the test area. In FIGS. 2 A-C, the diagram of the test area is divided into an eastern and a western portion by a dashed-line. The locations of numerous radio transmitters 16 connected by transmission lines 22 to circumferentially disposed antenna arrays or transmission devices 12 are shown throughout the test area. Antenna arrays 12 in the eastern portion of the test area were actively transmitting radio waves during the first six years of the 10-year test period (between 1992 and 1998). Those antenna arrays west of the dashed-line were inactive for several years prior to the test period. After the inspection for termite activity in 1998, the antenna arrays 12 in the western portion of the test area were actively transmitting for the last four years of the 10-year test period (between 1998 and 2002). Numerous areas of identified termite activity 24 shown in FIGS. 2B and 2C as shaded areas were identified by the inventors during inspections in 1998 and subsequently in 2002. As depicted in the diagrams, new termite activity was identified in those areas where antenna arrays 12 were actively transmitting while new termite activity was not found in areas with inactive antenna arrays.
[0030] [0030]FIG. 3 shows a diagram of antenna arrays associated with a radio transmitter and the location of wooden poles, which served as termite attractants 20 in the area of the antenna arrays 12 . Identified termite activity at the attractant 20 is shown as a shaded area. As shown in the diagram, the inventors identified a high level of termite infestation of wooden poles 20 placed along the transmission line 22 , which operationally connects a remote radio transmitter 16 to the active antenna array 12 (antenna array number 442 ).
[0031] As discussed earlier, antennas arrays in the eastern portion of the test area were actively transmitting whereas antennas in the western portion of the facility remained inactive during the first six years of the test. Those active antenna arrays having the best attraction for termites broadcast a frequency of about 2-30 megahertz at an intensity of about 1 to 10 kilowatts. For those antenna arrays having the best attraction of termites, the average frequency transmitted was about 9 megahertz at an average intensity of about 4 kilowatts. The antenna arrays broadcasting in the lower frequencies and lower intensities can have an effective attraction distance in excess of 100 feet from the antenna arrays. The effective distance of the termite attraction effect of the antenna arrays is believed to vary with increased radio wave frequency and intensity. FIGS. 4 A-G and FIGS. 5 A-H provide an indication of the termite attraction effect of the inactive and active antenna arrays 12 . Circumferentially disposed around the individual antenna arrays were wooden poles that served as an attractant 20 within the transmission area 14 . These attractant poles 20 provided a foci for the termites attracted by the antenna arrays system of the present invention and permitted the inventors to measure the effect of the transmitted radio waves. In FIGS. 4 A-G and FIGS. 5 A-H, it can been seen that the attractant poles 20 that were disposed near active antenna arrays 12 were observed to have different amounts of termite infestation while those inactive antenna arrays 12 had reduced or no termite infestation.
[0032] The results of the years of testing the radio wave transmitting system 10 of the present invention demonstrated the ability of the system to attract termites by the use of radio wave transmission. The test also showed that by attracting termites to the transmitting system 10 , adjacent wooden structures could be protected from termite infestation.
[0033] The present invention can be employed to attract termites to an active transmitting device 12 and by doing so protect an adjacent area from termite infestation. The invention can also be employed as a method to increase the efficiency of other devices used to attract insects such as the conventional light traps, termite traps, bait stations and the like.
[0034] It is also within the concept of the present invention to employ the inventor's discovery of the termite-attractant ability of a radio wave transmitting system 10 to provide an electronic sweeper that can identify structures or buildings that are more susceptible to termite infestation due to the emission of attractant radio waves.
[0035] The discovery of the inventors can also be used to provide a device that scrambles or “masks” the emission of attractant radio waves from termite susceptible structures or buildings.
[0036] The inventors have also determined that the effect of radio waves on termites can be adapted to produce a high intensity electronic field at or about 60 hertz and 20 megawatts to create a repellant shield around susceptible structures.
[0037] The invention claimed herein has been described generically, and by reference to specific embodiments. Examples and specific features are not intended to be limiting unless so indicated above. Modifications will occur to those of skill in the art without departing from the invention, except as excluded by the claims set forth below.
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A novel method of positively directing termite activity by the use of radio waves. Also provided is a method of protecting a natural or man-made structure from termite infestation based on termite attractancy of specific radio waves.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to adjustable drop nipples as employed to adjustably position sprinklers relative to the distribution piping of a sprinkler system and a drop ceiling.
2. Description of the Prior Art
Prior devices of this type have employed various arrangements of fittings and nipples with various rotational locks for securing the fittings and nipples in desired telescopic relation. See for example U.S. Pat. Nos. 1,833,040, 3,084,869, 3,194,316, 3,451,483, 3,675,952, 3,807,503, and 3,847,392.
This invention provides a simple, easily adjustable device and insures against the accidental blocking of the distribution piping by parts of the adjustable nipple.
SUMMARY OF THE INVENTION
An adjustable drop nipple includes a sealing coupling engaged on a fixed nipple in a sprinkler system and a rotational lock for securing a telescopically arranged tube relative thereto. A sprinkler is positioned in one end of the telescopically arranged tube and a sleeve on the sealing coupling prevents undesirable longitudinal movement of the telescopically arranged tube into the distributing pipe. The rotational lock secures the telescopically adjustable tube and the sprinkler thereon in desirable adjusted relation to the fixed nipple and sealing coupling.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional elevation through an adjustable drop nipple illustrating the same in communication with a distributing pipe; and
FIG. 2 is a horizontal section on line 2--2 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
By referring to FIG. 1 of the drawings, a preferred embodiment of the invention may be seen and wherein a distributing pipe 10, as for example that of a fire extinguishing sprinkler system, has a T 11 and a fixed standard nipple 12 of a known minimum length engaged in the T 11 in depending relation thereto. The lower end of the fixed nipple 12 is threadably engaged in the uppermost portion of a sealing coupling 13, the lower end 14 of which is externally threaded so as to receive an apertured nut 15 which is preferably hexagonal. The inner lower end of the sealing coupling 13 is tapered as at 16 so that in effect it flares outwardly toward the external threads and the outer end of the sealing coupling 13.
A sleeve 17 split longitudinally to form an elongated aperture 17A is tack welded to the outer upper surface of the sealing coupling 13 and extends upwardly therebeyond to an uppermost end 18. The arrangement is such that the total length of the split sleeve 17 and the sealing coupling 13 is substantially the same as the minimum length of the fixed nipple 12.
Still referring to FIG. 1 of the drawings, it will be seen that an annular rib 19 is formed on the inner surface of the sealing coupling 13 inwardly of the lower end thereof and that immediately below the annular rib 19 an annular channel 20 is formed in the inner surface of the sealing coupling 13. An O-ring 21 is positioned in the annular channel 20 and a split metal ring 22 is positioned within the nut 15 and adjacent the tapered inner surface 16 of the sealing coupling 13.
A tube 23 is telescopically positioned partially within the fixed nipple 12 and extending through the sealing coupling 13 and through the aperture 24 in the nut 15. The upper end of the tube 23 has a heavy straight knurl 25 formed on the exterior thereof so as to increase the effective diameter thereof at this point and the lower or opposite end of the tube 23 is internally threaded so that a fire extinguishing sprinkler can be threadably engaged therein.
It will thus be seen that the adjustable tube 23 extends through and engages the O-ring 21 to form a fluid tight seal between its exterior and the interior of the sealing coupling 13 and through the split ring 22. The arrangement is such, that when the nut 15 is rotated on the externally threaded end 14 of the sealing coupling 13 so that it moves inwardly thereof, it will move the split ring 22 against the tapered surface 16 in the lower end of the sealing coupling 13 is a wedging action which will lock the adjustable tube 23 in desired adjusted relation thereto.
Still referring to FIG. 1 of the drawings, it will be seen that the fixed nipple 12 must have a minimum length of, for example, six inches, and that the overall combined length of the sealing coupling 13 and the split sleeve 17 is substantially the same. The adjustable tube 23 is, for example, approximately six and one-half inches in length and it will occur to those skilled in the art that the length of the split sleeve 17 is such that when the adjustable drop nipple is mounted as close to the T 11 as possible and when the tube 23 is telescoped as far into the sealing coupling 13 as possible, the upper end of the adjustable tube 23 will not extend into the water way of the distributing pipe 10. In the event a shorter fixed nipple 12 is substituted in the assembly the arrangement is such that the upper end 18 of the split sleeve 17 will engage the T 11 before the upper end of the adjustable tube 23 can move into the T 11 or the waterway of the distributing pipe 10.
As hereinbefore described the loosening of the apertured nut 15 permits the adjustable tube 23 to be moved longitudinally of the sealing coupling 13 so as to position a sprinkler engaged in the outer end of the tube 23 in desired relation to the distributing piping 10 and for example a ceiling suspended therebelow.
The split 17A in the sleeve 17 permits immediate drainage of water if the connection between the fixed nipple 12 and the sealing coupling 13 leaks at the time of installation or adjustment. The entire sleeve 17 does not have to fill with water before a leak can be observed.
The adjustable drop nipple thus provides satisfactory adjustment and incorporates a safety factor in preventing blocking of the distributing piping as aforesaid. Additionally the device permits adjustment as to length without leakage of water and eliminates the heretofore necessary draining of the piping system and saves the labor in connection therewith.
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An adjustable drop nipple is disclosed for connecting a pendant sprinkler to a sprinkler system. The nipple includes outer and inner telescoped pipes with a gripping means therebetween which permits an adjustment of the telescoped relation of the pipes for a desired position of the pendant sprinkler below a drop ceiling.
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[0001] This Application is a continuation of co-pending, commonly owned U.S. patent application Ser. No. 10/273,681, filed Oct. 17, 2002, now U.S. Pat. No. 7,472,033 entitled “APPARATUS FOR CONTROLLING SEMICONDUCTOR CHIP CHARACTERISTICS” by Godfrey P. D'Souza et al., assigned to the assignee of the present invention, which is a continuation of U.S. patent application Ser. No. 09/595,196, filed Jun. 16, 2000, entitled, “APPARATUS FOR CONTROLLING SEMICONDUCTOR CHIP CHARACTERISTICS” by Godfrey P. D'Souza et al., and assigned to the assignee of the present invention.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to computer systems and, more particularly, to an arrangement for varying semiconductor chip characteristics based on attributes determined by monitoring the chip in operation.
[0004] 2. History of the Prior Art
[0005] A modem computer is typically constructed from a plurality of modular semiconductor chip components connected together in circuit by means such as conductive traces arranged on a circuit board. For example, a computer may include a modular microprocessor chip, a plurality of memory chips, various input/output devices each including chips providing electronic circuitry for controlling the device, and other circuitry joined together to provide a system for manipulating data in response to instructions.
[0006] In order to assure that the circuit elements of each of the chips function together to provide a system which correctly manipulates data, each of the different chips includes interface circuitry adapted to correctly handle and interpret signals received from and sent to circuit elements on the other chips of the system. For example, memory circuits are designed to respond to signals provided at particular voltage and current levels which appear at particular input terminals at particular times with respect to other signals. In order to cause the memory circuits to respond correctly, the signals must fall within the expected ranges and must appear at the correct times with respect to other signals.
[0007] Chip manufacturers provide specifications which define the signals with which circuits on their chips will function correctly. Among these specifications are characteristics called “output valid time” and “output hold time.” As is illustrated in FIG. 1 , output valid time measures the period after a clock signal before valid data is guaranteed at a terminal; data received before this period has ended may not be properly processed by the chip. Output hold time measures a period after a next clock signal during which data is guaranteed to remain valid. In order to function properly with signals received from circuitry on another chip, the output circuitry of the other chip must provide signals meeting these and other specifications.
[0008] A chip designer can assure that a chip will meet the design specifications for an interface with another chip only by providing output (and input) characteristics which meet the specifications of the other chip. Thus, a chip designer must assure that the output data it produces for another chip comply with, among other things, the input setup and input hold times specified for that other chip. The designer must assure that the delays provided in the data output paths comply with the specifications for the other chip.
[0009] If a chip is to interface with a number of different chips serving the same purpose (e.g., memory chips from different manufacturers), then the chip must meet the specifications of all of the different chips. Often these specifications vary sufficiently that reaching this result is quite difficult.
[0010] For example, the propagation characteristics of signals provided by a particular chip depend upon a number of factors including the particular process used in the manufacture of the chip, the voltage of operation, and the temperature of operation. As these factors vary during operation, so do the propagation characteristics of the chip and its ability to meet the specifications required by the various interfaces with other chips.
[0011] In order to assure that their chips are able to meet the specifications of a variety of other chips, prior art designers have provided a number of different solutions. One technique which has been utilized selects from among a plurality of output paths having different delay characteristics measured in hardware during operation.
[0012] The ability to meet interface specifications is made even more difficult as computer systems become more advanced. For example, each step in the constant increase in system clock frequencies utilized by computers makes it more difficult to meet both the output valid time and the output hold time specifications of an interface. Although it becomes easier to assure that valid data reaches another chip by the specified time as silicon speed rises, it becomes more difficult to guarantee that the data will remain for a specified hold time. It has become necessary in many cases to provide latching circuitry to meet specified hold times. However, when a chip is to operate with other chips having different characteristics, the need to provide circuitry to meet the specifications of each of the different chips becomes overwhelmingly complicated.
[0013] To meet this problem, an advanced arrangement, described in U.S. Pat. No. 5,180,937, includes a plurality-of delay lines that are monitored during operation of circuitry on a chip to provide an output indicative of the operating speed of the chip. More particularly, the different delay lines provide output signals which are longer than, near to, or shorter than a measurement period. These outputs are utilized by a timing synchronizer circuit (a state machine) to determine whether the circuitry on the chip is running at a fast or slow rate. The result provided by the timing synchronizer circuitry is then used to the delay which is selected for an output circuit in order to match the specifications for output valid time and output hold time required by interfaces to other chips during the operation of the chip being controlled. In one embodiment, the timing synchronizer selects a delay line to be inserted in a path controlling the timing for a latch in the output path based on the results obtained through the controlled measurements of the output of the monitoring delay lines.
[0014] The circuitry described in this patent helps significantly to increase the ability of semiconductor chips to meet specifications for interfaces with other chips. However, it is quite difficult to provide the ability for such circuitry to manipulate circuitry characteristics over more than limited ranges of operating conditions without the cost becoming too great and the circuitry too large.
[0015] Moreover, an even more difficult problem has been raised by a recent advance in the computer art. A new microprocessor has been developed which combines a simple but fast host processor (called a “morph host”) and software (called “code morphing software”) to execute application programs designed for a processor having a different instruction set at a rate equivalent to the processor for which the programs were designed (the target processor). The morph host processor executes the code morphing software to translate the target application programs into morph host processor instructions which accomplish the purpose of the original target software. As the target instructions are translated, they are stored in a translation buffer where they may be accessed without further translation. The resulting translations are then executed and perform the same functions that they would on a processor that implemented the target architecture in hardware. Although the initial translation and execution of a program may be slow, once translated, many of the steps normally required to execute a program in hardware are eliminated. The new processor is described in detail in U.S. Pat. No. 6,031,992, entitled Combining Hardware And Software To Provide An Improved Microprocessor, Cmelik et al, issued Feb. 29, 2000, and assigned to the assignee of the present application.
[0016] Because of its design, the new microprocessor utilizes many fewer circuit elements than do competitive processors. Consequently, it uses much less power than prior art processors to accomplish similar operations. An enhancement to this microprocessor farther reduces its power dissipation and allows the microprocessor to run for significantly- extended periods using limited power sources such as batteries. This enhancement constantly monitors system operation and adjusts both the system voltage and operating frequency based on the requirements of the system as it operates. This enhancement is described in U.S. patent application Ser. No. 09/484,516, entitled Adaptive Power Control, S. Halepete et al, filed Jan. 18, 2000, and assigned to the assignee of the present invention. Because this power-conserving enhancement constantly varies frequency and voltage, the various propagation characteristics of the system which control the ability of the chip to meet interface specifications may also vary constantly.
[0017] It is therefore desirable to provide improved arrangements for controlling the characteristics of semiconductor chip circuitry based on attributes determined by monitoring the chip in operation.
SUMMARY OF THE INVENTION
[0018] The present invention is realized by apparatus comprising functional components of circuitry defined on a semiconductor chip, the functional components including a component having modifiable operating characteristics, a performance measuring circuit providing an output indicative of operating characteristics of the circuitry defined on the semiconductor chip during operation of the circuitry, and computer implemented software means for controlling a value for an operating characteristic of the component having modifiable operating characteristics in response to the output provided by the performance measuring circuit.
[0019] These and other features of the invention will be better understood by reference to the detailed description which follows taken together with the drawings in which like elements are referred to by like designations throughout the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a timing diagram illustrating properties of circuitry which may vary depending on other circuitry connected in a system.
[0021] FIG. 2 is a block diagram of circuitry designed in accordance with the present invention.
[0022] FIG. 3 is diagram illustrating a detail of the circuit of FIG. 2 .
DETAILED DESCRIPTION
[0023] Referring now to FIG. 2 , there is illustrated an arrangement designed in accordance with the present invention for modifying circuit characteristics with changes in operating conditions and characteristics of the chip carrying the circuitry. Although the arrangement is described in the context of adjusting input/output characteristics, it has wide application to many other characteristics of operating circuits which change during operation or between parts and which may be monitored and modified as those characteristics change. It should be noted that the changing conditions and characteristics may be related to circuits being monitored and to circuitry connected in circuit through interfaces with the monitored circuitry.
[0024] The arrangement of FIG. 2 utilizes one or more ring oscillator circuits Ring0-RingN constructed as a portion of the circuitry of the semiconductor chip 30 which includes the circuitry 31 the characteristics of which are to be controlled.
[0025] A typical ring oscillator includes an odd-numbered plurality of inverter stages connected in series with the output of the last stage furnished as input to the first stage. A positive clock signal furnished at an input to a first inverter stage of any ring oscillator generates a negative clock signal at the output of the first inverter stage. Since the stages are connected in series, the input to each next stage is opposite in value to that of both the preceding and succeeding stage. With an odd number of stages, the signal resulting from the last stage is opposite to that originally furnished to the first inverter. By feeding the signal produced at the output of the last stage to the input of the first stage, a succession of alternating pulses may be produced at any node between stages. The pulses produced at a selected node of a ring oscillator are at a frequency which depends on the operating properties of the semiconductor chip, the voltage of operation, and the temperature of operation.
[0026] Ring oscillators are well known in the computer arts for testing purposes. It is typical for computer processors to include a number of ring oscillators for measuring the various characteristics of the circuitry to determine whether and how the circuitry fulfills design requirements. However, the results of such measurements have only been utilized to provide static values from which the operating characteristics of the circuitry may be estimated.
[0027] The present invention utilizes the output of a selected ring oscillator to determine various operating characteristics of the circuitry on the chip 30 . The circuit of FIG. 2 includes circuitry for selecting from among the different ring oscillator circuits R0-RN. Selection is made on the basis of inputs provided at an input terminal to a multiplexor 37 . In the particular arrangement illustrated, the values provided for selecting the particular ring oscillator may be determined in two ways. First, the ring oscillator may be determined from a tester or other external source which applied values on input terminals pin0-pin3. The signals applied to the various pins may be used to view operating characteristics of the circuitry on the chip 10 .
[0028] However, in addition to the values provided at terminals pin0-pin3 which are essentially used for manufacturing tests, the invention allows selection of a particular ring oscillator by means of a value stored in a register 32 . The particular mode of selection (i.e., terminals or register value) depends on an enabling signal furnished by control software to an enable register 34 .
[0029] The values placed in the registers 32 and 34 are furnished by control software. The value in register 34 specifically determines whether the values on pin0-pin3 or the value in register 32 is used for selection of the ring oscillator to provide output.
[0030] In one particular embodiment, the controlling software utilizes the 15 register 32 to select from outputs of one or more of the ring oscillators to determine characteristics of the circuitry 31 on the chip 30 during operation of the circuitry. Thus, the controlling software may provide a value to the register 32 which indicates that the output produced by ring0 is to be monitored. Alternatively, the value provided may indicate any of the other ring oscillators R1-RN. Typically, the different ring oscillators are constructed in such a manner that they provide indications measuring different characteristics of the semiconductor chip and the circuitry thereon. Thus, the output of a single oscillator may be sufficient to provide those characteristics necessary to determine an exact value for input/output characteristics or other characteristics of interest in controlling operating characteristics of the circuitry on the chip 30 .
[0031] In addition to the values produced by the ring oscillators, other characteristics may be utilized by the controlling software. For example, operating specification for memory circuits from a plurality of different manufacturers may be stored in read only memory 36 for use by the controlling software. These values may be utilized by the controlling software to determine specifications which are to be met for values such as the output valid time and hold time described above.
[0032] In accordance with the present invention, the controlling software selects a particular one or more ring oscillators from which to read frequency-related output signals. It accomplishes this by providing a value to register 32 designating a particular ring oscillator R0-RN and furnishing an enable value to the register 34 indicating that the value in register 32 is to be used for the selection. This causes the value in register 32 to be furnished by a multiplexor 35 to the selection terminal of the multiplexor 37 so that the output of the desired ring oscillator may be read.
[0033] In one embodiment, the software selects output from the ring oscillator. The system clock remains constant so that the number of fast system clocks during an interval of two periods of output from the ring oscillator indicates the speed of operation of the circuitry on the silicon chip 30 .
[0034] With knowledge of the speed of operation of the circuitry 31 on the chip 30 provided by the selected ring oscillator, the controlling software selects from the data stored in read-only memory the specifications for the particular interface the characteristics of which are being controlled.
[0035] Having these values, the controlling software selects a particular delay path to utilize in the output circuitry on the chip 30 to the interface involved.
[0036] In the particular embodiment illustrated in FIG. 2 , the invention 5 counts the number of fast processor clock pulses during two ring oscillator periods. It does this by furnishing the output of the ring oscillator to a counter circuit 38 . The ring oscillators are enabled by the same signals which enable the selection of ring oscillator output and which initiate the generation of signals by the ring oscillator. Consequently, the counter 38 begin counting output signals produced by the oscillator selected.
[0037] In one embodiment, the counter is a three bit counter which generates a signal to enable a second counter 39 after a selected number of periods of ring oscillator output. When counter 39 is enabled, it begins to count system clock signals. The period during which the counter 39 continues to count is limited by the removal of the enabling signal produced by the counter 38 after a selected number of additional periods. In the described embodiment, the enable signals is produced for two periods of ring oscillator output. Thus, the result is to count the number of system clock signals which occur during a period controlled by the ring oscillator output. When the enable is removed, the result remains in the counter circuit 39 where it may be read by the controlling software.
[0038] The control software reads the value, applies an algorithm by which the speed of the chip and its consequent delays are determined, and selects an appropriate delay line for generating the output from the chip. This delay line may be utilized to produce output signals with the correct timing to meet the specifications of the associated chips in the system.
[0039] In one embodiment illustrated in FIG. 2 , the control software selects the delay provided by an output latch by providing a programmable delay signal to a clock delay circuit 40 . The clock delay circuit utilizes a selected delay path ( FIG. 3 illustrated one simplified arrangement 40 ) to enable output from a latch 41 thereby control 1 in the duration of the hold time for data generated by the circuit 31 to meet the specification values computed by the control software. In a similar manner, the value is used by the control software to compute a programmable delay for controlling a second clock delay circuit 40 which controls the duration provided by a latch 42 transferring input data to the circuitry 31 .
[0040] The present invention offers a number of advantages over prior art circuits. Because the control software has at hand in ROM 36 an essentially unlimited amount of data defining characteristics of other chips with which the chip 30 is to function, parameters of the chip 30 , and may determine the changes in the characteristics of the circuitry 31 while that circuitry is operating, the control software may make very accurate and rapid changes in the input and output characteristics of the chip 30 to meet changing operating conditions.
[0041] The ability to select from a plurality of different ring oscillators adapted to provide outputs related to different properties also offers a number of advantages. For example, the different parameters available together with the broad measurements of operating characteristics available allow software solutions of advanced problems which have troubled computer designers. The invention can be used, for example, to manipulate cache timing parameters, to control phase delays, to generate external clocks, and for solutions to similar problems.
[0042] The embodiment of the invention described offers a number of advantages among which two are especially important. Without the invention, the range of operation of the chip is severely constrained by variations in chip processing, environmental conditions such as voltage and temperature, and specifications of other associated system components. This invention increases the range of operation and hence the manufacturing yield which may have significant financial effect. Additionally, it is beneficial to intentionally and dynamically vary the frequency of operation of the chip as well as the voltage of operation based on task requirements. This embodiment allows the output and input characteristics of the chip to be operated at the optimal point in concert with these dynamic changes.
[0043] Although the present invention has been described in terms of a preferred embodiment, it will be appreciated that various modifications and alterations might be made by those skilled in the art without departing from the spirit and scope of the invention. The invention should therefore be measured in terms of the claims which follow.
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Apparatus including functional components of circuitry defined on a semiconductor chip, the functional components including a component having modifiable operating characteristics, a performance measuring circuit providing an output indicative of operating characteristics of the circuitry defined on the semiconductor chip during operation of the circuitry, and computer implemented software means for controlling a value for an operating characteristic of the component having modifiable operating characteristics in response to the output provided by the performance measuring circuit.
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RELATED APPLICATION
This application is continuation of U.S. patent application Ser. No. 10/339,579, filed 10 Jan. 2003, entitled “SYSTEM AND METHOD FOR MANAGEMENT OF AN AUTOMATIC OLAP REPORT BROADCAST SYSTEM,” now U.S. Pat. No. 7,330,847 (issued 12 Feb. 2008), which is a continuation of U.S. patent application Ser. No. 09/345,440, filed 1 Jul. 1999, entitled “SYSTEM AND METHOD FOR MANAGEMENT OF AN AUTOMATIC OLAP REPORT BROADCAST SYSTEM,” now U.S. Pat. No. 6,567,796 (issued 20 May 2003), which claims priority from U.S. Provisional Application No. 60/126,055, filed, 23 Mar. 1999, entitled “SYSTEM AND METHOD FOR AUTOMATIC TRANSMISSION OF ON-LINE ANALYTICAL PROCESSING SYSTEM REPORT OUTPUT.” This application is also related by subject matter to the following U.S. patent applications: U.S. patent application Ser. No. 09/597,689, filed 19 Jun. 2000, entitled “SYSTEM AND METHOD FOR AUTOMATIC TRANSMISSION OF PERSONALIZED OLAP REPORT OUTPUT,” now U.S. Pat. No. 6,269,393 (issued 31 Jul. 2001), which is a continuation of U.S. patent application Ser. No. 09/343,562, filed 30 Jun. 1999 entitled “SYSTEM AND METHOD FOR AUTOMATIC TRANSMISSION OF PERSONALIZED OLAP REPORT OUTPUT,” now U.S. Pat. No. 6,154,766 (issued 28 Nov. 2000); U.S. patent application Ser. No. 09/345,439, filed 1 Jul. 1999, entitled “SYSTEM AND METHOD FOR SUBSCRIPTION INTERFACING IN AN AUTOMATIC BROADCAST OLAP SYSTEM,” now abandoned; U.S. patent application Ser. No. 09/773,516, filed 2 Feb. 2001, entitled “SYSTEM AND METHOD OF ADAPTING AUTOMATIC OUTPUT OF SERVICE RELATED OLAP REPORTS TO DISPARATE OUTPUT DEVICES,” now abandoned, which is a continuation of U.S. patent application Ser. No. 09/343,561, filed 30 Jun. 1999, entitled “SYSTEM AND METHOD OF ADAPTING AUTOMATIC OUTPUT OF SERVICE RELATED OLAP REPORTS TO DISPARATE OUTPUT DEVICES,” now U.S. Pat. No. 6,260,050 (issued 10 Jul. 2001); U.S. patent application Ser. No. 09/460,708, filed 14 Dec. 1999, entitled “SYSTEM AND METHOD FOR AUTOMATIC TRANSMISSION OF AUDIBLE ON-LINE ANALYTICAL PROCESSING SYSTEM REPORT OUTPUT,” now U.S. Pat. No. 7,082,422 B1 (issued 25 Jul. 2006); which is a continuation-in-part of U.S. patent application Ser. No. 09/343,561(referenced above); and U.S. patent application Ser. No. 09/343,563, filed 30 Jun. 1999, entitled “SYSTEM AND METHOD FOR AUTOMATIC TRANSMISSION OF ON-LINE ANALYTICAL PROCESSING SYSTEM REPORT OUTPUT,” now U.S. Pat. No. 6,173,310 (issued 9 Jan. 2001).
FIELD OF THE INVENTION
This invention relates to a system and method for managing automatic broadcasting of information derived from on-line analytical processing system reports to subscriber devices, including electronic mail, personal digital assistants, pagers, facsimiles, printers, mobile phones, and telephones, based on subscriber-specified criteria.
BACKGROUND OF THE INVENTION
The ability to act quickly and decisively in today's increasingly competitive marketplace is critical to the success of any organization. The volume of data that is available to organizations is rapidly increasing and frequently overwhelming. The availability of large volumes of data presents various challenges. One challenge is to avoid inundating an individual with unnecessary information. Another challenge is to ensure all relevant information is available in a timely manner.
One known approach to addressing these and other challenges is known as data warehousing. Data warehouses, relational databases, and data marts are becoming important elements of many information delivery systems because they provide a central location where a reconciled version of data extracted from a wide variety of operational systems may be stored. As used herein, a data warehouse should be understood to be an informational database that stores shareable data from one or more operational databases of record, such as one or more transaction-based database systems. A data warehouse typically allows users to tap into a business's vast store of operational data to track and respond to business trends that facilitate forecasting and planning efforts. A data mart may be considered to be a type of data warehouse that focuses on a particular business segment.
Decision support systems have been developed to efficiently retrieve selected information from data warehouses. One type of decision support system is known as an on-line analytical processing system (“OLAP”). In general, OLAP systems analyze the data from a number of different perspectives and support complex analyses against large input data sets.
There are at least three different types of OLAP architectures—ROLAP, MOLAP, and HOLAP. ROLAP (“Relational On-Line Analytical Processing”) systems are systems that use a dynamic server connected to a relational database system. Multidimensional OLAP (“MOLAP”) utilizes a proprietary multidimensional database (“MDDB”) to provide OLAP analyses. The main premise of this architecture is that data must be stored multidimensionally to be viewed multidimensionally. A HOLAP (“Hybrid On-Line Analytical Processing”) system is a hybrid of these two.
ROLAP is a three-tier, client/server architecture comprising a presentation tier, an application logic tier and a relational database tier. The relational database tier stores data and connects to the application logic tier. The application logic tier comprises a ROLAP engine that executes multidimensional reports from multiple end users. The ROLAP engine integrates with a variety of presentation layers, through which users perform OLAP analyses. The presentation layers enable users to provide requests to the ROLAP engine. The premise of ROLAP is that OLAP capabilities are best provided directly against a relational database, e.g., the data warehouse.
In a ROLAP system, data from transaction-processing systems is loaded into a defined data model in the data warehouse. Database routines are run to aggregate the data, if required by the data model. Indices are then created to optimize query access times. End users submit multidimensional analyses to the ROLAP engine, which then dynamically transforms the requests into SQL execution plans. The SQL is submitted to the relational database for processing, the relational query results are cross-tabulated, and a multidimensional result set is returned to the end user. ROLAP is a fully dynamic architecture capable of utilizing pre-calculated results when they are available, or dynamically generating results from atomic information when necessary.
The ROLAP architecture directly accesses data from data warehouses, and therefore supports optimization techniques to meet batch window requirements and to provide fast response times. These optimization techniques typically include application-level table partitioning, aggregate inferencing, denormalization support, and multiple fact tablejoins.
MOLAP is a two-tier, client/server architecture. In this architecture, the MDDB serves as both the database layer and the application logic layer. In the database layer, the MDDB system is responsible for all data storage, access, and retrieval processes. In the application logic layer, the MDDB is responsible for the execution of all OLAP requests. The presentation layer integrates with the application logic layer and provides an interface through which the end users view and request OLAP analyses. The client/server architecture allows multiple users to access the multidimensional database.
Information from a variety of transaction-processing systems is loaded into the MDDB System through a series of batch routines. Once this atomic data has been loaded into the MDDB, the general approach is to perform a series of batch calculations to aggregate along the orthogonal dimensions and fill the MDDB array structures. For example, revenue figures for all of the stores in a state would be added together to fill the state level cells in the database. After the array structure in the database has been filled, indices are created and hashing algorithms are used to improve query access times.
Once this compilation process has been completed, the MDDB is ready for use. Users request OLAP reports through the presentation layer, and the application logic layer of the MDDB retrieves the stored data.
The MOLAP architecture is a compilation-intensive architecture. It principally reads the pre-compiled data, and has limited capabilities to dynamically create aggregations or to calculate business metrics that have not been pre-calculated and stored.
The hybrid OLAP (“HOLAP”) solution is a mix of MOLAP and relational architectures that support inquiries against summary and transaction data in an integrated fashion. The HOLAP approach enables a user to perform multidimensional analysis on data in the MDDB. However, if the user reaches the bottom of the multidimensional hierarchy and requires more detailed data, the HOLAP engine generates an SQL to retrieve the detailed data from the source relational database management system (“RDBMS”) and returns it to the end user. HOLAP implementations rely on simple SQL statements to pull large quantities of data into the mid-tier, multidimensional engine for processing. This constrains the range of inquiry and returns large, unrefined result sets that can overwhelm networks with limited bandwidth.
As described above, each of these types of OLAP systems are typically client-server systems. The OLAP engine resides on the server side and a module is typically provided at a client-side to enable users to input queries and report requests to the OLAP engine. Current client-side modules are typically stand alone software modules that are loaded on client-side computer systems. One drawback of such systems is that a user must learn how to operate the client-side software module in order to initiate queries and generate reports.
Although various user interfaces have been developed to enable users to access the content of data warehouses through server systems, many such systems experience significant drawbacks. All of these systems require that the user connect via a computer system to the server system to initiate reports and view the contents of the reports.
Moreover, current systems require that the user initiate a request for a report each time the user desires to have that report generated. A particular user may desire to run a particular report frequently to determine the status of the report.
Further, reports may be extensive and may contain a large amount of information for a user to sort through each time a report is run. A particular user may only be interested in knowing if a particular value or set of values in the report has changed over a predetermined period of time. Current systems require the user to initiate the new report and then scan through the new report to determine if the information has changed over the time period specified.
These and other drawbacks exist with current OLAP interface systems.
SUMMARY OF THE INVENTION
An object of the invention is to overcome these and other drawbacks in existing systems.
Another object of the present invention is to provide a system that manages and controls the automatic broadcast of messages to subscribers based on criteria established by the subscriber when those criteria are determined to be satisfied by an on-line analytical processing system.
Another object of the present invention is to provide a subscriber-based system for automatic broadcast of OLAP reports that enables a system administrator to monitor performance and output of the system.
Another object of the present invention is to provide a subscriber-based system for automatic broadcast of OLAP reports that enables a system administrator to view subscribers to various services of the system.
Another object of the present invention is to provide a subscriber-based system for automatic broadcast of OLAP reports that enables a system administrator to manage the scheduling of services to output reports.
Another object of the present invention is to provide a subscriber-based system for automatic broadcast of OLAP reports that stores an address book for subscribers of the system and enables a system administrator to modify and maintain the address book.
Another object of the present invention is to provide a subscriber-based system for automatic broadcast of OLAP reports that enables use of dynamic recipient lists that are rendered to determine who receives output from the system.
These and other objects are realized by a system and method according to the present invention as described below. Such a system and method comprises a broadcast module that connects to an on-line analytical processing (OLAP) system comprising a server system for accessing information in one or more data warehouses to perform report analysis. The broadcast module may enable the defining of a service. A “service” as used herein should be understood to include one or more reports that are scheduled to be run against one or more data warehouses, relational databases, files in a directory, information from web or file transfer protocol sites, information provided by a custom module, by a server system. These services may be subscribed to by users or user devices to enable the broadcast module to determine who should receive the results of a service. The broadcast module enables the creation of a service, the scheduling of the service, subscription of users to the defined services, generation of reports for the service, formatting of outputs of the service and broadcasting of messages based on the output for the service, among other functions.
Also, an administrator module may be provided that manages automatic generation of output from the on-line analytical processing system. The administrator module manages the operation of the service processing system to increase throughput, increase speed, and improve the administrator control over the processing. The system may maintain dynamic recipient lists that are resolved by system. The system enables administrator control over processing by enabling administrators to view all services and all subscribers of the system, by maintaining an address book containing entries for subscribers of the service and enabling the administrator to view the contents of the address book, and by scheduling processing of services. The system also governs the volume of services being processed, the number of subscribers to a particular service, and the number of output devices to which a service may be broadcast.
According to one embodiment of the present invention, a system for automatically generating output from an on-line analytical processing system based on scheduled services specified by subscribers of the system is provided. The system processes scheduled services in an on-line analytical processing system with each service comprising at least one query to be performed by the on-line analytical processing system. The system then automatically forwards output from the services to one or more subscriber output devices specified for that service. The system may also provide management of the output devices. Users may define new services, including the schedule of the services and the type, such as alert services or scheduled services, and may also subscribe to the services provided by the system. If an alert service is processed, the system may forward output only when one or more alert criteria are satisfied. Subscribers may be specified by a dynamic recipient list that is resolved each time the service is processed to determine recipients of the service output. A dynamic recipient list may be, for example, a list that determines the recipients of a service based on dynamically resolved criteria. For example, a bank may generate a list every month that identifies customers who have an account balance greater than $100,000 and who have not made a transaction within the last three months. The output devices the system may forward output to may comprise electronic mailbox, facsimile, printer, mobile phone, telephone, pager, PDA or web pages.
According to another embodiment of the present invention, a system that enables subscribers to personalize services used for automatically generating output from an on-line analytical processing system is provided. In addition to enabling subscribers to specify the content and schedule of one or more services, the system enables subscribers to personalize various other parameters relating to the service. For example, subscribers may specify the format of service output, filters to be applied to the service, and a variety of other personalization options described in greater detail below.
According to another embodiment of the invention, the system utilizes static recipient lists (“SRL”) and dynamic recipient lists (“DRL”) for determining subscribers to a service. SRLs may be a list of manually entered subscriber names of a particular service. DRLs, however, may be a report generated by the system listing subscriber names that meet a predetermined criteria for a service. DRLs enable lists of subscribers to change according to certain criteria applied to contents of a database. For example, a DRL may be used to broadcast a sales report to only those subscribers who are managers of stores who have not met a predetermined sales goal.
Other objects and advantages of the present invention will be apparent to one of ordinary skill in the art upon reviewing the detailed description of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of a system in accordance with an embodiment of the present invention.
FIG. 2 is a schematic block diagram of a method for automatic transmission of OLAP report information.
FIG. 3 is a schematic block diagram of a method for creating a service according to an embodiment of the present invention.
FIG. 4 is a schematic block diagram of an overall system in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to one embodiment of the present invention, a system is provided for automatic transmission of OLAP report output to one or more of a plurality of user output devices. FIG. 1 depicts an embodiment of a system 100 according to the present invention. System 100 may comprise a data warehouse 12 , a server system 14 , a broadcast module 20 , an object creation module 24 , an agent module 28 , and one or more user devices 40 . User devices 40 may comprise a facsimile 40 a , pager 40 b , mobile telephone 40 c , electronic mail 40 d , and web page output 40 e.
Broadcast module 20 may comprise a module that broadcasts personalized information derived from the OLAP system (e.g., data warehouse 12 and sever system 14 ) to users via one or more user devices 40 such as electronic mail, PDA, facsimile, printer, pager, mobile phone, telephone, and multiple other types of user information devices. Broadcast module 20 enables users to define services (e.g., queries and reports) that are to be run against an OLAP system such as server system 14 and data warehouse 12 based on a predetermined schedule. A “service” as used herein should be understood to include one or more reports that are scheduled to be run against data warehouse 12 by server system 14 . Broadcast module 20 also enables users on the system to subscribe to one or more services and then broadcast module 20 outputs the results of these services to subscribers according to criteria established by the subscribers.
Data warehouse 12 may comprise any data warehouse or data mart as is known in the art, including a relational database management system (“RDBMS”), a multidimensional database management system (“MDDBMS”) or a hybrid system. Server system 14 may comprise an OLAP server system for accessing and managing data stored in data warehouse 12 . Server system 14 may comprise a ROLAP engine, MOLAP engine or a HOLAP engine according to different embodiments. Specifically, server system 14 may comprise a multithreaded server for performing analysis directly against data warehouse 12 . One embodiment of server system 14 may comprise a ROLAP engine known as DSS Server™ offered by MicroStrategy. Accordingly, data warehouse 12 and server system 14 comprise an OLAP system that connects to broadcast module 20 for broadcast of user-specified reports from data maintained by data warehouse 12 .
Broadcast module 20 may also be connected to an agent module 28 which may also be connected to server system 14 . Agent module 28 may be provided to define reports and queries that may be selected as part of one or more services by broadcast module 20 . Agent module 28 may be used to define queries to be performed against the data contained in data warehouse 12 using components, templates, filters, reports, agents, etc. Components may include dimensions, attributes, attribute elements, and metrics—in other words, the building blocks for templates, filters, and reports. Templates generally define a report format and specify the attributes, dimensions, metrics, and display properties comprising a report. Filters generally qualify report content and identify a subset of data warehouse 12 to be included in a report. For example, filters may be used with set math, multidimensional qualifications, and metric qualifications. Using set math, users can define and embed any set of limiting criteria (e.g., union, intersect, exclude). Multidimensional qualifications enable users to indicate general subject areas or perspectives on data (e.g., time, geography, product). Metric qualifications may be used to compute mathematical calculations of various numerical data (e.g., total sales, profit, cost, percent change, profit). Metrics may be displayed in a variety of formats (e.g., percentages, currency, fonts indicating predetermined values). Reports are generally understood to be a data analysis created by combining a template (the format) with a filter (the content). Agents may be a group of reports cached on a time- or event-based schedule for rapid retrieval and batch processing. According to one embodiment of the invention, agent module 28 may comprise a software package known as DSS Agent™ offered by MicroStrategy.
Agent module 28 may operate on any user system 26 including personal computers, network workstations, laptop computers or any other electronic device connected to server system 14 or may comprise an object connected to broadcast module 20 .
Broadcast module 20 therefore, cooperates with server system 14 and agent module 28 to send personalized information to users at predefined intervals or when criteria specified in reports defined through either broadcast module 20 or agent module 28 exceed predefined thresholds. To provide this functionality, broadcast module 20 enables users of the system to create services that run against the OLAP system to generate information and subscriptions that specify the recipients of the information derived from a service. A service may comprise one or more reports that are processed by the OLAP system and may be a specific report, series of reports or elements within a report. Also, subscribers may include users, groups of users or only specific user devices 40 for a particular user. Services may be based on predefined reports from broadcast module 20 or agent module 28 or may be based on filter/template combinations set up through broadcast module 20 and/or agent module 28 .
Once services have been defined and subscribers to that services are established, broadcast module 20 continually monitors the schedules for the services, runs the scheduled reports, and automatically generates outputs where conditions specified in the service are satisfied using push technology. Outputs from broadcast module 20 may be personalized to subscriber demands and/or formatted to meet a subscriber's user device requirements to ensure that users see only that portion of a report that is relative to that user and in a manner that is most useful for the user. Accordingly, a user can thus have up-to-date information about the contents of data warehouse 12 without having to submit a query or log-in to a software module on the user system.
To provide the functionality described above, broadcast module 20 may comprise a plurality of modules that perform certain functions. Although described as separate modules, it should be understood that such modules may be combined or separated further. In an embodiment of the present invention, as depicted in FIG. 1 , broadcast module 20 may comprise a service definition module 42 , a service schedule module 44 , a service generation module 46 , a service format module 48 , a personalization module 50 , a subscription interface module 52 , and a service administration module 54 .
Service definition module 42 of broadcast module 20 may comprise a module for enabling a user to create or modify a service. In an embodiment, the services may be defined based on reports or workbooks specified in agent module 28 . Users may then subscribe to services defined in service definition module to enable broadcast module 20 to determine who should receive the results of a service.
At least two types of services may be provided—scheduled services and alert services. A schedule service may comprise a service that generates information to subscribers at a given time interval. An alert service may comprise a service that provides information to all subscribers if an alert condition is true.
Service schedule module 44 may provide the functionality to enable selection of when a service should be run. Service schedule module 44 may enable a user, administrator or other person having access thereto to specify the frequency that the service should be performed. The schedule may be based on an interval (such as every several hours, days, weeks, months, years, etc.) or on one or more specified days (such as March 15th and September 15th). Other methods of scheduling events to be processed may also be used.
Service generation module 46 may comprise a module for following a schedule set by service schedule module 44 and completing the operation specified in service definition module 42 . For example, if a service were specified to run the monthly sales totals for the Midwest region of a company every weekend and generate an alert to the supervisor on Monday morning if sales drop below 5%, then service generation module 46 would be responsible to monitor the schedule of this service to ensure that the report contained therein was processed over the weekend and then generate an alert report if the criteria set in the service is satisfied. To monitor the schedule of all services specified by broadcast module 20 , service generation module 46 may operate constantly to ensure that every scheduled service is completed.
Service format module 48 may be responsible for taking the results of a service and formatting it to a proper format corresponding to each of the subscribers of a particular service. Service format module 48 may be responsible for formatting service results for generation to user devices 40 a - 40 e.
Personalization module 50 may be provided to enable subscribers to specify the content for a service in which they are interested. Users may input personalized choices for personalization module 50 through subscription interface module 52 by selecting personalization filters from filters available in the service. Personalization module 50 captures the criteria selected by the user and creates a subscription based on the selected criteria which may be multidimensional based on the data structure in the data warehouse, relational database, etc. Because personalization module 50 enables subscribers to specify the content of a service, this reduces the amount of data output to a subscriber by providing the subscriber with data that the subscriber is interested in.
Personalization may also be set in an address book module maintained by broadcast module 20 . The address book may comprise an entry for each subscriber of any service on the system. That subscriber may define global personalization filters to be applied to all services to which the subscriber applies rather than providing personalization on only a service by service basis. For a chosen user, personalization may also be set on a project level basis. For example, a project may comprise multiple reports. Each report within a project may have different personalized filters applied according to user desires. Personalization module 50 , however, also enables subscribers to personalize the entire rather than doing so for each. For example, subscribers may assign particular operations to be performed for each of the reports within a project. This enables subscribers to personalize multiple reports simultaneously.
Additionally, subscribers may personalize style parameters using, for example, personalization module 50 . Styles may be used to tailor a display format of a report to a particular device (e.g., pager, electronic mail, facsimile). Styles may be designed according to the needs of each subscriber depending on the characteristics and properties of a recipient. For example, a user may desire to have pages generated from the report sent in a particular format and may set up that format using styles.
Further, in the address book, the data warehouse login and password may also be stored to enable access to the data warehouse. Each subscriber may have multiple addresses in the address book, each address assigned to a different output device. Thereby, a subscriber may have multiple addresses, each of which may be assigned to receive different services based on different filters, etc. This provides for the ultimate in customization for receipt of information. For example, a user may desire to get stock information via pager but sales information via e-mail. By setting up two separate addresses and applying different services and/or filters, that may be accomplished according to the present invention.
Through the address book module, administrators may also be able to add subscribers to the address book, import subscribers from other applications into the address book, create groups and add subscribers to those grounds and delete or edit information, including personalization features for subscribers. This enables administrators to also determine who all of the subscribers are and to view personalization features for each subscriber.
Subscription interface module 52 may be provided to enable users or administrators of the system to monitor and update subscriptions to various services provided by broadcast module 20 . Service administration module 54 may be provided to provide administrative functions to monitor a queue to schedule services and to provide throughput of services to ensure efficient completion of those services by broadcast module 20 .
Subscription interface module 52 may be used to create a subscriber list by adding one or more subscribers to a service. Users or system administrators having access to broadcast module 20 may add multiple types of subscribers to a service such as a subscriber from either a static recipient list (SRL) (e.g., addresses and groups) or a dynamic recipient list (DRL) (described in further detail below). The subscribers may be identified, for example, individually, in groups, or as dynamic subscribers in a DRL. Subscription interface module 52 permits a user to specify particular criteria (e.g., filters, metrics, etc.) by accessing data warehouse 12 and providing the user with a list of available filters, metrics, etc. The user may then select the criteria desired to be used for the service.
A SRL is a list of manually entered names of subscribers of a particular service. The list may be entered using service administration module 54 or subscription interface module 52 . SRL entries may be personalized such that for any service, a personalization filter (other than a default filter) may be specified. A SRL enables different personalizations to apply for a login alias as well. For example, a login alias may be created using personalization module 50 . Personalization module 50 enables subscribers to set preferred formats, arrangements, etc. for displaying service content. The login alias may be used to determine a subscriber's preferences and generate service content according to the subscriber's preferences when generating service content for a particular subscriber.
A DRL may be a report which returns lists of valid user names based on predetermined criteria that are applied to the contents of a database such as data warehouse 12 . Providing a DRL as a report enables the DRL to incorporate any filtering criteria desired, thereby allowing a list of subscribers to be derived by an application of a filter to the data in data warehouse 12 . In this manner, subscribers of a service may be altered simply by changing the filter criteria so that different user names are returned for the DRL. Similarly, subscription lists may be changed by manipulating the filter without requiring interaction with service administration module 54 . Additionally, categorization of each subscriber may be performed in numerous ways. For example, subscribers may be grouped via agent filters. In one specific embodiment, a DRL is created using DSS Agent™ offered by Microstrategy.
Service administration module 54 enables monitoring of reports (e.g., ability to see who is using system, what reports they are generating, etc.), scheduling of reports, address book and dynamic recipient list maintenance, subscriber management, and statistics tracking. Subscriber management involves enabling system administrators to review, access, and generate information about subscribers to the system through the maintenance of detailed subscriber lists including the DRL's and SRL's. This list may track information on which subscribers subscribe to which services and vise-versa.
The present invention provides an administration console that enables organizations to rapidly implement and fully administer enterprise broadcast deployments. As briefly described above, service administration module 54 may comprise the administration console.
Service administration module 54 enables monitoring of reports (e.g., ability to see who is using system, what reports they are generating, etc.), scheduling of reports, address book and dynamic recipient list maintenance, and subscriber management. Subscriber management involves enabling system administrators to review, access, and generate information about subscribers to the system through the maintenance of detailed subscriber lists. This list may track information on which subscribers subscribe to which services and vise-versa.
According to one aspect of the present invention, service administration module 54 may comprise a service queue management system that creates and presents a service queue. The service queue may comprise a listing of all services that the system is to be running within a predetermined period of time (which may be modified by the user, for example, to extend from seconds to years). The service queue may comprise a list of upcoming service initiation times for each active service. The service queue management system monitors the services to ensure that they initiate on a predefined schedule.
The service queue management module may also present this information by subscriber to enable an administrator or a user to view the services to which that user subscribes. This enables the administrator to gain an understanding of what information that user finds helpful. The administrator may use that information to interest the user in additional information. The service queue may also be viewed by service or with all services as desired.
Further, according to one embodiment, upon selecting a service in the queue, the system may display the specifics of the service to enable the administrator to view the information sought in that service, the subscribers to that service, and modify various parameters for that service.
Service administration module 54 may also maintain the address book and dynamic recipient lists to enable administrators to review subscriber information contained in those lists. The address book may contain the name and specific settings of all valid subscribers and may interact with other address book programs for importing and exporting names.
Personalization may also be set in the address book. For a chosen user, personalization may be set for each project which is currently loaded. A personalization filter may be selected for the project. The data warehouse login and password may also be stored to enable access to the data warehouse. One or more display styles may be set up. Each subscriber may have multiple addresses in the address book, each address assigned to a different output device. Thereby, a subscriber may have multiple addresses, each of which may be assigned to receive different services based on different filters, etc. This provides for the ultimate in customization for receipt of information. For example, a user may desire to get stock information via pager but sales information via e-mail. By setting up two separate addresses and applying different services and/or filters, that may be accomplished according to the present invention.
Service administration module 54 may also be responsible for governing services to ensure that the server system does not become overloaded with the number of services being performed and that broadcast module 20 does not become overloaded with the number of messages to be broadcast. This may be performed by setting a maximum numbers of jobs that may be performed by each of these systems, a maximum number of subscribers per service or a maximum number of recipient user systems per service, for example. Other governing techniques may also be used.
Further, service administration module 54 may comprise a job reduction component that functions to limit the number of jobs submitted to server system 14 . This component generates a distinct list of jobs to send to server system 14 to satisfy all services and all personalization filters for all subscribers for each service. This component may remove duplicate subscribers using the report name, login identification and personal filter values for the subscribers to the service. For example, this module may operate as follows. First, the system may associate each subscriber with a login identification and a personalization filter for that subscriber (a blank filter may be used if the user did not specify either a default or subscription level personalization filter). Duplicates may then be eliminated by comparing the personalization filters provided and grouping all subscribers requesting the same personalization filter together to generate a single report for that group and using the login identification for those subscribers to later generate individual outputs for the subscribers having that personalization filter from the single report.
A method 200 of operation of system 100 is provided in FIG. 3 . Method 200 comprises several steps for generating information to a plurality of user systems using “push” technology. In step 100 , one or more services are defined by users or system administrators for broadcast module 20 to monitor, as described in more detail below with respect to FIG. 4 , such as through service definition module 42 . In step 102 , subscribers for each of these various services are provided, such as through subscription interface module 52 . In step 104 , the system monitors and processes services according to their defined schedules. Step 104 may be performed by service schedule module 44 , and/or service generation module 46 , for example.
In step 106 , the system determines whether an alert criteria has been met or if a scheduled service has been completed, such as through service generation module 46 . If an alert criteria has not been satisfied or a scheduled service has not completed, the system continues to monitor and process services. If an alert condition has been met, or if a scheduled service has been completed, in step 108 , the system, such as through service generation module 46 , builds the service output and the subscription list for that particular service. Building the subscription list for a service may involve using a recipient list resolution method. For example, a recipient list resolution (RLR) may be used to build a list of all of the subscribers to a service in step 108 . This may be performed by resolving and merging all DRLs with all SRLs for a given service. All DRLs are generated and the resulting list is merged with the SRL. Typically, there is only one SRL (although additional SRLs may be used) and none to numerous DRLs per service. The list that results from merging all of the DRLs and SRLs produces a list which consolidates all subscribers of a given service.
Next, in step 110 , the system, such as through personalization module 50 , applies personalization filters to services that are scheduled to be output to the subscribers. Personalization filters may modify the output of a service according to the subscriber's desired criteria. The personalized outputs may then be formatted for the user device 40 selected by the user for output. Additionally, personalization module 50 may also be used to personalize the contents of one or more services as described above. In step 114 , broadcast module 20 broadcasts the formatted and personalized services to subscribers at user devices 40 a - 40 e.
As described above, step 100 defines the service or services to be monitored by broadcast module 20 . FIG. 4 depicts a method 210 according to one embodiment of the present invention for performing step 100 . According to one embodiment, in step 116 , a user may name and provide a description of the service or services to be monitored. By providing a name and description, users may be able to uniquely identify the services from an object browser or in a service queue.
Next, in step 118 , the user selects the type for the service. As described above, at least two types of services may be provided. A first type, a scheduled service, is a service that is run according to a predetermined schedule and output is generated each time the service is run. An alert service is one that is run periodically as well, however, output is only generated when certain alert criteria is satisfied. If an alert service is selected by the user, the user may then specify a report or a template/filter combination upon which the alert is based. According to one embodiment, reports and template/filter combinations may be predefined by other objects in the system including agent module 28 or object creation module 24 . For example, agent module 28 such as the DSS Agent™ offered by MicroStrategy, may be used to create and define reports with filters and template combinations, and to establish the alert criteria that are to be used for an alert service.
Next, in step 120 , the duration of the service is input by the user. Service duration indicates the starting and stopping dates for the service. The start date is the base line for the scheduled calculation, while the end date indicates when the broadcast will cease to be sent. The user has the option of starting the service immediately or waiting until some time in the future. Various calendaring features may be provided to enable the user to easily select these start and stop dates. For example, a calendar that specifies a date with pull-down menus that allow the users to select a month and year may be provided according to known methods of selecting dates in such programs as electronic calendaring programs and scheduling programs used in other software products. One specific aid that may be provided is to provide a calendar with a red circle indicating the present date and a blue ellipse around the current numerical date in each subsequent month to more easily allow the user to identify monthly intervals. Other methods may also be used.
Next, in step 122 , the user selects the schedule for the service. According to one embodiment, predefined schedules for services may be provided or the user may choose to customize the schedule for the service. If the user desires to create a new schedule, a module may be opened to enable the user to name the schedule and to set the parameters for the schedule. Schedules may be run on a several-minute, hourly, daily, monthly, semi-annual or annual basis, all depending upon what frequency is desired.
The next step, step 123 , may be performed to enable the user to specify the content of a service. The content of a service is the various information reports and template/filter combinations that the server system 14 processes using the data in data warehouse 12 in order to provide the output requested for that particular service. The content of a service may comprise many different items or combination of items to suit the user's needs. For example, the user may be able to include a text grid, an agent alert, a web uniform resource location (URL), a spreadsheet container, a new sheet container, a text container, a text message, contents from a text file, or a file attachment. According to one embodiment, the system may organize these various contents into containers. A broadcast container may comprise the highest level container under which all content pieces reside. A grid may comprise an element that is associated with a report or a template/filter combination. The grid may be bound via a macro to a report/filter and template combination. An agent alert may be associated with a particular report that is therefore incorporated within the service. Any report available on agent module 28 may be selected. The web URL item may be associated with the report through network output module 22 that specified that URL for the particular report. A spreadsheet container may be the parent of an embedded spreadsheet attachment. When created, a particular spreadsheet may be included as a child. Additionally, markup language (e.g., XML and/or HTML) documents may also be included.
After the user has named the service, selected the type, duration, and schedule for the service, the user may select the personalization type in step 124 . For example, the user may select an option to either prevent personalization, require personalization, or allow personalize optionally. Upon completion of these steps, the service may be stored by service definition module 42 in a database structure to enable users to retrieve predefined services to subscribe to these services through subscription interface module 52 .
Method 210 may also comprise an error condition step. An error condition step may be used to enable users to specify “error” conditions and actions. For example, an “error” condition may be a user notification that a server is “down” or that there is no data to be returned. A user may specify particular actions to be performed by the system in response to one or more error conditions. For example, a user may specify a “server” error (e.g., not responding) and indicate a particular action to be performed in response to a “server not responding” error (e.g., reattempt in a predetermined time). Various other conditions and actions may be specified.
The system described may also comprise a portion of a larger decision support system 10 as depicted in FIG. 4 . System 10 may comprise a data warehouse 12 , a server system 14 , an architect module 16 , an administrator module 18 , a broadcast module 20 , a network output module 22 , a plurality of user systems 26 , and an object creation module 24 . User systems 26 may comprise an agent module 28 as described above.
Agent module 28 may enable a user access to the contents of data warehouse 12 to provide detailed analysis on an ad hoc basis. One of the advantages of DSS Agent™ includes its use of a ROLAP architecture on server system 14 and a RDBMS in data warehouse 12 to provide a more scaleable environment. Through DSS Agent™, a user can “drill down.” Drilling down allows the user to dynamically change the level of detail in a report to a lower level attribute so that the resulting report displays data with a greater level of detail. For example, one can drill down from year to month to week to day. DSS Agent™ also enables users to “drill up” to a higher level attribute. Drilling up summarizes the selected data to a higher level total. For example, one can drill from day to week to month to year. DSS Agent™ also enables a user to “drill within.” Drilling within allows a user to go to a different hierarchy within the same dimension. Drilling within is often used to examine the characteristics of selected data. For example, drilling within enables a user to drill from item to color when looking at a particular retail item such as an automobile, clothing or the like. Drilling across allows the user to drill to an altogether different dimension. For example, one can drill across from a region to a month. Accordingly, through use of agent module 28 , server system 14 , and data warehouse 12 , drilling is a powerful tool that is easily implemented using a ROLAP architecture which is not as easily accessible in MOLAP.
Architect module 16 may comprise a module that enables developers to create and maintain data and metadata in data warehouse 12 . Metadata may be considered to be data about data, such as data element descriptions, data type descriptions, attributes/property descriptions, range/domain descriptions, and process/method descriptions. Data and metadata stored in data warehouse 12 may thus be modified and organized by architect module 16 . According to one embodiment of the invention, architect module 16 may comprise a software package known as DSS Architect™ offered by MicroStrategy.
Administrator module 18 may comprise a module for facilitating the development, deployment, and management of data warehouse applications supporting large volumes of users over various distribution mechanisms. Administrator module 18 may comprise an object manager and a warehouse monitor. The object manager allows objects to be shared across databases for easy migration from development to production. The warehouse monitor provides performance monitoring and management tools to support thousands of users across a distributive database environment. The warehouse monitor collects statistics for the purpose of identifying performance bottlenecks, warehouse tuning, cost analysis and various other purposes. According to one embodiment of the invention, administrator module 18 may comprise a module known as DSS Administrator™ offered by MicroStrategy.
Server system 14 may also connect to an object creation module 24 . Object creation module 24 may comprise an open object linking and embedding (“OLE”) application program interface (“API”) for custom decision support development. According to one embodiment of the invention, object creation module 24 may comprise a software module known as DSS Objects™ offered by MicroStrategy. Additionally, custom applications may interface with object creation module 24 including Delphi, Visual Basic, and C++ programming modules.
User systems 26 may also include a report writing module 30 , an executive module 32 , and a spreadsheet module 34 . Report writing module 26 may comprise an OLAP report writer. Executive module 32 may comprise a module design tool for developing custom EIS applications. This module is a design tool for developing briefing books that provide high level users with a series of views that describe their business. Once created, end users can access briefing books through agent module 28 in EIS mode. Such a system is easily implemented with agent module 28 by compiling sets of analyses into dynamic pages that immediately focus users on their key business drivers. One embodiment of executive module 32 may comprise software known as DSS Executive™ offered by MicroStrategy.
Spreadsheet module 34 may comprise an add-on to existing spreadsheet programs or may comprise an entirely new spreadsheet program. Spreadsheet module 34 may enable reports and analyses generated from agent module 28 to be presented in a traditional spreadsheet program format to enable users to view results in preexisting front-end interfaces. Spreadsheet module 34 may comprise the Microsoft Excel™ spreadsheet program offered by Microsoft and/or an Excel™ Add-in program offered by MicroStrategy.
Another module for accessing content of server system 14 may comprise a network output module 22 . Network output module 22 enables user system 26 access to server system 14 and data warehouse 12 without requiring an additional agent module 28 to be stored on user system 26 . Instead, user system 26 may have a user interface module 38 residing thereon. User interface module 38 may comprise any module that enables a user system, such as user system 26 , to interface with network output module 22 over a network 36 . According to one embodiment of the invention, network 36 may comprise an intranet, the Internet or other developed Internet-type networks. Further, user interface module 38 may comprise any standard browser module such as Microsoft Internet Explorer™, Netscape Navigator™ or other. As many user systems 26 already have a user interface module 38 stored and operating thereon, network output module 22 offers the advantage of enabling users access to server system 14 and data warehouse 12 without learning to operate a new module such as agent module 28 . One embodiment of network output module 22 may comprise a web-based module called DSS Web™ offered by MicroStrategy. Accordingly, in one embodiment, a user can access server system 14 through a standard web browser, such as Microsoft Internet Explorer™, or over the Internet through network output module 22 , such as DSS Web™.
In this embodiment, network output module 22 may comprise a World Wide Web tool used in conjunction with server system 14 for allowing users to deploy data warehouse/decision support applications over the Internet using industry standard World Wide Web browsers as a client. As a result, a user can access the data warehouse with little or no client maintenance, little or no software to install, and only a small amount of additional training while still maintaining all of the capabilities of agent module 28 . One embodiment of network output module 22 comprises DSS Web™ offered by MicroStrategy. This embodiment provides a broad array of options for viewing information sets, such as spreadsheet grids and a wide variety of graphs. Through this module's reporting capabilities, users receive key elements of a report in easily interpretable, plain language messages. This module also allows users to “drill” dynamically to a lower level of detail to view the underlying information or to create and save new analyses. For sensitive information, this module provides security plug-ins that allow the user to extend the standard security functionality with additional user authentication routines. This module may also provide an API that allows users to customize, integrate, and imbed this functionality into other applications. For example, a data syndicator for health care information may utilize this module with a customized interface to sell access to health care information to Health Maintenance Organizations, hospitals, pharmacies, etc.
Other embodiments and uses of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. The specification and examples should be considered exemplary only. The scope of the invention is only limited by the claims appended hereto.
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A system, method and processor medium that manages automatic generation of output from an on-line analytical processing (OLAP) system. Scheduled services are processed in an OLAP system and output from the OLAP system is then automatically forwarded to one or more subscriber output devices specified for that service. The system manages the operation of the service processing system to increase throughput, increase speed, and improve the administrator control over the processing. The system enables administrator control over processing by enabling administrators to view all services and all subscribers of the system, by maintaining an address book containing entries for subscribers of the service and by scheduling processing of services. The system governs the volume of services being processed, the number of subscribers to a particular service, and the number of output devices to which a service may be broadcast.
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FIELD OF THE INVENTION
The present invention pertains to the printing of graphic and textual information onto surfaces that ordinarily cannot be accommodated by inkjet printers and, more particularly, to the inkjet printing of license plate blanks by means of a paper transfer technique.
BACKGROUND OF THE INVENTION
The present invention entails the transfer of inkjet printing images and/or textual information onto license plate substrates. Such license plate blanks cannot be fed into an inkjet printer, due to their stiffness, size, thickness and irregular surfaces containing embossed characters and peripheral ridges.
Only certain label materials can accept inkjet inks. Having pressure-sensitive backings, the labels are pasted onto objects. Some labels are sufficiently transparent so that the background"fades", leaving only the image visible. Such materials, however, are not acceptable for a "graphic" application and, thus, would not serve as a means to provide a license plate substrate with graphics and text. Additionally, a license plate window area is too large and the labels utilizing inkjet printing too small to satisfactorily jibe for a successful print job.
Images produced by means of inkjet printers may be transferred to other substrates by utilizing transfer or carrier sheets. Inkjet receptive layers (single or multiple) are coated onto a carrier sheet. The carrier sheet is first coated with a silicone release system, so that the inkjet layer(s) may be easily removed by pressure-sensitive adhesive or by heat and pressure. The inkjet layer(s) are sufficiently cohesive enough to be manually placed onto another substrate such as a license plate blank.
In the present invention an image produced by a computer is printed by an inkjet printer or an inkjet plotter. A treated transfer sheet material that will accept the image is placed in the media compartment of the printer or plotter. Once the printing is complete, the image disposed upon the carrier layer is easily removed from the backing of the transfer sheet material. The carrier sheet, bearing the graphics and text, is then adhered to a license plate blank.
The production of a transferable medium that will accommodate inkjet printing requires several elaborate steps, hereinafter enumerated:
1. On a dense, solvent hold-out paper, a coating of commercial silicone release is applied.
2. The solvent is removed from the paper, and the paper layer is then cured.
3. A carrier layer is coated onto the silicone release layer. This carrier layer is designed by this invention to have a greater cohesion than the adhesion to the silicone layer. A second characteristic of the carrier sheet is its ability to resist penetration of the inkjet ink. This ink resistance is necessary, so that the ink will not coat the silicone surface. The carrier must adhere to the silicone to allow for transport and manipulation which would otherwise be impaired by the penetrating ink. The carrier layer, however, must also be designed so that it is removable from the silicone layer (by peeling, for example).
4. A final coating is layered upon the upper surface of the carrier in order to receive the inkjet image. This layer is composed of resins/pigments to absorb and enhance the ink characteristics. This coating layer is designed by this invention to adhere well to the carrier layer.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a method of applying images and text to surfaces that ordinarily cannot be accommodated by an inkjet printing machine, such as license plate blanks. The method of the invention uses a specially designed transfer sheet to receive inkjet ink images and text. The carrier layer of the transfer sheet containing the inkjet image and text is removed or otherwise peeled from the transfer sheet backing and then adhered to the license plate blank. A computer is used to construct the inkjet image and text that are printed onto the carrier surface of the transfer sheet. A final resin/pigment layer is coated upon the upper surface of the carrier layer in order to receive the inkjet ink that has been fashioned into image and text by means of the computer.
The transfer sheet of this invention is fabricated by first coating a dense, solvent hold out-paper with a silicone release substance. After the solvent is removed therefrom, the paper is cured. To the silicone release layer is then applied a carrier layer that has a greater cohesion than adhesion used for the silicone release surface of the hold-out paper. Over the carrier layer is applied an ink absorption layer that is composed of resins and pigments to absorb and enhance the ink characteristics. This final layer is designed by this invention to adhere well to the carrier layer.
BRIEF DESCRIPTION OF THE DRAWINGS
A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent detailed description, in which:
FIG. 1 is a schematic view of a solvent hold-out paper, upon which a silicone coating is applied;
FIG. 2 is a schematic view of a carrier layer coating being applied to the hold-out paper depicted in FIG. 1; and
FIG. 3 is a schematic view of a final coating being applied to the carrier layer of FIG. 2. This final coating is for adapting the carrier layer to receive the inkjet ink.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Generally speaking, the present invention comprises a method whereby an image produced by a computer is printed by an inkjet printer or an inkjet plotter upon a transfer medium. The medium is then placed in the appropriate compartment of the printer or plotter. The transfer medium accepts the image and text being printed thereon. Once printing is complete, the image disposed upon the transfer sheet's carrier layer is transferred to a license plate blank by removing the carrier from the backing of the transfer sheet material and adhering it then to a license plate blank.
The manufacture of the transfer sheet of this invention is explained with reference to FIGS. 1 through 3 and the following EXAMPLES.
Now referring to FIG. 1, a solvent hold-out paper (substrate layer) 10 is shown, upon which a silicone coating 11 is applied. The solvent is then removed, usually by heating and curing the paper 10.
Referring to FIG. 2, a carrier layer coating 12 is then applied over the silicone coating layer 11 of the hold-out paper 10. This carrier layer 12 is designed by this invention to have a greater cohesion than adhesion to the silicone layer 11. A second design criterion of the carrier sheet 12 is its ability to resist penetration of inkjet ink that is later applied. This ink resistance is necessary, so that the inkjet ink will not coat the silicone surface. The carrier must adhere to the silicone layer 11 to allow for transport and manipulation which would otherwise be impaired by the penetrating ink. The carrier layer 12, however, must also be designed so that it is removable from the silicone layer 11 (by peeling, for example).
Referring to FIG. 3, a final coating 14 is layered upon the upper surface 15 of the carrier layer 12 in order to receive the inkjet image. This layer 14 is composed of resins/pigments to absorb and enhance the ink characteristics. This coating layer 14 is designed by this invention to adhere well to the carrier layer 12.
The transfer sheet is fabricated according to the following EXAMPLES:
EXAMPLE 1
Onto a commercially coated silicone-release paper 10, the following carrier layer 12 composition is coated:
______________________________________Pigment paste @ 40% silica 104 lbs. @ 18% resin @ 42% solventUrea formaldehyde resin 100% 9.25 lbs. Carboxylated acrylic resin 40% 126 lbs. p-TSA catalyst sufficient for drying conditions Fluorinated surfactant FC 431 0.6 lbs. Ethyl acetate 90.0 lbs. Methyl Ethyl Ketone 48.0 lbs.______________________________________
This coating is applied by any conventional means at a coat weight of about 20-259/ml, wet. This layer has sufficient adhesion to the base so that typical manipulation will not cause delamination or cracking. If an adhesion test with moderately tacky tape is performed, however, the layer will come off easily with the tape.
Common inkjet ink is not compatible with the carrier layer 12, so another ink absorption surface layer 14 that will accept the ink must be provided. The composition of layer 14 is:
______________________________________Methanol 111 lbs. Isopropanol 39 lbs. Cationically modified film forming Acrylic resin 119 lbs. Formic acid 11 lbs. Syloid 72 (Silica) 40 lbs.______________________________________
This coating 14 is applied to the carrier layer 12 by conventional means at a dry coat weight of about 8 lbs./3000 square feet.
This medium can be placed in a Hewlett-Packard Paintjet inkjet printer and an image produced in reverse reading mode. The printing surface becomes tacky after a few moments, since paintjet inks contain a considerable amount of glycol. The tack is sufficient to allow the entire layer 12 to be removed from the backing sheet 10 when the sheet is pressed firmly onto another surface in order to transfer the image and text thereto.
EXAMPLE 2
Onto the same silicone release liner 10 as in EXAMPLE 1, the following clear lacquer composition is coated:
______________________________________Methanol 40 lbs. Dowanol PM 110 lbs. Calgon 7091 (cationic polymer) 15 lbs. MEK 135 lbs. Cellulose Acetate Propionate 25 lbs. Uformite F-200 E 10 lbs. p-TSA 340 gms. Fluorad FC 431 0.6 lbs.______________________________________
The same ink-receptive layer 14 as employed in EXAMPLE 1 is coated onto this carrier layer. When transfer is complete, the image is glossy.
EXAMPLE 3
In the previous EXAMPLES the carrier was inert to the inkjet ink. This is an example of the carrier being part of the ink-absorption process.
A lacquer is prepared in the following manner:
______________________________________Methanol 75 lbs. Polyvinyl Pyrollidone K-90 6.4 lbs. Acrylic resin solution SP-7 30% 8.6 lbs. Ethyl Acetate 25 lbs.______________________________________
When coated at a coat weight of about 3 lbs./3000 sq. ft., this layer produces a layer that will absorb significant amounts of ink. To prevent this layer from becoming greasy, a second layer is used. The second layer allows the ink solvents to penetrate and be trapped while maintaining a dry feel. The second layer composition is as follows:
______________________________________Water 94 lbs. Polyvinyl Alcohol 5 lbs. Pigments, additives, cross-linkers, etc. 1 lb.______________________________________
Since no tack develops in this case, an external adhesive must be used to achieve transfer.
EXAMPLE 4
This EXAMPLE does not employ a carrier layer at all; instead, it uses the inkjet lacquer described in EXAMPLE 1. The lacquer is coated to a coat weight of about 13 lbs./3000 sq. ft. This amount is significantly higher than in the first EXAMPLE. When printed with glycol and anionic ink ingredients, the layer becomes tacky. The image is washed in a stream of warm water. The unprinted background is flushed away, and a relief image remains. Such a method is very useful in an instance where any background at all might mar the appearance of a transferred product.
EXAMPLE 5
Onto a commercially coated silicone-release paper 10, the following carrier layer 12 is coated:
______________________________________micro crystaline silica.sup.1 42 lbs. thermoplastic acrylic resin.sup.2 19 lbs. propylene glycol mono methyl ether.sup.3 42 lbs. urea formaldehyde resin.sup.4 10 lbs. carboxylated acrylic resin.sup.5 126 lbs. p-toluene sulfonic acid 250 gm. nonionic flourinated alkyl ester.sup.6 272 gm. methyl ethyl ketone 75 lbs. ethyl acetate 25 lbs.______________________________________ From: .sup.1 Imsil A10 Illinois Minerals, Cairo, IL .sup.2 Acryloid B99 Rohm & Haas, Phila, PA .sup.3 Dowanol PM Dow Chemical, Midland, MI .sup.4 Beckamine 21500 Richold Chemicals, Elizabeth, NJ .sup.5 Surcol SP2 Allied Colloids, Suffolk, VA .sup.6 3M Fluorad FC431 3M Co., St. Paul, MN
The common inkjet layer is comprised of:
______________________________________methanol 111 lbs. isopropanol 39 lbs. cationically modified film forming acrylic resin.sup.1 119 lbs. formic acid 11 lbs. precipitated silica.sup.2 40 lbs.______________________________________ From: .sup.1 Surcol SP6 Allied Colloids, Suffolk, VA .sup.2 Syloid 72 Grace Chemical Co., Baltimore, MD
EXAMPLE 6
A lacquer is prepared in the following manner:
______________________________________methanol 75 lbs. polyvinylpyrollidone (high mol wt).sup.1 6.4 lbs. carboxylated, hydroxylated acrylic resin soln. 30% 8.6 lbs. in ethyl acetate.sup.2______________________________________ From: .sup.1 PVP K90 IPS Co., Wayne, NJ .sup.2 Surcol SP7 Allied Colloids, Suffolk,VA
The second layer is comprised as follows:
______________________________________water 94 lbs. Polyvinylalcohol.sup.1 5 lbs. precipitated silica.sup.2 0.5 lbs. glyoxal 40% 0.2 lbs. fluorinated alkyl ester.sup.3 0.01 lbs.______________________________________ From: .sup.1 Polyvinyl alcohol Nipon Gohsei, Osaka, Japan .sup.2 Syloid 72 Grace Chemical Co., Baltimore, MD .sup.3 Fluorad FC430 3M Co., St Paul, MN
Inkjet Inks
Inkjet inks as defined by HP and Canon patents contain:
1. Cationic or anionic dyes in water or diethylene glycol and water
2. The amount of glycol is between 30 and 60 wt %
3. Inkjet inks may contain a water-soluble resin
4. Multivalent ions are often added as precipitation agents for drying
5. Polyether polyols are added as surface tension modifiers
6. Buffers, humectants and bactericide are also used to prevent clogging
The relevant patents for HP and Canon ink include the following U.S. Pat. Nos.:
______________________________________ HP: 5198023 5188664 5143547 5183502 5169437 5165968 Canon: 5172133 5167703______________________________________
For those skilled in the art, it is clear that many variations in the composition of the various layers are possible. For example, the carrier may be matte, clear, or contain nacreous pigments for decorative effects. The carrier may be inert to inkjet ink or play a part in ink-drying through absorption.
For EXAMPLE 5, the following ingredients can be formulated in the approximate ranges of:
______________________________________micro crystaline silica.sup.1 40 to 60 lbs. thermoplastic acrylic resin.sup.2 15 to 25 lbs. propylene glycol mono methyl ether.sup.3 42 lbs. urea formaldehyde resin.sup.4 8 to 20 lbs. carboxylated acrylic resin.sup.5 100 to 140 lbs. p-toluene sulfonic acid 200 to 450 gm. nonionic fluorinated alkyl ester.sup.6 139 to 386 gm. methyl ethyl ketone 75 lbs. ethyl acetate 25 lbs.______________________________________
The common inkjet ink receiving layer can also be formulated in the approximate ranges of:
______________________________________methanol 111 lbs. isopropanol 39 lbs. cationically modified film 72 to 180 lbs. forming acrylic resin.sup.1 formic acid 11 lbs. precipitated silica.sup.2 25 to 60 lbs.______________________________________
Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.
Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims.
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The present invention features a method of applying images and text to surfaces that ordinarily cannot fit within an inkjet printing machine, such as license plate blanks. The method of the invention uses a specially designed transfer sheet to receive inkjet ink images and text. The carrier layer of the transfer sheet containing the inkjet image and text is removed or otherwise peeled from the transfer sheet backing and then adhered to the license plate blank. A computer is used to construct the inkjet image and text that are printed onto the carrier surface of the transfer sheet. A final resin/pigment layer is coated upon the upper surface of the carrier layer in order to receive the inkjet ink that has been fashioned into image and text by means of the computer.
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BACKGROUND
1. Field of the Invention
This invention relates to apparatus and methods for pressing or ironing a strip material, such as metal foil, as it is being wound onto the mandrel of a take-up reel and, more particularly, to such apparatus and methods wherein a constant force is applied to the growing coil by an ironing roll, and a constant distance is maintained between the point of contact of the ironing roll with the coil and the tangent point where the strip is wound onto the mandrel or coil, to avoid entrainment of air between overlapping wraps of the strip.
2. Description of Prior Art
The pressing or ironing of sheet or strip material by pressing a rotatable roll against a mandrel onto which the material is being wound is old in the art. It also is known to effect a constant pressing force of the roll against the mandrel or growing coil. For example, U.S. Pat. No. 4,404,831 provides a pressurizable hydraulic cylinder, concentrically surrounded by a pneumatic cylinder providing a constant spring characteristic for the compressed air in that cylinder. Rate of movement of the pressing roll relative to the mandrel or coil is controlled by controlling the velocity of fluid flow into the hydraulic cylinder, and the pressing force of the roll against the mandrel or coil is controlled by regulating the pressure of the hydraulic fluid.
In U.S. Pat. No. 4,736,605, an ironing roll pressure and position control mechanism is designed to avoid scrap loss of initially wound wraps due to the "hump" caused by the leading edge of the coiled strip. This is done by changing the pressure of the ironing roll against the coil as the "hump" on the rotating coil comes under the ironing roll, that is, the roll pressure is changed as a function of the position of the leading edge of the strip relative to the roll.
U.S. Pat. No. 4,964,587 discloses an apparatus for facilitating wrapping a strip of material on a mandrel, and comprises a first frame having a pivoted end and another end attached to a second, pivoted frame carrying a roller for pressing against the strip being wound and a curved guide plate for directing the strip onto the mandrel.
U.S. Pat. No. 5,275,345 relates to an ironing roll apparatus for winding metal foil and comprising a fluid pressure cylinder for moving the roll toward and away from the growing coil, and a pair of fluid pressure cylinders disposed at either end of the coil and actuable to adjust the roll at an angle to the width of the coil in order to correct improper coiling due to strip defects.
In the winding of very thin strip materials, such as aluminum foils and strip, e.g. of thicknesses on the order of 0.0003-0.030 inch, onto a mandrel, there is a tendency for the strip to flutter with accompanying air entrainment between the coil wraps which can cause defects in the coil during winding. This condition is to be avoided if possible. The above-mentioned U.S. Pat. No. 5,275,345 mentions this phenomenon and characterizes pressing or ironing rolls generally as functioning to reduce this air entrainment tendency by squeezing a portion of the air from between the wraps.
SUMMARY OF THE INVENTION
We have found that conventional ironing roll arrangements are relatively ineffective in preventing air entrainment in the winding of thin metal foils, which is due, in large part, to the substantial displacement, as the coil is built up, of the ironing roll relative to the tangent point where the strip is wound onto the mandrel or the growing coil.
The present invention provides means to maintain, not only a constant force of an ironing roll against a growing coil being built up on a rotating mandrel, but also provides means to maintain a constant, minimum distance between the point of contact of the ironing roll and coil and the tangent point of entry of the strip onto the mandrel, thereby effectively minimizing the amount of air entrained between the coil wraps as they are formed. To this end, there is provided a pivoted frame carrying a guide tube having an ironing roll support mounted on a free end of the guide tube, and a fluid pressure cylinder having a piston rod thereof attached to and driving the roll support element and associated roll. A cam arrangement is connected to another end of the guide tube and, by following a cam track on withdrawal of the guide tube away from the coil as it builds up, maintaining a constant distance between the ironing roll and tangent point where the moving strip is laid onto the mandrel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the ironing roll mechanism of the invention, and
FIG. 2 is a schematic illustration of the system for controlling the force and movement of the ironing roll relative to a coil of strip being wound on a mandrel.
DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1, an ironing roll assembly, denoted generally by the numeral 1, comprises an elongated frame 2 pivotally mounted at P on a stanchion 3. A guide tube 4 is slidably mounted on the frame 2 and, at one end, carries a roll support 6 on which is rotatably mounted an ironing roll 7 for bearing against a mandrel 8 of a winding reel (not shown). Also mounted on the frame 2 is a fluid pressure cylinder 9 having a piston rod 11 connected to the roll support 6 for forcing the ironing roll 7 against the mandrel 8 or coil of strip 12 as it is wound onto the mandrel after passing over a deflection roll 13. Cylinder 9 has a position transducer mounted internally of the cylinder on an end of piston rod 11 and is provided with an electrical lead line 15 extending outside the cylinder. In FIG. 1, the ironing roll 7 is shown in contact with the mandrel 8 in the maximum extended position of the rod 11 of the cylinder 9 and as close as possible to the tangent point of the entering strip 12.
As also shown in FIG. 1, as the coil of strip 12 builds up on the mandrel 8, the increasing diameter of the coil causes the tangent point where the entering strip is laid on the growing coil to move outwardly, away from the mandrel. The locus of the tangent point in such movement is shown by a path B in dotted line FIG. 1.
Conventional ironing rolls become progressively more distant from the strip tangent point as the coil builds up in diameter, thus affording greater opportunity for entrainment of air between the coil wraps in the increasing spacing between the contact point of the roll and the coil and the strip tangent point. In order to prevent such occurrence, and to permit ironing roll 7 to effectively track the locus path B by linear movement of the roll relative to the coil and by pivoting of the frame about the pivot point P, and thereby to maintain a constant distance between the tangent point and the contact point of roll 7 with the growing coil, there is provided a plate 14 having a cam track 16 in which there is slidably movable a cam roll 17 connected to an outer end of the guide tube 4. Cam track 16 is so shaped that the cam roll 17 and associated guide tube 4 and ironing roll 7 move parallel to and at a constant distance from the locus B of the moving tangent point as the coil of strip is built up. This constant distance is as small as practical and may be, for example, about 35-70 mm, in order to prevent air entrainment between the coil wraps and also, by application, through the roll force, of interlap friction substantially at the tangent point, to prevent weaving of the entering coil from side to side.
The control system for operation of the ironing roll assembly of the invention is shown schematically in FIG. 2 which shows a double-acting piston 19 slidably movable with the piston rod 11 within the cylinder 9, and the position transducer 21 mounted on an end of rod 11 and having electrical lead 18 extending outside the cylinder 9 and connected to a programmable logic computer (PLC) 22 and through which lead 18 a position reference signal is input into PLC 22. By means of a control algorithm, the PLC computes a desired pressure signal which is input, through line 23, to a pressure control valve 24, connected via line 25 to a fluid pressure source, and which valve controls the fluid pressure in cylinder 9 through line 26 to one side of the piston 21 to maintain a constant force of the ironing roll on the coil by moving the piston rod 11 and associated ironing roll 7 toward the coil to increase the ironing force on the coil, or through line 27 to the other side of the piston 21 to move the piston rod and ironing roll away from the coil to decrease the ironing force on the coil.
In calculating the control equation relating the actuating cylinder fluid pressure to the changing coil diameter, the control algorithm takes into account a number of variables: the ironing force F i acting normal to the ironing roll surface; the fluid pressure P applied to the blank end (the end outwardly of the coil) of the actuating cylinder; F cyl , the cylinder force developed; D cyl , the distance from pivot point P to the centerline of the cylinder, measured perpendicularly; D i , the torque arm of the ironing force about the pivot point P; W 1 , the weight of the sliding components of the ironing roll assembly; D wi , the torque arm of W 1 about the pivot point P; W 2 , the weight of the pivoting components of the ironing roll assembly; D w2 , the torque arm of W 2 about pivot point P; N, the normal force applied to the guide tube 4 by a guide bushing supporting the inwardly extending end of the guide tube; D C , the couple arm, that is, the distance between the normal forces N, measured perpendicularly; μ, the coefficient of friction between the aforesaid bushing and the guide tube; σ R the angle formed by the vertical centerline of the mandrel 8 and the mandrel/ironing roll centerline; ν F , the angle formed by the centerline of the main frame 2 and the horizontal plane; F CAM , the cam roll reaction force perpendicular to the cam roll contact surface; D.sub.μ, the friction force (μ×N) torque arm about the pivot point P; F CH , the horizontal component of the cam roll reaction force F CAM ; D CH , the torque arm of F CH about the pivot point P; F CV , the vertical component of the cam roll reaction force F CAM ; D CV the torque arm F CV about the pivot point P; R PH , the horizontal reaction force at the pivot point P, and R PV , the vertical reaction force at the pivot point P. Using these variables, development of the algorithm using well-known principles of rigid body mechanics are applied, and by solving for static equilibrium in two dimensions, an equation is developed which is used to control fluid pressure in the actuating cylinder as the coil builds up in diameter. This controlled pressure provides a near-constant ironing force at a predetermined distance behind the strip tangent point. Actual values for at least some of these variables will change with different ironing roll assembly designs and dimensions for particular installations within the scope of the invention, and the corresponding algorithm will change accordingly.
The invention as above described is particularly useful in conjunction with underwound coil installations in which it normally is not possible to install a more space-consuming pivoting or swinging arm arrangement for tracking the locus of the tangent point of the strip as the coil builds up.
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An apparatus and method for pressing a rotatable ironing roll against an outermost wrap of strip material being coiled with substantially constant force and at a minimum constant distance from the tangent point of entry of the strip onto the coil, comprising an ironing roll support linearly and pivotally movable with respect to the coil, a sensor to determine a position of the ironing roll and to determine a corresponding desired roll pressure, and a cam connected to the ironing roll support and adapted to cause the ironing roll to follow a curved locus of the tangent point as the coil diameter increases.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an electric furnace, particularly an arc furnace, with a liquid cooling device for thermally highly stressed construction parts of the furnace cover and with essentially horizontal cooling pipes which carry liquid and empty in a cooling liquid distributing conduit on a cover ring.
2. Description of the Prior Art
Such a liquid-cooled furnace cover is known from the publication Clesid; Croupe Creusot Loire; "Panneaux et Voutes Refroidis" [French-Cooled Panels and Vaults], undated. This cover consists of pipe bundles which are basically slightly arched, radially positioned parallel and adjacent to each other and extend from the central cover opening to the cover edge. The liquid is supplied through a ring line in the wall of the central cover opening and the liquid is removed through a ring line in the cover ring.
A protective layer of fireproof material which is comparatively thin compared to the thickness of a customary arc furnace cover consisting of fireproof construction material is applied to the part of the cooling pipes which faces the inside of the furnace. This protective layer both protects the cooling pipes from heat radiation and prevents too much heat from being removed from the furnace area.
It is possible to save fireproof material when such liquid-cooled furnace covers are used, but there is also the danger, given the relatively thin protective layers, that they can loosen at certain spots in an uncontrolled fashion, e.g. by mechanical action when the cover is raised or lowered, by thermal tensions inside the layers as a result of inhomogeneous heat radiation, unequal cooling action or when the furnace cover cools down. The heat transfer and thus the heat loss is particularly great at the exposed areas where the metal surface of the cooling pipes is directly irradiated by the arcs. Moreover, the non-protected areas of the cooling pipes receive a greater thermal stress then the other, protected part of the cooling pipes facing the inside of the furnace. The non-protected areas in the furnaces can become greatly heated by the smelting in two-shift or three shift operation which is normally continuous in steel plants and foundries, without being noticed by the personnel. In the most unfavorable instances, if, for example, the cooling conditions are unsatisfactory, these hot areas can lead to perforations which can entail severe consequences.
Detection systems for monitoring cooling systems are complicated and expensive. If there were an indication of trouble, the furnace cover would then have to be taken out of operation so that the defective areas could be repaired. In addition, cooling pipes which face the inside of the furnace and are covered only with a relatively thin protective layer are constantly exposed to forces of expansion and construction due to sharp variations of temperature, even though they are given a stress-free annealing before assembly. These forces exert thermal stresses on the cooling pipes which are transferred to the welding seams connecting the cooling pipes to the cover ring, and tears can form under constant stress which then result in a breakthrough of water. Moreover, the weight of a liquid-cooled cover which consists of lined-up cooling pipes is great, and special measures must be taken when it is transported and placed on the furnace vessel.
SUMMARY OF THE INVENTION
Accordingly, the objects of this invention are to provide a novel liquid-cooled furnace cover for electric furnaces, particularly for arc furnaces, which is simple to construct, economical to finish, with which a high useful life can be achieved and the construction of which practically eliminates instances of damage.
These and other objects are achieved by providing a novel liquid cooled furnace cover including cooling pipes which run essentially parallel to each other, approximately vertically to the tipping direction, are at a predetermined distance from each other, are embedded in the fireproof construction material of the cover and constitute its reinforcement; wherein the cooling liquid is supplied and removed exclusively via a cover ring, which is constructed as a cooling liquid distributing conduit.
This invention has the following advantages:
Cooling a qualitatively high-grade fireproof construction material reduces its wear and tear under high thermal stress, resulting in a high service life of the furnace cover.
The weight of the furnace cover can be considerably reduced.
Any vapor bubbles arising in the cooling pipes are immediately removed from them and pass into the distributing conduit, from which they can freely escape.
According to the invention one part of the cooling conduits empty directly into the distributing conduit and another part of the cooling conduits are interconnected to each other in one piece or by deflection means in the distributing conduit and hydraulically separated from the distributing conduit. The walls of the cover openings have several cooling chambers which are separated hydraulically from each other and into which another part of the cooling conduits empty, whereby successive cooling conduit pairs connected inside the distributing conduit by deflection chambers empty into successive cooling chambers of this cover openings. The has the advantage that as a result of the one-piece connection of the cooling pipes to each other or of the use of deflection chambers in the distributing conduit, the heat can be taken up and given off evenly by the cooling pipes, since the pipe connections are located in the distributing conduit and no thermal stresses can develop. This largely removes the cooling system from the effects of alternating temperature stresses.
According to the invention the liquid cooling device includes several hydraulically separated cooling circulatory systems. Each cooling circulatory system is formed by several series-connected parallel cooling conduit pairs, and the cooling liquid entrance and exit openings of all cooling circulatory system empty into the cover ring constructed as a distributing conduit. Bypass openings are provided between the cooling liquid entrance and exit openings of each cooling circulatory system in the cover ring constructed as a distributing conduit. This has the advantage that the cooling occurs evenly over the entire surface of the furnace cover, and that the cooling liquid in the distributing conduit which passes through the cooling conduits and is heated thereby is cooled by the relatively cold cooling liquid which enters directly through the bypass openings in the distributing conduit.
According to a further embodiment of the invention the cooling pipes are constructed in inner and outer layers, where in the inner layer cooling pipes face the inside of the vessel and are constructed in one piece, and the one end of one part of the cooling pipes empties with their cooling liquid entrance openings directly into the distributing conduit and the other part of the one end of the cooling pipes empties into deflection means located inside the distributing conduit and is hydraulically separated from the distributing conduit, and the other end of the cooling pipes is U-shaped and connects up with the outer layer of the cooling pipes. One part of the outer layer of cooling pipes empties directly into the distributing conduit with the liquid exit openings and the other part of the outer layer of cooling pipes empties in deflection chambers located inside the distributing conduit and is hydraulically separated from the distributing conduit. Due to the one-piece construction and the rounded ends of the inner layer cooling pipes, the heat is evenly received and given off by the cooling pipes. Since there are no edges and corners or material connections in the cooling pipe layer facing the inside of the vessel, no thermal stresses can develop and the cooling system is largely removed from the effects of alternating temperature stresses.
Further according to the invention the deflection means are formed by chambers in the distributing conduit which guide the cooling liquid of two adjacent cooling pipes of a cooling circulatory system and hydraulically separate it from the cooling liquid in the distributing conduit. This arrangement allows the cooling pipes to be connected in a simple manner.
Additionally the spacing of the oppositely adjacent cooling pipes is approximately twice as great as their outer diameter. This keeps the weight of the composite construction of cooling pipes and fireproof construction material low while assuring an optimum cooling of the fireproof construction material and sufficient strength of the carrying construction for the fireproof construction material.
Furthermore the fireproof construction material can be set as a prefabricated construction unit into the cooling system of the furnace cover. This makes possible an economical manufacture of the furnace cover.
According to the invention the prefabricated construction units are permanently connected to each other mechanically by a fireproof binding agent, e.g. silicon rubber. The construction units can be simply and securely connected by these measures.
According to the invention dilatation spaces are provided between the cooling pipes and the surrounding fireproof construction material. The dilation spaces are filled with a fireproof compressible means, e.g. silicon rubber. This has the advantage that as a result of the dilation spaces, which are filled with silicon rubber, for example, the fireproof construction material can expand in an unimpeded manner without deforming forces being exerted on the cooling pipes.
According to the invention the bypass opening(s) in the distributing conduit is (are) dimensioned so that, taking into consideration the hydraulic resistance of the associated cooling conduits, a predeterminable amount of cooling liquid flows through the bypass opening(s) which is smaller than the amount which flows through the associated cooling conduits. Alternatively, the bypass opening(s) in the distributing conduit is (are) dimensioned so that, taking into consideration the hydraulic resistance of the associated cooling conduits, a predeterminable amount of cooling liquid flows through the bypass opening(s) which is just as great or greater than the amount which flows through the associated cooling conduits. This has the advantage that the rate of flow, flow speed, etc. of the cooling liquid which is introduced into the cooling conduits and the cooling conduits themselves can be dimensioned so that if part of the cooling liquid vaporizes in the cooling conduits, the vapor is immediately removed from the cooling system through the associated bypass opening(s) of every associated cooling circulatory system in the cooling liquid distribution chamber without the occurrence of an interaction between the cooling liquid and the vapor, which would be disadvantageous for the cooling action. A combined liquid-vapor cooling is obtained in this manner, in contrast to the classic liquid cooling, whereby the heat required for vaporization is removed from the construction parts to be cooled and is thus made useful for cooling. The flow speed of the cooling liquid in the cooling pipes is measured so that no vapor bubbles can settle in the cooling pipes, but rather they are carried away with the cooling liquid and transported into the distributing conduit.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a schematic front view of an embodiment of an arc furnace including the furnace cover of the invention;
FIG. 2 is a schematic top view partially in cross-section, of a first embodiment of the furnace cover of the invention provided with a single layer of the cooling pipes;
FIG. 3 is a vertical cross-sectional view through the furnace cover of FIG. 2;
FIG. 4 is an enlarged horizontal cross-sectional view through a part of the furnace cover of FIG. 2;
FIG. 5 is a cutaway portion of a schematic top view partially in cross-section, of a second embodiment of the furnace cover of the invention provided with two layers of the cooling pipes;
FIG. 6 is a vertical cross-sectional view through the furnace cover of FIG. 5;
FIG. 7 is a schematic diagram of the cooling circuit arrangement;
FIG. 8 is a vertical cross-sectional view through the cooling pipes and the fireproof construction material;
FIG. 9 is a vertical cross-sectional view through the cooling pipes and the construction units of fireproof construction material.
FIG. 10 is a vertical cross-sectional view through another embodiment of the cooling pipes and the construction units of fireproof construction material.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals dsignate identical or corresponding parts throughout the several views, and more particularly to FIG. 1 thereof, there is shown an arc furnace boiler 1 provided with flat furance cover 5 carried in an opening on a platform 6 which is supported on two hob cradles 7 supported on cradle beams 8 which are permanently anchored to foundation 9. FIG. 1 also shows pouring lip 2. Movable rotary pad 10 is located on platform 6, to which a pad cover raising and pivoting device 11 is fastened. Cover raising and pivoting device 11 consists of carrier arm 13 and carrier arm column 2.
Platform 6 also carries three electrode positioning columns 14, ony one of which is visible in FIG. 1. Electrode positioning columns 14 are connected to electrode positioning cylinders 15 so that they can be moved individually hydraulically in a vertical direction. Electrode carrier arms 16 are fastened to electrode positioning columns 14 and electrodes 18 are held in electrode holders 17 on their outer ends.
Only one of the three electrode carrier arms 16 is completely visible, and only two of the electrodes 18 can be seen, as the third is covered. Boiler gas removal piece 19 with flange 20 is located on furnace cover 5, the cover ring 4 of which rests on cover carrier ring 3 of furnace boiler 1.
Carrying lugs 22 are located on cover ring 4 of furnace cover 5, in which carrying cables 23 are fastened in the embodiment of FIG. 1, only two of which from a total of four are visible. Carrying cables 23 run over rollers 24 which are carried in roller carriers 25 on carrier arm 13. Carrying cables 23 are connected to hydraulic cylinder 26, which can raise and lower cover 5 from and onto boiler 1.
In the embodiment shown in FIG. 2, the cover 4 includes plural cooling pipes 30 disposed in parallel and in a single layer.
All parallel cooling pipes 30, which are at a distance from each other, empty into cover ring 4 with outer jacket 4' and inner jacket 4". This cover ring 4 is constructed as cooling liquid distributing conduit 27. For the sake of clarity, the fireproof construction material in which the cooling pipes are embedded is not shown in FIG. 2. Distributor conduit 27 is interrupted by end plate 33' and is divided into a left and a right distributing conduit cooling circulatory system. One cooling liquid entrance opening 28 is provided for both distributing conduit cooling circulatory system and for removing the cooling liquid short pipe 29a for the left distributing conduit cooling circulatory system and short pipe 29b for the right distributing conduit cooling circulatory system are provided on outer jacket 4' of cover ring 4. The direction of flow in both cooling circulatory systems in distributing conduit 27 is indicated by arrows 31. The liquid cooling device of furnace cover 5 includes several hydraulically separate cooling circulatory systems formed by several seriesconnected, parallel cooling conduit pairs, whereby dividing wall 33 is provided between the cooling conduit entrance openings and the cooling conduit exit openings of each cooling circulatory system. The cooling conduit entrance openings of all cooling circulatory systems are designated by arrows 41, 43, 45, 47, 49, 51, 53, 55 and the cooling conduit exit openings are designated by arrows 42, 44, 46, 48, 50, 52, 54, 56.
Bypass openings 34 are formed between dividing walls 33 and outer jacket 4' of cover ring 4, whereby, taking into consideration the hydraulic resistance of the associated cooling pipes 30, a predetermined amount of cooling liquid flows directlly through distributing conduit 27 and a predetermined amount of cooling liquid flows through cooling pipes 30. Part of cooling pipes 30 empty directly into distributing conduit 27 and another part of cooling pipes 30 are connected among each other inside distributing conduit 27 by deflection chambers 32 and hydraulically separated from distributing conduit 27.
Cover opening 35 for the electrodes is in the center of the cover and the opening for the boiler gas outlet 36 is in the right part. Cooling chambers 37 and 38, into which another part of cooling pipes 30 empty, are provided in the walls of openings 35 and 36. Arrow 39 indicates the tipping direction of the furnace during pouring, and arrow 40 the direction for removing the slag. This cooling arrangement assures that any vapor bubbles formed by the tipping process during pouring can be completely removed from the cooling system.
FIG. 4 shows clearly the arrangement of the cooling circulatory systems. However, FIG. 2 is intended to make clear the flow path of the cooling liquid and the operation of the cooling system using a cooling circulatory system.
The cooling water enters through the cooling conduit entrance opening designated by arrow 41 into cooling pipe 30, passes into cooling chamber 37 of cover opening 35, exits from it, flows back through cooling pipe 30, is deflected by deflection chamber 32 and then enters into cooling chamber 38 of cover opening 36. The cooling liquid now circulates back and forth between cooling chambers 37 and 38, then flows only between cooling chambers 37 and deflection chambers 32 in distributing conduit 27 until it finally passes back through the exit opening designated by arrow 42 into distributing conduit 27. The cooling water is heated during its travel in cooling pipes 30 and cooling chambers 37 and 38 and now mixes with the relatively cooler liquid which flowed directly through distributing conduit 27 through bypass openings 34 which cools down the heated liquid. The process is repeated in every cooling circulatory system. This avoids overheating, and any vapor bubbles produced are removed without delay from the cooling system.
In the vertical cross-sectional view shown in FIG. 3, deflection chambers 32 and cooling chambers 38 of cover opening 36 can be seen, which are connected to cooling conduits 30' of cooling pipes 30.
FIG. 4 shows an enlarged cutout of a part of furnace cover 5 of FIG. 2. The flow paths of the cooling liquid, which have already been shown in FIG. 2, can be seen more clearly. Dividing walls 33 according to the embodiment of FIGS. 2 and 4 could also be in another position than the one shown in FIGS. 2 and 4. However, it is significant for the effectiveness of the cooling system that dividing walls 33 and bypass openings 34 are located between the entrance and exit openings of cooling pipes 30 of each cooling circuit.
In FIG. 4 two cooling circulatory systems border on each other. From the one the heated water passes from cooling pipe 30 in the direction of arrow 42 into distributing conduit 27, is mixed there with the relatively cooler cooling liquid (arrow 31) which flowed through bypass opening 34. Then, the current of cooling liquid divides into two parts. The one part flows in the direction of arrow 45 into the adjacent cooling circulatory system through cooling pipe 30, while the other part flows further in distributing conduit 27 along deflection chamber 32 through upper bypass opening 34 shown in FIG. 4. This process just described is constantly repeated and assures an efficient cooling action in every cooling circulatory system of the furnace cover.
FIG. 5 shows a cutout of a schematic top view partially in cross-section, of a second embodiment of the furnace cover according to the invention provided with two layers of cooling pipes 30a and 30b. All cooling pipes 30a, 30b, which are parallel and positioned approximately vertically to the tipping direction and at a predetermined distance from each other, empty into cover ring 4 with outer jacket 4' and inner jacket 4" constructed as the cooling liquid distributing conduit 27. In contrast to the cooling pipe arrangement of FIG. 2, cooling pipes 30a, 30b are in two layers in two planes. Cooling pipes 30a form an inner layer which faces the inside of the vessel, and are constructed in a single piece pipes 30a are U-shaped at their end opposite distributing conduit 27 and link up with the pipes 30b which form an outer layer of cooling pipes. Thus, cooling pipes 30a, 30b are constructed in pairs, whereby several cooling pipes 30a, 30b are series-connected in groups and are subdivided over the entire furnace cover 5 into several cooling circulatory systems as in FIG. 5.
The cooling circulatory system shown in FIG. 5 is more fully explained in the following description.
The cooling liquid enters centrally through entrance opening 28 into distributing conduit 27, flows to the left in the direction of arrow 31 and divides into two partial currents, one of which 31' flows through cooling conduit entrance opening 60 into lower cooling pipe 30a and the other of which flows through bypass opening 34 formed by dividing wall 33 and outer jacket 4' of cover ring 4. After the U-shaped deflection, the cooling liquid flows back through upper cooling pipe 30b toward distributing conduit 27, but is hydraulically separated from it by deflection chamber 32'. Deflection chamber 32' guides the cooling liquid to cooling liquid entrance opening 60' of the following lower cooling pipe 30a and the circulation repeats until the cooling liquid passes according to arrow 31' through exit opening 62 back into distributing conduit 27 and mixes there with partial current 31, which flows directly through distributing conduit 27, and cools off. Then, the cooling liquid flows in part through the next-following cooling circulatory system and in part directly through distributing conduit 27 in the manner described in more detail above.
The U-shaped ends of cooling pipes 30a, 30b projecting into furnace cover 5 are mechanically held fast by fastening traverses 62. Fastening traverses 62 are indicated only schematically in FIG. 5. Cooling conduit 37', the cooling liquid supply and removal of which is not shown in FIG. 5, is provided for cooling the wall of cover opening 35. The arrangement of cooling pipes 30a, 30b shown in FIG. 5 is given only as an example and for illustrating the two layers of cooling pipes 30a, 30b. Another embodiment would consist of arranging cooling pipes 30a, 30b over each other and not set off to the side as in FIG. 5. This would mean that the coiled continuation of cooling pipes 30a, 30b occurs exclusively through the U-shaped bend in a lateral direction and that distributing chamber 32' guides the cooling liquid vertically in the distributing conduit and not in a lateral direction as in FIG. 5.
FIG. 6 is a vertical cross-sectional view through furnace cover 5 according to FIG. 5, whereby lower layer 30a and upper layer 30b of the cooling pipes can be clearly recognized. Since cooling pipes 30a, 30b form the reinforcement for the fireproof construction material not shown in FIGS. 5 and 6, they must have sufficient mechanical rigidity to carry continuously the composite construction of cooling pipes and fireproof construction material in the level construction of furnace cover 5. This purpose is served by fastening traverses 62, which are supported on cover ring 4 and run at cover opening 35 along the outer wall of cooling conduit 37'. As they are not necessary for a direct understanding of the present invention, they are only indicated in FIGS. 5 and 6.
FIG. 7 is a schematic diagram of the cooling circuit arrangement. As has already been described in detail for FIG. 2, distributing conduit 27 is divided into a right and a left part. Four cooling circulatory systems are connected to each part, to the left part the circulatory systems with entrance openings 41, 43, 45 and 47 and with exit openings 42, 44, 46 and 48, and to the right part the circulatory systems with entrance openings 49, 51, 53 and 55 and with exit openings 50, 52, 54 and 56, whereby bypass openings 34 are located between the entrance and the exit openings of each cooling circulatory system.
FIG. 8 is a vertical cross-sectional view through the cooling pipes and the fireproof construction material. Dilatation spaces 58 are provided between cooling pipes 30 and the surrounding construction material 57 which can be filled with silicon rubber, for example, in order to allow for the expansion of the fireproof mass and to avoid damage to cooling pipes 30. Silicon rubber is fireproof and compressible and acts as a buffer between cooling pipes 30 and fireproof construction material 57. In addition, it is possible that pressure forces from fireproof mass 57 act to a certain extent on the cooling pipes and deform them elastically. However, this deformation is reversible and has no disadvantageous effect on the service life of cooling pipes 30 or on the cooling action.
FIGS. 9 and 10 show further variations of the concept of the invention. Prefabricated construction units 57' of fireproof construction material 57 are positioned in varying arrangements around the cooling pipes, whereby the connection areas 59 of prefabricated construction units 57' are provided for mechanical fastening with a fireproof binding agent, e.g. silicon rubber.
Obviously, numerous additional modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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A liquid cooled cover for an electric furnace, wherein in order to lengthen the service life of the thermally highly stressed cover, cooling pipes are located essentially parallel and approximately vertically to the furnace tipping direction at a predetermined distance from each other. The cooling pipes are embedded in a fireproof construction material (57, 57') and constitute its reinforcement. The cooling liquid is supplied and removed exclusively via a cover ring, which is constructed as a cooling liquid distributing conduit in the periphery of the cover and which provided with integrated bypass openings. The composite construction of cooling pipes and fireproof construction material achieves a high thermal and mechanical stability of the furnace cover and the cooling system is largely removed from altering temperature stresses.
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[0001] This application is a continuation of U.S. Ser. No. 13/554,801 filed Jul. 20, 2012.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to roof ventilating systems, and particularly to roof ventilating systems for commercial and industrial buildings, that typically have substantially flat roofs.
[0003] A typical commercial roof includes a structural roof deck, covered by a vapor barrier. A layer of insulation is placed over the vapor barrier. An impermeable synthetic plastic roofing membrane is placed over the insulation. Water leaks from above the membrane may wet the insulation or water from inside the building may condense between the vapor barrier and the plastic roofing membrane and wet the insulation. Wet insulation has a reduced heat transfer resistance and can degrade.
[0004] Vents are used above the building roof membrane to vent the space between the membrane and the vapor barrier. With effective roof venting, wet roofs can be dried over a period of time.
[0005] Another problem with membrane covered flat roofs is that a strong wind flowing across the membrane creates a suction that tends to lift the membrane up off of the roof structure. The present inventor has recognized that roof vents, if in air flow communication with the space beneath the membrane, transfer the suction force caused by the wind to an underside of the membrane and tends to pull the membrane down onto the roof structure in the vicinity of the vent.
SUMMARY OF THE INVENTION
[0006] The present invention provides a roof venting grid applied to a substantially flat roof that not only effectively dries wet insulation between a roof membrane and the vapor barrier, but also effectively holds down the roof membrane to the roof against high winds.
[0007] The present invention provides at least one lengthwise vapor path that extends substantially along a length of the roof and having a roof vent flow connected to the vapor path at each end of the vapor path. Furthermore the invention can have at least one widthwise vapor path that intersects the lengthwise vapor path and spans substantially the width of the roof and having a roof vent at either end of the widthwise vapor path.
[0008] Preferably, the invention provides a plurality of spaced apart lengthwise vapor paths and a plurality of spaced apart widthwise vapor paths, the widthwise vapor paths intersecting the lengthwise vapor paths and each of the lengthwise and widthwise vapor is paths having a vent at opposite ends thereof. Also preferably, vents can also be located at the intersections of the lengthwise and widthwise vapor paths. Preferably, the vents at the intersections are turbine style vents.
[0009] According to another aspect, the vents are arranged around a perimeter of the building roof. Additional vents can be applied in corners of the building roof. The vents are all connected to a grid of vapor paths.
[0010] The vapor paths constitute open mesh fabric or mesh filter material. The open mesh fabric is fit on top of the insulation and below the upper membrane.
[0011] Numerous other advantages and features of the invention will become readily apparent from the following detailed description of the invention and the embodiments thereof, from the claims, and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a schematic plan view of a flat building roof;
[0013] FIG. 2 is a sectional view taken generally along line 2 - 2 of FIG. 1 ;
[0014] FIG. 3 is a sectional view taken generally along line 3 - 3 of FIG. 1 ;
DETAILED DESCRIPTION
[0015] While this invention is susceptible of embodiment in many different forms, there are shown in the drawing and will be described herein in detail specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated.
[0016] FIG. 1 schematically illustrates a building 18 having venting system 20 arranged on a flat building roof 26 . The roof 26 has a lengthwise dimension Y 1 of about 150 feet and a widthwise dimension X 1 of about 100 feet. The flat roof is substantially covered on a top side by a membrane 30 , typically EPDM material (ethylene propylene diene monomer). The venting system 20 illustrated includes twenty perimeter roof vents 32 and eight central turbine vents 38 . Each vent, 32 , 38 can be supported on a base mesh fabric 129 described below, although only two are shown in FIG. 1 for simplicity. Four transverse pathways 42 , 44 , 46 , 48 extend across the roof 20 . Each pathway includes a perimeter roof vent on each end and a pair of turbine vents 38 between the two roof vents. The remaining roof vents each are in communication with one of twelve tributary pathways 56 that communicate with either the first transverse pathway 42 or the fourth transverse pathway 48 . Interior connecting pathways 66 , 68 each connect to four turbine vents 38 that are substantially aligned. The pathways 56 , 42 , 44 , 46 , 48 , 66 and 68 form a grid of pathways that substantially cover the roof top in both the X and Y directions.
[0017] The vapor paths 56 , 42 , 44 , 46 , 48 , 66 and 68 are formed by open mesh fabric or filter material such as mesh material designated C06.03, at ⅞ inch thickness; 1 SB10, at 1⅛ inch thickness; or 1 ECO, at 1 inch thickness, all available from Superior Fibers Inc. of Bremen, Ohio, US. The open mesh fabric is fit on top of the insulation and below the upper membrane 30 or below the vents 32 , 38 . The open mesh fabric allows air or vapor to pass horizontally through the fabric and vertically through the fabric. The vapor paths 56 , 42 , 44 , 46 , 48 , 66 and 68 preferably have a width between 9 and 12 inches wide, and more preferably 10 inches wide. The mesh fabric of the vapor paths can be secured to the insulation by insulation block fasteners and/or by adhesive or sealant.
[0018] Referring to FIG. 2 , the roof 26 may typically consist of an interior metal or wood building deck 100 , supported on roof purlins 102 which are part of a typical commercial building's frame structure. A near impermeable vapor barrier sheet 106 , covers the building deck 100 . Rigid fibrous or foam insulation boards or blocks 112 are provided between the barrier sheet 106 and the outer roof covering membrane 30 . Membrane 30 has an opening 114 in air flow communication with the vent 32 .
[0019] The vent 32 is more particularly described in U.S. Pat. No. 4,909,135, herein incorporated by reference. The vent 32 is fabricated in two component parts and, as shown, these parts include an upwardly extending open-ended tube 126 formed at its lower end with a radially outwardly extending annular flange 128 . The flange 128 is supported on one or more layers of a base mesh fabric 129 , which can be approximately 2 feet by 2 feet, and overlies the path 46 of mesh fabric. The flange 128 can be adhesively secured to the base mesh fabric 129 . The base mesh fabric 129 can be composed of one or more layers of mesh material K02.03, at 1½ inch thickness per layer and available from Superior Fibers Inc. of Bremen, Ohio, USA. The base mesh fabric is air permeable vertically and can be air permeable horizontally as well. The base mesh fabric must support the vent while at the same time not becoming too compressed by the weight of the vent to adversely affect its air permeability. The base mesh fabric can be secured to the insulation by block insulation fasters and/or by adhesive or sealant. The skirt 130 typically composed of cured EPDM wide cover tape is adhered onto the membrane 30 around the vent and sealed by calk or sealant around its inside and outside perimeter to the tube 126 and to the membrane 30 . The tape of the skirt 130 can be applied in two strips and sealed along its seem to form approximately a 2 foot by 2 foot skirt.
[0020] As shown in FIG. 2 , the tube structure 126 has an upwardly tapered peripheral wall portion 140 , terminating to leave a top opening (not shown) in the upper end of tube 126 . The lower end of tube 126 is open to a space 142 , provided above the insulation blocks 112 and occupied by the pathway 46 of mesh fabric and the base mesh fabric 129 .
[0021] A cap or hood, generally designated 152 , is provided for the upper end of the tube or stack 126 to prevent the entry of rain, snow and the like, and comprises a top wall 154 spaced above the top opening of the tube 126 , and has a downwardly divergent peripheral wall 156 extending generally parallel to wall portion 140 but overhanging the wall 140 .
[0022] When wind is present, an air stream traveling up between the walls 140 and 156 is converged by the fins within the hood 152 , such that its velocity is increased, and a venturi suction is created tending to pull an air current upwardly out of the tube 126 . The air pulled upwardly out of tube 126 is then moved outwardly, along the path “x.”
[0023] The vent 32 can alternately be constructed according to U.S. Pat. Nos. 6,234,198; 5,749,780; 4,593,504; or 3,984,947 which are all herein incorporated by reference. The roof vents in these patents incorporate a one way valve to allow air or vapor to exit the vent to ambient, but closes to prevent outside air from entering the vent 32 and flowing into the space between the membrane 30 and the barrier 106 .
[0024] FIG. 3 illustrates a typical turbine style vent 38 . The vent depicted can be constructed in accordance with U.S. Pat. No. 3,893,383 or U.S. Pat. No. 3,797,374, herein incorporated by reference. The vent 38 can also be constructed according to U.S. Pat. Nos. 3,066,596; 6,352,473 or 6,302,778 all herein incorporated by reference.
[0025] The vent 38 includes a turbine ventilator 164 mounted on an open-ended tube or stack 165 . The turbine ventilator 164 comprises a rotatable turbine 166 mounted on a shaft 174 . The shaft is stationary and supports the turbine 166 on a bearing assembly 176 . The bearing assembly is received in a socket or recessed opening on the lower side of a bonnet 178 . The bonnet 178 covers the top portions of the turbine 166 . The bonnet 178 is curved and approximates a segment of a sphere although it need not be precisely spherical in shape. It extends outwardly to a flat portion or encircling lip 180 . The lip 180 is preferably in a single plane which is perpendicular to the shaft 174 which supports the turbine 166 .
[0026] The bonnet 178 supports a number of ribs 184 . There are many ribs, and they are preferably arranged evenly around the bonnet 178 . They all extend downwardly to a ring 190 . Rotation of the turbine 166 , particularly the ribs, causes air or vapor to be drawn up the open ended tube 165 along the path x.
[0027] The stack 165 is installed onto the roof in identical fashion as the stack 126 shown in FIG. 2 and supported on one or more layers of base mesh fabric 129 that overlies the path 68 of mesh fabric.
[0028] Each of the vents 32 is installed in similar fashion to that shown in FIG. 2 and each of the vents 38 is installed in similar fashion to that shown in FIG. 3 . Each of the vents 32 , 38 is supported on, and in air flow communication with, one or ore layers of a base mesh fabric 129 which is in air flow communication with a path of mesh fabric such as to exert an upward suction through the base mesh fabric 129 and the particular path depending on the wind condition on the roof.
[0029] The vapor paths 56 , 42 , 44 , 46 , 48 , 66 and 68 , allow air to be drawn though one or more of the turbine ventilators 38 and/or one or more of the vents 32 to dry out wet insulation and also to hold down the membrane 30 tightly to the insulation 112 . Because each path has two or more vents 32 , 38 in air flow communication with the pathways, any wind direction across the roof assists in drying large portions of the roof and assists in holding down the roof membrane.
[0030] Because of the interconnection of the paths 56 , 42 , 44 , 46 , 48 , 66 and 68 an overall drying of the insulation 112 can be achieved no matter the wind direction. Because of the interconnection of the paths 56 , 42 , 44 , 46 , 48 , 66 and 68 an overall hold down of the membrane 30 to the insulation 112 can be achieved no matter the wind direction.
[0031] From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred.
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A venting method and arrangement for a roof includes a plurality of venting stacks each having a first open base end open to an area on top of the roof insulation layer and below the roof outer membrane, the venting stacks arranged spaced apart around a perimeter of the roof. A venting path grid of air permeable material is arranged between the roof membrane and the insulation layer. The grid is in air flow communication with the first open base ends. Centrally located wind-driven turbine ventilators can also be in air flow communication to the grid.
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FIELD OF THE INVENTION
The present invention relates to an absorbable surgical suture material based on monocarboxycellulose and method for producing thereof.
Said material is intended to join tissues by surgical sutures and may find application in medicine, biology, and veterinary practice.
The use of absorbable suture materials in surgical practice has long been known. Such materials obviate the need for an additional procedure of suture removal.
The demands placed upon said materials get over more stringent in the course of time. Modern absorbable surgical suture materials should offer an adequate mechanical strength in both dry and moist states, elasticity, as well as a combination of additional properties, the most important of which are:
a concordance between the time of disintegration and hence also of a drop in the mechanical strength of the absorbable surgical suture material and the wound healing time;
absence of allergic and inflammatory reactions in application of sutures and over the period of a complete absorption of the suture material.
One more property essential in modern suture materials is that their colour should be in contrast with respect to the blood and wound tissues, which is needed to facilitate surgical manipulations.
Absorbable suture materials from animal intestines, i.e., catgut and chromic catgut, which have found an extensive application in the surgical practice feature an allergizing effect and a pronounced inflammatory reaction in biologic tissues resulting in a coarse cicatrization and deformation of the latter, and therefore their use at present is being sharply limited.
The surgical practice has gained a many-year experience of a successful use of oxidized cellulose-based hemostatic materials. Such materials as well as the products of their disintegration, glucose and glucuronic acid, are known to exert no toxic and allergenic effect on the organism. In addition, cellulose is a readily available and cheap raw material.
Attempts to utilize oxidized cellulose for producing an absorbable suture material have also been known, but the produced materials featured a low mechanical strength, which prevented their extensive and dependable application in the surgical practice. That is why further developments of methods for producing oxidized cellulose-based absorbable surgical suture materials offering a higher mechanical strength are being continued.
DESCRIPTION OF THE PRIOR ART
There have been proposed surgical threads (U.S. Pat. No. 2,537,979) produced through cellulose oxidation by nitrogen oxides, the oxidation being carried out till attaining a carboxyl group content of 4 to 12.5%.
The process of producing said surgical threads lasts 64 hours and is conducted at a temperature of 25° C. After treating the threads with nitrogen oxides has been completed, the threads are washed with distilled water and dried. The ratio of the tensile strength of the threads after treating with nitrogen oxides to that of the initial threads is of 36.8-43.5%, i.e. the loss of strength is of 63.2% to 56.5%.
The low tensile strength of the surgical threads produced in accordance with said invention greatly impedes surgical manipulations, since it fails to exclude such postoperative complications as a separation of wound edges.
Furthermore, an absorbable surgical thread produced in accordance with U.S. Pat. No. 2,537,979 completely lost the mechanical strength in 5 days in the tests conducted in a phosphate buffer solution of pH 7.5 at 37° C., where the thread disintegration process proceeds slower than in living tissues. No tests of said thread with living tissues are described in said patent.
SUMMARY OF THE INVENTION
A principal object of the present invention is to provide an absorbable surgical suture material based on monocarboxycellulose, which allows its disintegration time to be matched with the wound healing time and brings about no allergic and inflammatory reactions both in the application of sutures and over the period of a complete absorption of the suture material.
A not less important object of the invention is to provide an absorbable surgical suture material whose colour is in contrast with the background of the blood and biologic tissues.
Another object of the invention is to upgrade the mechanical strength of the suture material.
Still another important object of the present invention is to provide a method for producing an absorbable surgical suture material based on monocarboxycellulose.
Other objects and advantages of the present invention will become apparent from the following description thereof.
The above-mentioned and other objects are attained by that there is proposed an absorbable surgical suture material based on monocarboxycellulose having the general formula: ##STR2## where: m=degree of polymerization of the initial cellulose from 250 to 3300;
p=molar fraction of d-glucopyranose cycles in one polymer period from 0.95 to 0.05;
q=molar fraction of cycles of d-anhydroglucuronic acid from 0.05 to 0.95;
S=molar fraction of the complex fragment of d-anhydroglucuronic acid, metal, and ligand from 0.03 to 0.55;
Me=transition metal;
n=valence of the transition metal;
k=coordination number of the transition metal≧4;
Lig=polydentate ligands;
Dent=dentation of the ligands≧2.
Such suture material based on monocarboxycellulose which also may be called suture material of complex monocarboxycellulose-metalligand compounds in the form of thread has been tested by conducting a series of operations on four species of experimental animals of both sexes: white laboratory rats weighing 150-200 g; guinea pigs weighing 250 g; short-haired rabbits of the chinchilla breed weighing 3-4 kg; and mongrel dogs weighing 12-15 kg.
The test results are listed in Table 1.
TABLE 1______________________________________ Num- ber of ex- Animal speciesItem peri- White Guinea Rab-No. Operation ments rats pigs bits Dogs1 2 3 4 5 6 7______________________________________1 Skin and musclesuturing 63 63 -- -- --2 Liver tissuestitching 89 81 8 -- --3 Stomach wallsuturing 180 160 -- 10 104 Enteroplasty 67 10 -- 47 105 Colonoplasty 34 -- -- 24 106 Large-small in-testinal anasto-mosis 10 -- -- 10 --7 Cholecystosto-myorraphy 26 -- -- 24 28 Application ofcholecystentero-anastomosis 15 -- -- 9 69 Application ofpancreatoduodeno-anastomosis 8 -- -- -- 8______________________________________
The above-specified thread has thus been tested on the principal experimental models simulating the surgical operations conducted under clinical conditions.
In its manipulation properties the proposed suture material offers a strength which allows making the main types of both interrupted and continuous surgical sutures such as single interrupted, blanket, U-shaped, purse-string, Connell's, Shmiden's, Matyshak's, etc. The thread is easily tied into all types of surgeons knots, slides through tissues in both dry and moist states and, owing to its softness and elasticity, does not traumatize the tissues of parenchymatous and hollow organs.
As little as two knots tied in an arbitrary manner sufficed for holding the sutures. Ends of the thread after its cutting neither protruded nor traumatized the tissues. The thread did not get fluffy at bends and in threading it into surgeon's needle eyes. Owing to a high elasticity, such a thread can take the shape of the tissues being joined, not deforming the latter.
In the organism, the thread of complex monocarboxycellulose-metal-ligand compounds disintegrated and got absorbed.
Changes in the suture material during absorption are given in Table 2.
Thus, in the course of disintegration said thread goes through a series of successive transformations accompanied by certain morphological changes in tissues and structural changes in the thread.
At first the thread of complex monocarboxycellulose-metal-ligand compounds loses the strength because of swelling. Said thread disintegrates into fragments which lose the fibrous structure and homogenize, turning into a homogeneous mass. Histologic investigations have shown that a thin membrane made up of connective tissue cells originates around the fibres of such a thread. The thickness of such a membrane is not more than 20 to 30 fibroblast layers and in 1-2 months after the operation diminishes to 5 to 10 such layers, which evidences an insignificant response of the organism to the implantation of the proposed suture material.
TABLE 2______________________________________Absorption Absorption Morphologicalstage form features1 2 3______________________________________I. Early (1) Structure Absence of absorption symp- changes retention toms (2) Swelling Imbibition by albuminous liquidII. Late (3) Loss of Thread retains fibrous changes strength structure, but offers no mechanical strength (4) Fragmentation Thread seperates into seg- ments (weakening of inter- fibrous bonds) (5) Homogeniza- Transformation into amor- tion phous substance (6) Full resorp- Absorption by macrophages tion (7) Trace reac- Cicatrization of suture tions channels______________________________________
The thread is subsequently absorbed by giant cells and macrophages, accumulates as a homogenous gray mass in their cytoplasm, and these cells in 6 to 12 months discharge it out of the organism via capillaries and lymphatic vessels. A skin cicatrix and fatty tissue develop in the place of such thread, which should be regarded as a favourable reaction of the organism.
In Table 3 there is given, by way of example, the time of mechanical strength loss and of complete absorption of the claimed suture material.
TABLE 3______________________________________ Nominal dia- Loss of Complete absorption,Nos. meter, mm strength, days months______________________________________1 0.40-0.45 10 62 0.50-0.55 14 8-123 0.80-0.85 15-20 12______________________________________
The thread of complex monocarboxycellulose-metal-ligand compounds was used for the application of interorgan anastomoses with stitching mucous membranes, muscular layers and all layers of the organs being sutured by both interrupted and continuous sutures. In most of operations on esophagous, stomach, and duodenum said thread was used in place of catgut for application of the first row of sutures; in application of interintestinal anastomoses of the Brown's type, said thread alone was used as the suture material.
The proposed suture material was also used for carrying out appendectomy, in mastectomies, for lung aerostases, stitching the gallbladder bed, stitching a wound on the liver, for sutures on the subcutaneous fat cellulose, for suturing skin wounds and in other cases. Postoperational sutures were characterized with good cosmetic appearance.
Endoscopy in the postoperative period showed that inflammatory changes in the gastroenteric tract of patients corresponded to the severity of the accomplished intervention and stopped in 2 to 3 weeks. In 2 to 3 months after the operation the endoscopic picture corresponded to the changes observed in 1 year with the use of catgut for similar purposes.
No postoperative complications which could be attributed to the use of the proposed suture material were observed.
CLINICAL EXAMPLES
1. Patient A. Operation on Aug. 7, 1979: colonic substernal esophagoplasty.
The anastomosis between large intestine lengths of the "end-to-end" type, between the stomach and the large-intestinal transplant of the "end-to-side" type, and between the esophagus and the transplant of the "end-to-end" type was made with the use of the thread of complex monocarboxycellulose-metal-ligand compound (mucous-submucous sutures).
The patient was discharged from hospital in a satisfactory state with no complications. The functions of all the anastomoses were good.
2. Patient B. Operation on Aug. 23, 1979: a combined gastrectomy with resection of pancreas body and cauda pancreatis.
Gastroenterostomy was carried out (mucous-submucous sutures were made with the use of said thread). An anastomosis between small intestine loops (the Brown's anastomosis) has been fully performed with the thread of complex monocarboxycellulose-metal-ligand compounds (two rows of sutures).
The patient was discharged with no complications.
3. Patient C. Operation on Jan. 30, 1980: intrathoracic gastroplasty, intussusceptional esophagogastrostomy. The anastomosis was performed (mucous-submucous suture) with said thread.
The postoperative period was without complications.
In 30 days after the operation the thread was not detected by endoscopy. The anastomosis was with no inflammatory changes and its appearance corresponded to that observed in 8-12 months after operation with the use of catgut.
These and other objects are attained also by that in a method for producing an absorbable surgical suture material based on monocarboxycellulose by treating cellulose threads with nitrogen oxides, according to the invention, after the treatment with nitrogen oxides the cellulose threads are additionally treated for 0.5 to 2.0 hours with 0.5-2.0 percent solution of a salt of a transition metal having a coordination number of not less than 4 in water or in a suitable organic solvent and then for 0.5 to 2.0 hours with a 1.0-2.0 percent solution of a polydentate complexing agent in water or in a suitable organic solvent.
Investigations conducted on both artificial media and living organisms have established that surgical threads made from the proposed material offer a higher mechanical strength. This stems from the formation of additional cross-links between the molecules of monocarboxycellulose. Such cross-links originate owing to the polyvalency and high coordination number of transition metals as well as to the polydentate character of ligands. This fact along with a relatively high strength of the bond in the forming complex compounds promote slowing down the process of absorption of the surgical threads in a living organism (disintegration), which allows the time, whereover the mechanical strength of tissues drops (the threads get absorbed), to be matched with the time of growth in the cicatrix strength in the course of wound cicatrization.
The rate of absorption may be controlled by adjusting the degree of oxidation of the initial monocarboxycellulose, absorption being more rapid when the degree of oxidation is higher.
For a better understanding of the exact nature of the present invention, the structure of the complex fragment of the general formula may be represented by the following examples:
for a complex compound formed with Cr as the transition metal and ethylene diamine tetraacetic acid as the polydentate complexing agent: ##STR3##
for a complex compound formed with Fe and 8-oxyquinoline: ##STR4##
It should be pointed out that surgical threads of the proposed material are harmless and bring about no allergic and inflammatory reactions in the application of sutures and over the period of the complete absorption of the thread.
This is due to the fact that the products of disintegration of monocarboxycellulose-metal-ligand complexes are neither toxic for living organisms nor feature antigenic properties.
Furthermore, the colour of said threads is in contrast with the background of the blood and biologic tissues, it is persistent, not washed out by biologic media, remaining till the end of thread absorption, which greatly facilitates the application of sutures on a wound and allows observing the entire absorption period. This advantage stems from that the colour of the threads is inherent in the thread substance itself rather than due to additions of pigments. Owing to this, surgical threads made from the proposed material, used to join tissues by surgical sutures, are completely absorbed as the wound heals and leave no tattooing traces on tissues. The above-specified procedures and conditions of the method of the invention provide for attaining the above-described effect.
To produce a surgical suture material, a thread from which exerts no general and local effects on a living organism in the course of the application of a suture and over the period of absorption of the thread, it is expedient to employ as the solution of a transition metal salt solutions of salts of Fe, Ni, Cr, Bi, or Mn or their mixtures in water or in a suitable organic solvent; it is appropriate to use as the polydentate complexing agent a solution of tannin, gallic acid, ethylene diamine tetraacetic acid, 8-oxyquinoline, or quinosol in water or in a suitable organic solvent.
One more aspect of the invention consists in that there is proposed an absorbable surgical suture material wherein complex monocarboxycellulose-metal-ligand compounds have a degree of polymerization of the initial cellulose of 250 to 3,300; a molar fraction of D-glucopyranose cycles in one polymer period of 0.88 to 0.60; a molar fraction of cycles of D-anhydroglucuronic acid of 0.12 to 0.40; and a molar fraction of a complex fragment of D-anhydroglucuronic acid, metal, and ligands of 0.04 to 0.24.
Such a material features hemostatic properties and a higher mechanical strength.
Hemostatic properties of the proposed suture material are explained by the presence of a certain number of free carboxyls not bonded into complex compounds.
To produce said material there is proposed a method consisting in that cellulose threads are treated with nitrogen oxides and after this are treated for 0.5 to 2.0 hours first with 0.5-2.0 percent solution of Fe, Ni, Cr, Bi, or Mn salt in water or in a suitable organic solvent till an ion exchange degree of 25 to 60% is attained and then with 1.0-2.0 percent solution of tannin, gallic acid, ethylene diamine tetraacetic acid, 8-oxyquinoline, or quinosol in water or in a suitable organic solvent.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the method of the invention, an absorbable surgical suture material of complex monocarboxycellulose-metal-ligand compounds is produced as follows.
Cellulose threads are subjected to oxidation with nitrogen oxides till monocarboxycellulose is obtained. Employed as the cellulose threads are cotton, flaxen, viscose, Polynosic ones, etc. which have a broad range of the thickness of fibres and of the number of ends. The oxidation is carried out by conventional methods. It is most effective to conduct oxidation of cellulose threads with nitrogen oxides in an organic solvent at a temperature of -11° to +21° C. with subsequently extracting the cellulose threads from the organic solvent and maintaining them at a temperature of 30° to 70° C. and a pressure of 506 to 1519 hPa. The oxidized threads are thoroughly washed with water.
The wet threads are placed into a stainless-steel reaction vessel of 20 l in capacity, filled with a 0.5-2.0 percent solution of a transition metal salt in water or in a suitable organic solvent, for 0.5 to 2.0 hours.
Next, the threads are extracted from the working solution and once again washed with water.
Used as the solution of a transition metal salt may be solutions of Fe, Ni, Cr, Bi, or Mn salts or mixtures thereof in water or in a suitable organic solvent.
The washed threads are immersed into a reaction vessel of 20 l in capacity, filled with a 1.0-2.0 percent solution of a polydentate complexing agent in water or in a suitable organic solvent, for 0.5 to 2.0 hours.
Used as the above-mentioned solution is a solution of tannin, gallic acid, ethylene diamine tetraacetic acid, 8-oxyquinoline, or quinosine in water or in a suitable organic solvent. The threads thus obtained are then tested for the content of the transition metal, relative moisture content, and tensile strength.
The proposed suture material may be also used for making napples, bandages, cotton wool, tampons and other non-woven articles used in surgical practice.
EXAMPLE 1
An absorbable surgical suture material in accordance with the proposed procedure was produced as follows.
1.2 kg of viscose threads No. 60/12 having a tensile strength of 2.20 kg were oxidized with nitrogen oxides by one of known methods till obtaining monocarboxycellulose with a carboxyl group content of 9.8%.
The wet threads were placed for 1 hour into a reaction vessel of 20 l in capacity, filled with 16 l of 1.0 percent aqueous solution of Cr(NO 3 ) 3 . After this the treads were extracted from the solution and washed with water.
Next, the washed threads were immersed for 1 hour into a reaction vessel of 20 l in capacity, filled with 16 l of 1.0 percent solution of 8-oxyquinoline in ethanole.
The threads thus processed were of orange colour. They were washed with water and dried in an air stream.
The obtained threads were tested for the content of the transition metal, relative moisture content, and tensile strength.
The test results were as follows:
______________________________________content of transition metal, % 1.99relative moisture content, % 12.5tensile strength, kg 2.45ratio of tensile strength of processedthreads to that of initial threads, % 111______________________________________
EXAMPLE 2
An absorbable surgical suture material was produced in accordance with the proposed procedure.
Viscose threads with the same initial characteristics as in Example 1 were processed according to the procedure described in Example 1.
Said threads were treated first with a 1 percent aqueous solution of Cr(CH 3 COO) 3 for 1.5 hours and then with a 2 percent solution of gallic acid in ethanol for 1 hour.
The threads thus processed were of green colour.
The obtained threads were tested as described in Example 1.
The test results were as follows:
______________________________________content of transition metal, % 2.13relative moisture content, % 12.6tensile strength, kg 2.40ratio of tensile strength of processedthreads to that of initial threads, % 109______________________________________
EXAMPLE 3
An absorbable surgical suture material was produced in accordance with the proposed procedure.
0.4 kg of strengthened viscose threads No. 20/2 having a tensile strength of 2.10 kg were oxidized with nitrogen oxides by one of known methods till obtaining monocarboxycellulose with a carboxyl group content of 3.5%, and then were processed in accordance with the procedure described in Example 1.
Said threads were treated first with a 2 percent aqueous solution of Cr(NO 3 ) 3 for 2 hours and then with a 2 percent solution of 8-oxyquinoline in ethanol for 2 hours.
The threads thus processed were of orange colour.
The obtained threads were tested as described in Example 1.
The test results were as follows:
______________________________________content of transition metal, % 0.38relative moisture content, % 7.8tensile strength, kg 3.0ratio of tensile strength of processedthreads to that of initial threads, % 142______________________________________
EXAMPLE 4
An absorbable surgical suture material was produced in accordance with the proposed procedure.
Strengthened viscose threads with the same initial characteristics as in Example 3 were processed in accordance with the procedure described in Example 1.
Said threads were treated first with a 1.5 percent aqueous solution of Cr(NO 3 ) 3 for 1 hour and then with a 1.5 percent solution of tannin in ethanol for 1 hour.
The threads thus processed were of green colour.
The obtained threads were tested as described in Example 1.
The test results were as follows:
______________________________________content of transition metal, % 0.30relative moisture content, % 7.95tensile strength, kg 2.45ratio of tensile strength of processedthreads to that of initial threads, % 116______________________________________
EXAMPLE 5
An absorbable surgical suture material was produced in accordance with the proposed procedure.
Strengthened viscose threads with the same initial characteristics as in Example 3 were processed in accordance with the procedure described in Example 1.
Said threads were treated first with a 1.5 percent aqueous solution of Cr(NO 3 ) 3 for 1 hour and then with a 1.5 percent aqueous solution of ethylene diamine tetraacetic acid for 1 hour.
The threads thus processed were of white colour.
The obtained threads were tested as described in Example 1.
The test results were as follows:
______________________________________content of transition metal, % 0.305relative moisture content, % 7.7tensile strength, kg 2.50ratio of tensile strength of processedthreads to that of initial threads, % 119______________________________________
EXAMPLE 6
An absorbable surgical suture material was produced in accordance with the proposed procedure.
0.4 kg of Polynosic threads No. 60/3 having a mechanical tensile strength of 0.85 kg were oxidized with nitrogen oxides by one of known methods till obtaining monocarboxycellulose with a carboxyl group content of 3.5% and then were processed in accordance with the procedure described in Example 1.
Said threads were treated first with a 1.5 percent aqueous solution of NiCl 2 for 1 hour and then with a 2 percent solution of gallic acid in 70 percent ethanol for 1 hour.
The threads thus processed were of green colour.
The obtained threads were tested as described in Example 1.
The test results were as follows:
______________________________________content of transition metal, % 0.59relative moisture content, % 7.85tensile strength, kg 1.0ratio of tensile strength of processedthreads to that of initial threads, % 117______________________________________
EXAMPLE 7
An absorbable surgical suture material was produced in accordance with the proposed procedure.
Polynosic threads with the same initial characteristics as in Example 6 were processed in accordance with the procedure described in Example 1.
Said threads were treated first with a 2 percent aqueous solution of NiCl 2 for 1 hour and then with a 2 percent solution of 8-oxyquinoline in 10 percent ethanol for 1 hour.
The threads thus processed were of green colour.
The obtained threads were tested as described in Example 1.
The test results were as follows:
______________________________________content of transition metal, % 0.62relative moisture content, % 7.9tensile strength, kg 1.05ratio of tensile strength of processedthreads to that of initial threads, % 124______________________________________
EXAMPLE 8
An absorbable surgical suture material was produced in accordance with the proposed procedure.
1.2 kg of viscose threads No. 60/12 having a tensile strength of 2.57 kg were oxidized with nitrogen oxides by one of known methods till obtaining monocarboxycellulose with a carboxyl group content of 5.9% and then were processed in accordance with the procedure described in Example 1.
Said threads were treated first with a 1 percent aqueous solution of NiCl 2 for 1 hour and then with a 2 percent aqueous solution of quinosol for 1 hour.
The threads thus processed were of bright green colour.
The obtained threads were tested as described in Example 1.
The test results were as follows:
______________________________________content of transition metal, % 1.37relative moisture content, % 8.4tensile strength, kg 2.85ratio of tensile strength of processedthreads to that of initial threads, % 111______________________________________
EXAMPLE 9
An absorbable surgical suture material was produced in accordance with the proposed procedure.
Viscose threads with the same initial characteristics as in Example 8 were processed in accordance with the procedure described in Example 1.
Said threads were treated first with a 2 percent aqueous solution of NiCl 2 for 1 hour and then with a 2 percent solution of 8-oxyquinoline in dimethyl sulphoxide for 1 hour.
The threads thus processed were of bright green colour.
The obtained threads were tested as described in Example 1.
The test results were as follows:
______________________________________content of transition metal, % 1.51relative moisture content, % 8.2tensile strength, kg 3.10ratio of tensile strength of processedthreads to that of initial threads, % 121.______________________________________
EXAMPLE 10
An absorbable surgical suture material was produced in accordance with the proposed procedure.
0.4 kg of strengthened viscose threads No. 60/4 having a tensile strength of 1.33 kg were oxidized with nitrogen oxides by one of known methods till obtaining monocarboxycellulose with a carboxyl group content of 6.8% and then were processed in accordance with the procedure described in Example 1.
Said threads were treated first with a 2 percent aqueous solution of NiCl 2 for 1 hour and then with a 2 percent solution of 8-oxyquinoline in dimethyl formamide for 1 hour.
The threads thus processed were of bright green colour.
The obtained threads were tested as described in Example 1.
The test results were as follows:
______________________________________content of transition metal, % 1.94relative moisture content, % 8.6tensile strength, kg 1.62ratio of tensile strength of processedthreads to that of initial threads, % 122______________________________________
EXAMPLE 11
An absorbable surgical suture material was produced in accordance with the proposed procedure.
Strengthened viscose threads with the same initial characteristics as in Example 10 were processed in accordance with the procedure described in Example 1.
Said threads were treated first with a 1.5 percent aqueous solution of NiSO 4 for 1 hour and then with a 2 percent solution of tannin in ethanol for 1 hour.
The threads thus processed were of dark-green colour.
The obtained threads were tested as described in Example 1.
The test results were as follows:
______________________________________content of transition metal, % 1.80relative moisture content, % 8.8tensile strength, kg 1.53ratio of tensile strength of processedthreads to that of initial threads, % 115______________________________________
EXAMPLE 12
An absorbable surgical suture material was produced in accordance with the proposed procedure.
0.6 kg of cotton threads No. 100/18 having a tensile strength of 2.31 kg were oxidized with nitrogen oxides by one of known method till obtaining monocarboxycellulose with a carboxyl group content of 6.3% and then were processed in accordance with the procedure described in Example 1.
Said threads were treated first with a 1 percent aqueous solution of BiBr 3 for 2 hours and then with a 1 percent solution of 8-oxyquinoline in 10 percent ethanol for 2 hours.
The threads thus processed were of green colour.
The obtained threads were tested as described in Example 1.
The test results were as follows:
______________________________________content of transition metal, % 3.12relative moisture content, % 8.45tensile strength, kg 2.62ratio of tensile strength of processedthreads to that of initial threads, % 110______________________________________
EXAMPLE 13
An absorbable surgical suture material was produced in accordance with the proposed procedure.
0.4 kg of Polynosic threads having a tensile strength of 0.62 kg were oxidized with nitrogen oxides by one of known methods till obtaining monocarboxycellulose with a carboxyl group content of 5.0% and then were processed in accordance with the procedure described in Example 1.
Said threads were treated first with a 2 percent solution of Bi(NO 3 ) 3 in 10 percent aqueous solution of CH 3 COOH for 2 hours and then with a 2 percent solution of tannin in ethanol for 2 hours.
The threads thus processed were of yellow colour.
The obtained threads were tested as described in Example 1.
The test results were as follows:
______________________________________content of transition metal, % 2.56relative moisture content, % 8.1tensile strength, kg 0.80ratio of tensile strength of processedthreads to that of initial threads, % 129______________________________________
EXAMPLE 14
An absorbable surgical suture material was produced in accordance with the proposed procedure.
1.2 kg of viscose threads No. 60/12 having a tensile strength of 2.03 kg were oxidized with nitrogen oxides by one of known methods till obtaining monocarboxycellulose with a carboxyl group content of 10.0% and then were processed in accordance with the procedure described in Example 1.
Said threads were treated first with a 2 percent aqueous solution of FeCl 3 for 1 hour and then with a 2 percent solution of quinosol in 10 percent ethanol for 2 hours.
The threads thus processed were of black colour.
The obtained threads were tested as described in Example 1.
The test results were as follows:
______________________________________content of transition metal, % 1.15relative moisture content, % 12.8tensile strength, kg 2.74ratio of tensile strength of processedthreads to that of initial threads, % 135______________________________________
EXAMPLE 15
An absorbable surgical suture material was produced in accordance with the proposed procedure.
0.4 kg of strengthened viscose threads No. 20/2 having a tensile strength of 2.1 kg were oxidized with nitrogen oxides by one of known methods till obtaining monocarboxycellulose with a carboxyl group content of 3.6% and then were processed in accordance with the procedure described in Example 1.
Said threads were treated first with a 2 percent solution of FeCl 3 in dimethyl sulphoxide for 2 hours and then with a 2 percent aqueous solution of quinosol for 2 hours.
The threads thus processed were of grey colour.
The obtained threads were tested as described in Example 1.
The test results were as follows:
______________________________________content of transition metal, % 0.41relative moisture content, % 7.6tensile strength, kg 3.12ratio of tensile strength of processedthreads to that of initial threads, % 148.______________________________________
EXAMPLE 16
An absorbable surgical suture material was produced in accordance with the proposed procedure.
0.6 kg of cotton threads No. 100/18 having a tensile strength of 2.32 kg were oxidized with nitrogen oxides by one of known methods till obtaining monocarboxycellulose with a carboxyl group content of 7.9% and then processed in accordance with the procedure described in Example 1.
Said threads were treated first with a 1.5 percent aqueous solution of FeCl 3 for 1 hour and then with a 1.5 percent solution of tannin in dimethyl sulphoxide for 1 hour.
The threads thus processed were of black colour.
The obtained threads were tested as described in Example 1.
The test results were as follows:
______________________________________content of transition metal, % 0.86relative moisture content, % 9.8tensile strength, kg 3.0ratio of tensile strength of processedthreads to that of initial threads, % 129______________________________________
EXAMPLE 17
An absorbable surgical suture material was produced in accordance with the proposed procedure.
0.4 kg of strengthened viscose threads No. 60/3 having a tensile strength of 0.95 kg were oxidized with nitrogen oxides by one of known methods till obtaining monocarboxycellulose with a carboxyl group content of 4.3% and then processed in accordance with the procedure described in Example 1.
Said threads were treated first with a 2 percent aqueous solution of MnSO 4 for 1 hour and then with a 2 percent solution of 8-oxyquinoline in 70 percent ethanol for 1 hour.
The threads thus processed were of green colour.
The obtained threads were tested as described in Example 1.
The test results were as follows:
______________________________________content of transition metal, % 0.61relative moisture content, % 7.0tensile strength, kg 1.20ratio of tensile strength of processedthreads to that of initial threads, % 126______________________________________
EXAMPLE 18
An absorbable surgical suture material was produced in accordance with the proposed method as follows.
0.6 kg of flax threads No. 22/3 having a tensile strength of 0.95 kgf were oxidized with nitrogen oxides by one of known methods till obtaining monocarboxycellulose with a carboxyl content of 5,6%.
The wet threads were placed for 1 hour into a reaction vessel of 20 l in capacity, filled with 16 l of 0.5 percent aqueous solution of MnSO 4 . After this the threads were extracted from the solution and washed with water. Next, the washed threads were immersed for 1 hour into a reaction vessel of 20 l in capacity, filled with 16 l of 2.0% solution of tannin in ethanol.
The threads thus processed were of green colour. They were washed in water and dried in a flow of air.
The obtained threads were tested for the content of the transition metal, relative moisture and tensile strength.
The tests results were as follows:
______________________________________Content of transition metal, % 1.18Relative moisture content, % 8.3Tensile strength, kg 1.42Ratio of tensile strength of processed -threads to that of initialthreads, % 100______________________________________
EXAMPLE 19
An absorbable surgical suture material was produced in accordance with the proposed method.
0.4 kg of viscose strengthened threads No. 60/4 having a tensile strength of 1.33 kg were oxidized with nitrogen oxides by one of known methods till obtaining monocarboxycellulose with a carboxyl content of 6.8% and then were treated as follows.
The threads were first treated with a 1% aqueous solution of NiCl 2 for 1 hour, then with a 2% aqueous solution of FeCl 3 for 2 hours and after this with a 2% aqueous solution of tannin for 1.5 hour.
The threads thus processed were of dark grey colour.
The tests results were as follows:
______________________________________Content of transition metal, % 0.95 Fe 1.23 NiRelative moisture content, % 8.9Tensile strength, kg 1.42Ratio of tensile strength of processedthreads to that of initial threads, % 106______________________________________
EXAMPLE 20
an absorbable surgical suture material was produced in accordance with the proposed method.
0.6 kg of Polynosic threads No. 51/15 having a tensile strength of 3.6 kg were oxidized with nitrogen oxides by one of known methods till obtaining monocarboxycellulose with a carboxyl content of 4.25% and then were treated as follows.
The threads were first treated with a 0.5% aqueous solution of Cr(CH 3 COO) 3 for 1 hour, after which with a 1% aqueous solution of FeCl 3 for 1.5 hour and then with a 1.5% aqueous solution of gallic acid for 2 hours.
The threads thus processed were of dark grey colour.
The obtained threads were tested as described in Example 1.
The test results were as follows:
______________________________________Content of transition metal, % 0.30 Cr 0.46 FeRelative moisture content, % 7.8Tensile strength, kg 3.65Ratio of tensile strength of processedthreads to that of initial threads, % 101______________________________________
While particular embodiments of the invention have been shown and described, various modifications thereof will be apparent to those skilled in the art and therefore it is not intended that the invention be limited to the disclosed embodiments or to the details thereof and the departures may be made therefrom within the spirit and scope of the invention as defined in the claims.
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An absorbable surgical suture material based on monocarboxycellulose having the general formula ##STR1## where: m is a degree of polymerization of the initial cellulose from 250 to 3,300;
p is a molar fraction of D-glucopyranose cycles in one polymer period from 0.95 to 0.05;
q is a molar fraction of cycles of d-anhydroglucuronic acid from 0.05 to 0.95;
S is a molar fraction of the complex fragment of D-anhydroglucuronic acid, metal, and ligand from 0.03 to 0.55;
Me is a transition metal;
n is a valence of the transition metal;
k is a coordination number of the transition metal ≧4;
Lig is polydentate ligands;
Dent is a dentation of the ligands ≧2.
A method for producing said material consists in that cellulose threads are first threaded with nitrogen oxides, then for 0.5 to 2.0 hours treated with a 0.5-2.0-percent solution of a salt of a transition metal with a coordination number not less than 4 in a suitable solvent, and after this treated for 0.5 to 2.0 hours with a 1.0-2.0-percent solution of a polydentate complexing agent in a suitable solvent.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/633,177, filed Aug. 1, 2003, hereby incorporated herein by reference, which claims priority to German Patent Applications DE 103 19 797.4 and DE 103 24 094.2 filed on Apr. 30, 2003 and May 27, 2003, respectively.
BACKGROUND
[0002] German Patent Application DE 198 10 509 describes welding of dissimilar materials without prior tests. In DE 198 10 509, ultrasonic waves can be coupled into a welding material and recorded as a measurement signal based on interactions with a joining layer. The measurement signal can be stored in a measurement data memory. Subsequently, an evaluation unit can use the measurement signal to determine characteristic quantities for a welding process.
[0003] German Patent Application DE 43 21 874 A1 describes control and regulation of process parameters during ultrasonic welding of plastic parts. In DE 43 21 874 A1, the joining force can be measured during welding to monitor the energy applied to the joining point between the parts being welded.
[0004] European Patent Application EP 0 567 426 B1 describes a method for welding of plastic parts in which an oscillation amplitude of a sonotrode that is welding plastic parts can be reduced after a pre-determined time. As such, the sonotrode can work at a reduced oscillation amplitude during a remaining welding time. A control signal for reducing the oscillation amplitude can be triggered directly or indirectly based on the power transmitted to the parts being welded, as described, for example, in International Patent Application Publication WO 98/49009 and U.S. Pat. Nos. 5,435,863, 5,658,408, and 5,855,706.
[0005] International Patent Application Publication WO 02/098636 describes a method for welding of plastic parts in which an oscillation amplitude of a sonotrode can be reduced based on a pre-determined course for optimization of welding. Subsequently, a characteristic parameter of a part being welded can be measured, and the sonotrode can complete the welding process based on the value of the measured parameter with a constant oscillation amplitude.
[0006] German Patent Application DE 101 10 048 A1 describes checking connections made by ultrasonic wire bonding. In DE 101 10 048 A1, connections can be monitored on-line based on pre-determined stored master values and, based on monitoring the connections, conclusions can be drawn about the strength of the connections.
SUMMARY
[0007] Systems and methods for welding of parts are described herein.
[0008] In one embodiment, a method for welding of parts can include generating a measured or actual curve of a time-dependent welding parameter during welding, comparing the actual curve with a set curve during the period between t 0 (the starting time of the set curve) and t e (the ending time of the set curve), and, based on a difference between the actual curve and the set curve, altering one or more welding process parameters such that the actual curve approaches the set curve during further welding.
[0009] In one aspect, the set curve and the actual curve can be compared at least at a time t 1 , in which t 0 <t 1 <t e .
[0010] In one aspect, the set curve and the actual curve can be compared at identical welding parameter values (e.g. power values) and/or identical areas underneath the curves (e.g. energy values). For example, the set curve and the actual curve can be compared based on an energy input, which can be represented by the integral of a power vs. time curve.
[0011] In one aspect, changes to one or more welding process parameters can be based on comparisons made at one or more times (for example, times t 1 , t 2 , . . . , t n , with n≧2) between the set curve and actual curve.
[0012] In one aspect, the welding process parameters can be gradually altered over time.
[0013] In one aspect, the welding process parameters can be regulated based on the differences between the set curve and actual curve.
[0014] In one aspect, the welding process parameters can be altered based on stored values associated with the set curve (e.g. from tables of values associated with the set curve) and/or based on mathematical functions (e.g. extrapolations and/or interpolations based on the tables of values).
[0015] The disclosed methods can be used in ultrasonic welding of parts. For example, the methods can be used with an ultrasonic welding device that includes a generator, a converter, and a sonotrode.
[0016] In one aspect, the time-dependent welding parameter can include the emitted and/or the received power of an ultrasonic welding device.
[0017] In one aspect, the welding process parameters can include one or more of an oscillation amplitude of a sonotrode, a pressure acting on the parts being welded, a force acting on the parts being welded, an energy input from a sonotrode, and an oscillation frequency of a sonotrode.
[0018] These and other features of the systems and methods described herein can be more fully understood by referring to the following detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 shows power vs. time curves for one system for welding conductors.
[0020] FIGS. 2-5 show power vs. time curves for an exemplary system for welding conductors.
[0021] FIG. 6 shows an exemplary system for welding conductors.
DETAILED DESCRIPTION
[0022] Illustrative embodiments will now be described to provide an overall understanding of the systems and methods described herein. One or more examples of the illustrative embodiments are shown in the drawings. Those of ordinary skill in the art will understand that the systems and methods described herein can be adapted and modified to provide devices, methods, schemes, and systems for other applications, and that other additions and modifications can be made to the systems and methods described herein without departing from the scope of the present disclosure. For example, aspects, components, features, and/or modules of the illustrative embodiments can be combined, separated, interchanged, and/or rearranged to generate other embodiments. Such modifications and variations are intended to be included within the scope of the present disclosure.
[0023] In one method of welding conductors, values of welding parameters for previous empirically-determined “good” welds of conductors (i.e. satisfactory welds of conductors) can be stored and associated with the total cross-sections of the conductors that were welded. The welding parameters can include one or more of pressure, amplitude, frequency, tool size, energy, welding time, and other parameters known to those of ordinary skill in the art. Subsequently, a weld of conductors having a given total cross-section can be performed based on the stored parameters associated with the given total cross-section. For example, during welding, a welding parameter (e.g. a power) can be compared to a corresponding stored parameter. If the value of the welding parameter is substantially similar and/or identical to the corresponding stored value of the parameter, a time window Δt following the stored welding end time t e can be determined. The time window Δt can be based on the time t e −t 0 , where t e is the stored welding end time and t 0 is the stored welding start time. The time window Δt can range from about 10% to about 20% of the time difference t e −t 0 . A weld can be classified as a “good” weld if a weld of conductors can be completed between t e and t e +Δt. A weld can be classified as an “insufficient” weld if the weld of conductors cannot be completed until after t e +Δt.
[0024] In one example of the previously described method, a power vs. time curve for a good weld can be empirically determined, in which the area underneath the curve can represent the energy input associated with a weld of conductors having a total cross-section. A subsequent welding of parts having the same total cross-section can be classified as “good” if the end time of welding occurs within the power vs. time curve or in a subsequent time window thereafter.
[0025] FIG. 1 shows power vs. time curves for the previously described method. In FIG. 1 , the power vs. time curve labelled 10 can correspond to a set curve associated with a satisfactory weld of conductors. The area underneath the set curve 10 can represent the energy input E, in which
E = ∫ t = 0 t = te P ⅆ t ,
where P represents power and t represents time. Other conductors having the same total cross-section as the conductors used to generate the set curve 1 can be welded using an energy input that is identical to that for the set curve 10 (i.e. identical to the value E, as previously provided). In FIG. 1 , the power vs. time curves labelled 12 (dash-dotted curve) and 14 (dashed curve) can represent subsequent welds of conductors, in which the areas underneath the curves (i.e. the energy inputs) are identical to that of the set curve 10 (i.e. identical to the value E, as previously provided). As shown in FIG. 1 , the subsequent welds can be completed at different times, such as the times t e1 and t e2 . Based on previously collected empirical data (e.g. the empirical data used to generate the set curve 10 ), welds in which the end of welding occurs before t e of set curve 10 or within a subsequent time window Δt after t e can be deemed good. In the present example, therefore, the weld represented by the curve 12 can be deemed good, since welding for curve 12 was completed at the time t e1 , which time occurs within the time window Δt of the time t e . In contrast, the weld represented by the curve 14 can be rejected, because welding for curve 14 was completed at the time t e2 , which time occurs later than the time t e +Δt. As previously described, the time window Δt can range from about 10% to about 20% of the duration of welding (i.e. the time difference t e −t 0 ) associated with the set curve 10 .
[0026] As will be understood by those of ordinary skill in the art, different materials, different placements of conductors in a welding tool (e.g. different placements of conductors between a sonotrode and an anvil), and/or fluctuations in temperature and/or environmental conditions can adversely affect welds. For example, one or more of these factors can cause a weld having the same total cross-section as a pre-determined weld to not be completed within a subsequent time window of the welding end time of a pre-determined power vs. time curve.
[0027] Potentially advantageously, the disclosed systems and methods can regulate welding processes to compensate for one or more of these factors.
[0028] FIGS. 2-5 shows power vs. time curves for an exemplary system for welding of conductors, in which set curves are labelled with reference numeral 10 . Generally, as further described herein, comparisons can be made between welds having total cross-sections that are substantially identical to the cross-section of the weld used to generate the set curve 10 . In embodiments, the comparisons can be made at one or more times, at one or more constant power values (i.e. when the set curve and an actual curve have the same power value), and/or at one or more constant energy input values (i.e. when the set curve and an actual curve have the same integrated area).
[0029] As shown in FIG. 2 , in one embodiment, a comparison can be made at a time, e.g. time t 1 , between the set curve 10 and one or more actual curves ascertained during welding, such as actual curves 16 (dash-dotted) and 18 (dashed). As shown, at time t 1 , the actual curve 16 can have a power value that is less than the power value of the set curve 10 . Based on the power values of the actual curve 16 and the set curve 10 at time t 1 , one or more welding process parameters in the weld represented by the actual curve 16 can be changed so that the actual curve 16 can approach the set curve 10 . For example, a welding process parameter such as the amplitude of a sonotrode and/or a force exerted by the sonotrode on the parts being welded can be changed (e.g. increased or decreased). In some embodiments, one or more welding process parameters can be increased based on an actual curve having a power value that is less than a power value of a set curve at a given time, while one or more welding process parameters can be decreased based on an actual curve having a power value that is greater than a power value of a set curve at a given time.
[0030] As shown in FIG. 2 , in one embodiment, a comparison can be made at a second time that is later than a first time, e.g. at a time t 2 that is later than the time t 1 . Based on changing one or more welding process parameters at time t 1 , the actual curve 16 can approach the set curve 10 , i.e. the former can comes closer to the latter at times t later than t 1 . As shown in FIG. 2 , the actual curve 16 can have a power value that is greater than the power value of the set curve 10 at time t 2 . As previously described, in some embodiments, one or more welding process parameters can be changed based on this difference between the actual curve 16 and the set curve 10 . For example, in some embodiments, the amplitude and/or the force associated with a sonotrode can be changed (e.g. reduced). Alternatively and/or in combination, the total energy input can be changed. In embodiments, regulation of welding can be performed at various frequencies of an ultrasonic welding device, for example, at frequencies including one or more of 20 kHz, 35 kHz, 40 kHz, etc.
[0031] As shown in FIG. 2 , the welding represented by the actual curve 16 can be completed at a time t e3 which can be later than the end time t e of the set curve 10 . Generally, for the disclosed systems and methods, a good weld can be formed regardless of whether the welding end time (e.g. t e3 ) occurs with a pre-determined time window Δt of the ending time t e of the set curve 10 . As used herein, a “good” weld can include a satisfactory weld as that term is understood by those of ordinary skill in the art. For the disclosed systems and methods, the welding end time of a good weld can be greater than or less than t e . As will be understood by those of ordinary skill in the art, an upper limit on the welding end time can be chosen to inhibit continued regulation of welding. For example, as shown in FIG. 2 , the upper limit of welding end time can be denoted as time t max . In one embodiments, welds having welding end times greater than time t max can be rejected.
[0032] FIG. 2 shows a second actual curve 18 (dashed curve). As shown in FIG. 2 , the actual curve 18 can run above the set curve 10 at time t 1 . As previously described herein, one or more welding process parameters can be changed (e.g. reduced) in order to approximate the actual curve 18 to the set curve 10 . As also shown in FIG. 2 , the actual curve 18 can match the set curve 10 at time t 2 . Based on the value of the welding process parameter previously stored and/or changed based of the difference between the set curve 10 and the actual curve 18 at time t 1 , the welding operation represented by the actual curve 18 can be completed at a time t e1 that is earlier than the time t e of the set curve 10 .
[0033] Generally, comparisons between a set curve, such as set curve 10 , and one or more actual curves, such as actual curves 16 and 18 , can be made at one or more times t n , and/or at one or more constant power values, and/or at one or more constant energy inputs. These comparisons are shown in FIG. 2 . For example, the actual curves 16 , 18 and the set curve 10 can be compared at constant times t 1 , and/or constant areas E 1 , and/or constant power values P 1 . As described herein, one or more welding process parameters of a welding operation represented by an actual curve 16 , 18 can be changed based on one or more of the comparisons shown in FIG. 2 . For example, based on a comparison between the set curve 10 and actual curves 16 , 18 at constant power value P 1 , the welding operations represented by the actual curves 16 , 18 can be changed, e.g. one or more welding process parameters can be increased (for curve 16 , for example) or decreased (for curve 18 , for example). Also for example, based on a comparison between the set curve 10 and actual curves 16 , 18 at constant energy input E 1 , the welding operation represented by the actual curve 16 can be changed to so that one or more welding process parameters can be increased, and the welding operation represented by the actual curve 18 can be changed so that one or more welding process parameters can be decreased.
[0034] FIGS. 3 to 5 show other power vs. time curves for an exemplary system for welding of parts as described herein, in which the set curves are labelled with reference numeral 10 .
[0035] As previously described herein with reference to FIG. 2 , a welding operation using an ultrasonic welding device can be regulated based on comparisons between a set curve 10 and an actual curve 20 at one or more power values P 1 . . . P n . Changes in welding process parameters can be triggered based on differences between the set curve 10 and the actual curve 20 at different power values P 1 . . . P n . For example, as shown in FIG. 3 , based on comparing the set curve 10 and the actual curve 20 at a power value P 2 , one or more welding process parameters can be changed (e.g. increased) in order to drive actual curve 20 to set curve 10 . Regardless of this change, the total energy inputs for the welding operation to be regulated (i.e. the welding operation represented by the actual curve 20 ) and the process upon which the set curve 10 is based can be kept identical. As shown in FIG. 3 , the end time t e1 at which the welding operation represented by the actual curve 20 is completed is between t 1 and t max .
[0036] As shown in FIG. 4 , a regulation between the set curve 10 and an actual curve 22 can be performed based on an energy input. For example, as shown in FIG. 4 , if the actual curve 22 and the set curve 10 diverge with reference to the energy input E at the respective measurement times t 1 , t 2 , . . . , t n , in which
E = ∫ t = 0 t = t 1 … tn P ⅆ t
then one or more welding process parameters can be changed based on the systems and methods described herein. Regardless of this change, the welding operation represented by the actual curve 22 can be completed when the energy input of actual curve 22 is identical to that of set curve 10 .
[0037] As previously described, one or more welding process parameters, such as a pressure and/or an amplitude of an ultrasonic welding device, can be changed based on the schemes described herein. Alternatively and/or in combination, an energy input can be changed (e.g. increased). For example, as shown in FIG. 5 , when the integral of actual curve 24 is identical to that of the set curve 10 , a further energy input ΔE zus can be made before the welding operation is completed at time t x . As previously described, comparisons between the actual curve 24 and the set curve 10 can be made at different times t 1 . . . t n .
[0038] FIG. 6 shows an exemplary system for welding of parts, such as electrical conductors. As shown in FIG. 6 , in one embodiment, a system 50 for welding parts as described herein can include an ultrasonic welding device 25 having a converter 26 and a sonotrode 30 . As shown in FIG. 6 , in some embodiments, the system for welding parts can include a booster 28 . The sonotrode 30 (i.e. the entire sonotrode 30 or a portion of the sonotrode 30 ) can be associated with a counter electrode 32 serving as an anvil. The counter electrode 32 can include one or more parts and can be constructed based on schemes similar to those described in U.S. Pat. Nos. 4,596,352 and 4,869,419. The counter electrode 32 can provide a compression area of adjustable cross-section inside of which parts to welded can be placed. The parts to be welded can include metallic parts (e.g. conductors) and/or non-metallic parts (e.g. plastic parts). The converter 26 can be connected via a lead 34 to a generator 36 , and the generator 36 can be connected via a lead 38 to a digital data processing device 40 (e.g. a personal computer (PC)). The digital data processing device 40 can control the ultrasonic welding device 25 and/or the generator 36 based on the schemes previously described herein. For example, the digital data processing device 40 can provide the welding process parameters and/or or the cross-section of conductors to be welded to the ultrasonic welding device 25 and/or the generator 36 . The digital data processing device 40 can be configured to determine the power emission of the generator 36 , generate and/or otherwise be provided with a set curve and an actual curve of a welding process, compare the actual curve with the set curve, and alter one or more welding process parameters based on a difference between the actual curve and the set curve. The digital data processing device 40 can include one or more software programs configured to perform one or more of these functions when executed on the digital data processing device 40 .
[0039] While the systems and methods described herein have been shown and described with reference to the shown embodiments, those of ordinary skill in the art will recognize or be able to ascertain many equivalents to the embodiments described herein by using no more than routine experimentation. Such equivalents are intended to be encompassed by the scope of the present disclosure and the appended claims.
[0040] For example, the systems and methods described herein can be used to weld metallic parts (e.g. conductors) and non-metallic parts (e.g. plastic parts) and are not limited to welding of electrical conductors.
[0041] Also for example, one or more welding process parameters can be changed based on the schemes described herein. The one or more welding process parameters can be altered sequentially and/or concurrently.
[0042] Also for example, the power curves described herein can be ascertained based on the power emitted by a generator and/or the power input of a sonotrode or oscillator over time based on schemes known by those of ordinary skill in the art
[0043] Accordingly, the appended claims are not to be limited to the embodiments described herein, can comprise practices other than those described, and are to be interpreted as broadly as allowed under prevailing law.
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Systems and methods for welding of parts are described. In one embodiment, a method for ultrasonic welding of parts by means of an ultrasonic welding device including at least a generator, a converter, and a sonotrode based on a set curve of a time-dependent welding parameter appropriate to a welding connection meeting set requirements, where the welding duration corresponding to the set curve runs between a starting time to and an end time t e , wherein during welding of the parts an actual curve of the time-dependent welding parameter is measured, where in the period between t 0 and t e the actual curve is compared with the set curve and, depending on the existing difference, at least one process parameter affecting welding is altered such that an equalization of set curve and actual curve occurs during further welding.
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RELATED APPLICATIONS
This patent application: is a divisional of U.S. patent application Ser. No. 12/419,123, filed Apr. 6, 2009, issued as U.S. Pat. No. 9,138,707 which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/043,064, filed Apr. 7, 2008, and is a continuation in part of U.S. patent application Ser. No. 11/751,523, filed May 21, 2007, issued as U.S. Pat. No. 7,939,045, on May 10, 2011, which is a continuation-in-part of U.S. patent application Ser. No. 10/733,805, filed Dec. 10, 2003, issued as U.S. Pat. No. 7,220,393, on May 22, 2007, which claims the benefit of Canadian Patent Application Serial No. 2,413,834, filed Dec. 10, 2002. All of the foregoing applications and patents are hereby incorporated by reference in their entirety,
BACKGROUND
1. The Field of the Invention
This invention relates generally to chemical reactors, and more specifically to apparatus and methods for generating nitric oxide.
2. Background
The discovery of certain nitric oxide effects in live tissue garnered a Nobel prize. Much of the work in determining the mechanisms for implementing and the effects of nitric oxide administration are reported in literature. In its application however, introduction of bottled nitric oxide to the human body has traditionally been extremely expensive. The therapies, compositions, and preparations are sufficiently expensive to inhibit more widespread use of such therapies. What is needed is a comparatively inexpensive mechanism for introducing nitric oxide in a single dosage over a predetermined period of time. Also, what is needed is a simple introduction method for providing nitric oxide suitable for inhaling.
It would be an advance in the art to provide a single dose generator suitable for administration of nitric oxide gas. It would be an advance in the art to provide not only an independence from bottled gas, but from the need for a source of power for heat, or the like. It would be a further advance in the art to provide a disposable generator to be initiated by a trigger mechanism and operate without further supervision, adjustment, management, or the like Likewise, it would be a substantial benefit to provide a system that requires a minimum of knowledge or understanding of the system, which might still be safe for an individual user to administer with or without professional supervision.
BRIEF SUMMARY OF THE INVENTION
In accordance with the foregoing, certain embodiments of an apparatus and method in accordance with the invention provide a self-contained reactor system. Nitric oxide may thus be introduced into the breathing air of a subject. Nitric oxide amounts may be engineered to deliver a therapeutically effective amount on the order of a comparatively low hundreds of parts per million, or in thousands of parts per million. For example, sufficient nitric oxide may be presented through nasal inhalation to provide approximately five thousand parts per million in breathing air. This may be diluted due to additional bypass breathing through nasal inhalation or through oral inhalation.
One embodiment of an apparatus and method in accordance with the present invention may rely on a small reactor. Reactive solids may be appropriately combined dry. Reactants may include compounds, such as potassium nitrite, sodium nitrite, or the like, nitrate compounds, such as potassium nitrate, sodium nitrate, or the like. The reaction may begin upon introduction of a heat. Heat may be initiated by liquid transport material to support ionic or other chemical reaction in a heat device.
An apparatus and method in accordance with the invention may include an insulating structure, shaped in a convenient configuration such as a rectangular box, a cylindrical container, or the like. The insulating container may be sealed either inside or out with a containment vessel to prevent leakage of liquids therefrom. Such a system need not be constructed to sustain nor contain pressure. Inside the containment vessel may be positioned heating elements such as those commercially available as chemical heaters.
In certain embodiments, chemical heaters may include metals finely divided to readily react with oxygen or solid oxidizers. Various other chemical compositions of modest reactivity may be used to generate heat readily without the need for a flame, electrical power, or the like.
Above the heating element or heater within the containment vessel may be located a reactor. The reactor may preferably contain a chemically stable composition for generating nitric oxide. Such compositions, along with their formulation techniques, shapes, processes, and the like are disclosed in U.S. patent application Ser. No. 11/751,523 and U.S. Pat. No. 7,220,393, both incorporated herein by reference in their entireties as to all that they teach.
The reactor may include any composition suitable for generating nitric oxide by the activation available from heat. The reactor may be substantially sealed except for an outlet, such as a tubular member secured thereto to seal a path for exit of nitric oxide from the reactor.
In certain embodiments, a system of water or salt water may be available in the container. In one embodiment, the water containers may be as simple as presealed bags, such as polyethylene bags that can be opened, cut, torn, or otherwise pierced in order to release water therefrom. Accordingly, a system may include a heating element or the reactor, such a water source to provide a chemical transport fluid, a piercing assembly for the water containers, a trigger for activating the piercing assembly, and blades, hooks, cutters, punches, or the like structured to open the bags containing water.
Upon triggering of the piercing assembly, the water is released from the water containers, vessels, bags, or the like, to be poured down through the assembly onto the heating elements where heaters are activated by the presence of a liquid. It has been found through experiments that adding the additional ionic content of salt improves the reaction rate of chemical heating systems.
Ultimately, an apparatus in accordance with the invention may include a cover through which an outlet penetrates from the reactor in order to connect to a cannula. This has been done effectively. It will also support a vent for steam generated by the heaters in the presence of the water used to activate the heaters. The system may be completely wrapped in a pre-packaged assembly. In one embodiment, a heat-shrinkable wrapping material may be used to seal the outer container of an apparatus in accordance with the invention. Thus, this system may be rendered tamper proof, while also being maintained in integral condition throughout its distribution, storage, and use.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing features of the present invention will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are, therefore, not to be considered limiting of its scope, the invention will be described with additional specificity and detail through use of the accompanying drawings in which:
FIG. 1 is a perspective view of one embodiment of an apparatus in accordance with the invention to generate nitric oxide from a chemically active source of nitric oxide, as a result of exposure to heat;
FIG. 2 is an exploded view of the apparatus of FIG. 1 for generating nitric oxide;
FIG. 3 is a top plan view of an insulating container for the apparatus of FIG. 1 ;
FIG. 4 is a side elevation view of the box-like container of FIG. 3 ;
FIG. 5 is an end, elevation, cross-sectional view of the container (box) of FIGS. 3-4 ;
FIG. 6 is a top plan view of a cover for the container of FIGS. 3-5 ;
FIG. 7 is an end elevation view of the cover of FIG. 6 ;
FIG. 8 is a side elevation view of the cover of FIG. 6 ;
FIG. 9 is a side elevation view of a vent for the portable nitric oxide device of FIG. 1 ;
FIG. 10 is a top plan view of the vent illustrated in FIG. 9 ;
FIG. 11 is a front elevation view of a triggering pin for the apparatus of FIG. 1 ;
FIG. 12 a is an end view of the pin of FIG. 11 ;
FIG. 12 b is a side elevation view of the pin of FIG. 11 ;
FIG. 13 is a bottom plan view of a guiding rod for holding a compression spring used in the trigger device of the apparatus of 2 ;
FIG. 14 is a side elevation view of the guide rod of FIG. 13 ;
FIG. 15 is a front elevation view of a spacer used in the piercing assembly of FIG. 2 ;
FIG. 16 is a top plan view of the spacer of FIG. 15 ;
FIG. 17 is a top plan view of the mounting assembly for a blade of the piercing assembly of the apparatus of FIG. 2 ;
FIG. 18 is an end elevation view of the mounting assembly or carrier for blades in the piercing assembly of FIG. 2 , and corresponds to the apparatus of FIG. 17 ;
FIG. 19 is a side elevation view of the mounting assembly with blades in place, and corresponds to the apparatus illustrated in FIGS. 17-18 ;
FIG. 20 is a side elevation view of a base or base plate for supporting the blades in the piercing assembly of the apparatus of FIG. 2 ;
FIG. 21 is a top plan view of the base or base plate of the apparatus of FIG. 20 ;
FIG. 22 is a side elevation view of a cover plate for the blades in the piercing assembly of the apparatus of FIG. 2 ;
FIG. 23 is a top plan view of the cover plate of FIG. 22 ;
FIG. 24 is a side elevation view of a spring, used as a compression spring to drive the mounting assembly of FIG. 17 , with the blades installed to operate the piercing assembly of FIG. 2 ;
FIG. 25 is a top plan view of one embodiment of a containment vessel operating as a reactor for the nitric oxide generation from the chemical species contained therein;
FIG. 26 is a side elevation view of the reactor's containment vessel of FIG. 25 ;
FIG. 27 is a side elevation view of one embodiment of a tube configured to operate as an outlet for the reactor vessel of FIG. 25 ;
FIG. 28 is a perspective view of one embodiment of a shrink-wrap sleeve that is applied to contain the overall enclosure of the apparatus of FIGS. 1-2 ;
FIG. 29 is a perspective view of the apparatus of FIGS. 1-2 ;
FIG. 30 is a top view of the apparatus of FIG. 29 open for viewing of the internal apparatus;
FIG. 31 is a graph showing data for the temperature rise in degrees Fahrenheit of the reactor of FIGS. 29 and 30 using a variety of heaters including a single heater relying on water as the liquid, two standard heaters relying on water, and a single heater using salt water as the activating liquid;
FIG. 32 is a graph depicting the temperature response of the reactor of FIGS. 1-30 over time in both a single heater and double heater configuration;
FIG. 33 is a graph depicting the temperature response of the reactor of FIGS. 1-30 as a function of time when heated by a single heater and by double heaters; and
FIG. 34 is a chart depicting the released volume of nitric oxide from the reactor of FIGS. 1-30 superimposed over the temperature response thereof as a function of time.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
It will be readily understood that the components of the present invention, as generally described and illustrated in the drawings herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the system and method of the present invention, as represented in the drawings, is not intended to limit the scope of the invention, as claimed, but is merely representative of various embodiments of the invention. The illustrated embodiments of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout.
Referring to FIG. 1 , an apparatus 10 may be configured as a portable nitric oxide device. In the illustrated embodiment, a container 12 or vessel 12 may provide insulation, liquid sealing, or both. Meanwhile, a fitting 14 or outlet 14 may be connected to feed nitric oxide to a line 15 proceeding toward a user, for distribution by a cannula, mask, tent, or the like.
In the illustrated embodiment, a trigger 16 or actuator 16 may be withdrawn from the apparatus 10 in order to trigger the initiation of a reaction generating nitric oxide. In certain embodiments, generation of nitric oxide may depend on temperature of reactants. The generation of heat (e.g., temperature) may rely on a reaction requiring moisture, which moisture may eventually be partially converted to steam needing to be vented. Accordingly, a vent 18 may vent the interior of the container 12 in order to avoid any buildup of pressure; in one embodiment, the entire container 12 may be sealed in a heat-shrinkable sleeve that maintains the integrity of the apparatus 10 during distribution, storage, and use.
Referring to FIG. 2 , an exploded view of the apparatus of FIG. 1 illustrates one embodiment of the apparatus 10 in accordance with the invention. In the illustrated embodiment, the outlet 19 , connected to feed through the fitting 14 and thus feed nitric oxide through the line 15 may be securely sealed to a reactor 20 . The reactor 20 may be formed by any of several suitable methods to contain the chemical constituents required to generate nitric oxide. A port 21 or aperture 21 may be formed to seal against the outlet 19 in order to discharge all of the generated nitric oxide to a location outside the apparatus 10 .
Below or around the reactor 20 may be located one or more heaters 22 or heating elements 22 . In the illustrated embodiment, the heaters 22 are formed to contain solid reactants in a non-woven fabric container. The reactants are stabilized by being completely dry. In the presence of liquid, ionic exchange promotes the reaction of the contained chemicals within the heaters 22 .
In order to contain any liquid to activate the heaters 22 , a containment vessel 24 may surround the heaters 22 , within the insulation container 26 or box 26 . In certain embodiments, the functionality of the containment vessel 24 and the insulated container 26 may be consolidated into a single structure. Likewise, in certain embodiments, the containment vessel 24 may actually be located external to the insulated container 26 .
In general, a liquid, and particularly a hydrating liquid such as water, salt water, or the like, may serve as an activation material. In the illustrated embodiment, the bags 28 containing salt water, water, or the like may be sealed for storage. In certain embodiments, the containers 28 may be capped, vented, or otherwise made resealable. However, in other embodiments, a fully disposable apparatus 10 may rely on inexpensive materials such as polyethylene film to form the containers 28 .
By any means, an opening assembly 30 (in the illustrated embodiment, a piercing assembly 30 ) may be actuated to open, pierce, or otherwise breach the sealing of the containers 28 of liquid. Upon piercing or otherwise breaching of the integrity of the containers 28 , the contained liquid then flows downward to be absorbed within the covering material of the heaters 22 . The presence of the liquid activates the chemical reactions within the heaters 22 , generating heat to initiate reaction of the chemical constituents contained within the reactor 20 .
A cover 32 may enclose the insulated container 26 , and may typically be formed of the same material. A vent 30 may vent steam from within the containment vessel 24 and the insulated container 26 in order to alleviate any pressure build up. Likewise, in order to direct the residual steam in a specific direction other than permitting it to escape about the interface between the cover 32 and the container 26 , a vent 18 may be advisable, required, or otherwise useful.
The outlet 19 for nitric oxide may penetrate through the cover 32 by means of an aperture 34 . The aperture 34 may be sealed against the outlet 19 in order that the steam generated from the heaters 22 escape substantially exclusively through the vent 18 , rather than near the fitting 14 and line 15 that may be subject to manipulation by the user.
Referring to FIGS. 3-8 and 29 , but referring generally to FIGS. 3 through 24 , the insulated container 26 may be formed in any suitable shape to contain all of the elements required for a single dosing of nitric oxide. Accordingly, the constituent structures of FIG. 2 may fit within the interior of the container 26 . Meanwhile, the cover 32 may be fitted thereto.
The vent 18 may be formed to fit snugly through a penetration in the cover 32 . A flange thereof may be labeled with colors and text appropriate to warn of the elevated temperature thereof as a safety measure.
A pin may act as a significant portion of the trigger assembly 16 or trigger 16 . Upon removal of the pin, such as by a user pulling on a handle or ring secured thereto, the blades may be released to pierce the containers 28 holding the liquid required to initiate the reaction of heaters 22 .
A guide 36 or guide rod 36 may direct the blades of the piercing assembly 30 . A compression spring wrapped around the guide 36 or rod 36 may push the blades forward. Referring to FIGS. 13-23 , generally, while specifically referring to FIGS. 15-16 , the piercing assembly 30 may be configured to protect against inadvertent exposure to sharp instruments. A spacer 38 may provide room for operation of a blade assembly 39 or mount 39 holding blades 40 secured thereto.
For example, a “T”-shaped mounting assembly may secure two blades 40 a , 40 b that will eventually slide parallel to the base of the T, and along the same direction of the guide 35 or guide rod 36 . In the illustrated embodiment, an aperture in the foot of the T-shaped mount may run along the guide rod 36 , driven by the compression spring acting along the length of the rod 36 .
The blade assembly or mount 39 , together with its attached blades 40 may operate by sliding along an upper surface of the baseplate 42 . Two apertures on opposing sides or near opposing edges of the baseplate 42 may receive fasteners to penetrate a pair of corresponding spacers 38 . The spacers 38 form a clearance above the baseplate 42 for operation of the mount 39 .
A cover 44 or cover plate 44 may include a pair of apertures at or near opposing edges thereof to receive the same fasteners that penetrate the baseplate 42 . Accordingly, the cover plate 44 , or simply cover 44 , is spaced away from the baseplate 42 sufficient distance to receive the mount 39 and attached blades 40 therewithin. Thus, the blade assembly 39 or mount 39 with its attached blades 40 is effectively “garaged” between the baseplate 42 , and the cover plate 44 . Meanwhile, a compression spring 46 pushes against the base of the T-shaped mount 39 , driving the aperture therein along the guide rod 36 captured in the aperture.
A reactor 20 may include a principal containment vessel 50 . In one embodiment, a conventional “tin,” or metal can, may be formed by conventional technology available for canning. In other embodiments, the reactor 20 may rely on other structures such as fiber-reinforced composites, cylinders, sealed and flexible but inextensible lattice work, fabrics, or the like, in order to contain the chemical constituents reacting to form nitric oxide.
In one embodiment, tablets, granules, or other configurations of reactants may be placed in a can, sealed to form the reactor vessel 50 . An aperture 40 in the vessel 50 may receive a tube 52 acting as a reactor outlet 19 . The outlet 19 may conduct nitric oxide generated within the containment vessel 50 to a location outside the insulated container 26 in order to deliver to a line 15 .
Various mechanisms may be available for maintaining the integrity of the apparatus 10 . In one embodiment, a heat shrinkable wrapping material may be formed in a seamless sleeve. The sleeve may be placed around the apparatus 10 , and judiciously penetrated to accommodate the fitting 14 , the vent 18 , the trigger 16 , and so forth. Thereupon, the sleeve 54 may be heated in order to shrink it snugly about the insulated container 26 . Thereafter, any breach of the sleeve 54 indicates a lack of integrity of the apparatus 10 .
One embodiment of an apparatus 10 in accordance with the invention was formed using expanded polystyrene for the insulated container 26 . A fitting 14 to receive a line 15 delivering nitric oxide to a cannula 56 received nitric oxide from a reactor 20 within the insulated container 26 . A vent 18 penetrated the cover 32 of the insulated container 26 to vent steam. A trigger mechanism 16 penetrated the cover 32 in order to reach the piercing assembly 30 described hereinabove.
Containers 28 filled with salt water were provided and placed above the piercing assembly 30 and the reactor 20 therebelow. The heaters 22 were placed entirely below the reactor 20 , although they may also be wrapped therearound, or even placed on top. However, inasmuch as the heaters 22 tend to vaporize some of the liquid in the containers 28 when released, the heated steam generated below the reactor was effective to heat the reactor 20 . Steam rising from heaters thereabove would not ever be in contact with the heaters 22 . That is, heat rising with steam originating above the reactor 20 , will not contribute as much heat to the reactor 20 . The outlet 14 from the reactor was formed of a stainless steel tube 52 penetrating the reactor 20 .
The blades 40 were positioned between the baseplate 42 , and the cover plate 44 . The guide rod 36 was secured to the baseplate 42 to maintain alignment of the mount 39 as the spring 46 drove the mount 39 forward along the guide rod 36 . Upon release of a trigger 16 , the mount 39 advanced out from under the cover plate 44 , exposing the containers 28 to the sharp blades 40 . The blades 40 compromised the containers 28 from below, thus substantially evacuating all the water therefrom. In the experiment illustrated, salt water was used as the liquid within the containers 28 . In some experiments, a single container was used. In other embodiments, including experiments conducted, multiple containers 28 filled with liquid were used.
In one embodiment, a method of producing nitric oxide may comprise the following steps. A mixture of reactants may be provided consisting essentially of potassium nitrate, sodium nitrite, and chromic oxide. The chromic oxide may be calcined to remove substantially all water bonded thereto. The reactants may be placed in a vessel, or reactor, and any moisture in the vessel may be substantially evacuated. The reactants in the vessel may be heated to a temperature selected to initiate a reaction generating nitric oxide gas. The nitric oxide gas generated may be drawn from the vessel at negative gauge pressure to substantially preclude further heating and limit further reaction, or any secondary reactions, of the nitric oxide gas. The nitric oxide gas may be cooled and mixed with a diluent gas to form a mixture breathable by a subject. The breathable mixture may be regulated to substantially ambient temperature and pressure and delivered to the subject to provide a therapeutically safe and effective concentration of nitric oxide gas.
Referring to FIG. 31 , in one set of experiments, a single standard heater was used with water, as indicated. In other experiments, multiple heaters 22 were used. In yet other experiments, a single heater was used, but the liquid used to activate the heater 22 , was salt water. The chart illustrates the substantial temperature increase due to the use of the ionized salt within the salt water. Throughout the course of the experiment, the temperature was observably higher, and in some instances substantially higher, when salt water was the electrolyte initiating the reaction in the heaters 22 . Moreover, a single heater provided more temperature rise in the reactor 20 than twice that amount of chemical (two standard heaters), relying only on water alone as the electrolyte.
Referring to FIG. 32 , one may see that the insulation value of the insulated container 26 has some effect. Nevertheless, in general, a more pronounced effect over the latter part of the subject time results from the addition of a second heater 22 .
Referring to FIG. 33 , in another experiment, the drop off over the subject time period is more pronounced in the last half of the time. Meanwhile, the reactor temperature is maintained close to two hundred degrees Fahrenheit for at least about 20 minutes, when two heaters are used.
Referring to FIG. 34 , the volume of nitric oxide produced, cumulatively, over the operation of an apparatus 10 in accordance with the invention provided the illustrated results. In the chart, temperature was maintained for an extremely long period, considering that a therapy session may typically only require about 30 minutes of nitric oxide generation. The chart illustrates that the volumetric rate of nitric oxide generated was substantially constant, giving rise to a substantially straight slope or line in the time period from about 16 minutes to about 100 minutes. Meanwhile, although the measured temperature dropped during that time period from about two hundred degrees Fahrenheit to just over one hundred degrees Fahrenheit, nitric oxide production did not drop off substantially throughout. Nevertheless, the graph illustrates an apparent decline eventually.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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An apparatus for portable delivery of nitric oxide without the need for pressurized tanks, power supplies, or other devices provides a single therapy session by triggering a heater to heat a reaction chamber. A piercing assembly may trigger to open sealed containers, such as bags, of liquid water or salt water in order to activate the heaters. Upon addition of liquid such as water or salt water to a chemically reactive heating element, heat is generated to activate the chemicals generating nitric oxide within a sealed reactor. Upon triggering, liquid containers are unsealed, the liquid drains down to initiate reaction of the heating chemicals, and the heat begins to penetrate the reactor. The reactor, in turn, heats its contents, which react to form nitric oxide expelled by the reactor to a line feeding a cannula for therapy.
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This application is a division, of application serial No. 07/167,906,. filed Mar. 14, 1988 now U.S. Pat. No . 4,905,737.
BACKGROUND OF THE INVENTION
This invention concerns a device for separating a broken warp thread at the warp stop motion from the warp sheet on a weaving machine--in particular on weaving machines of the type in which the warp stop motion consists of one or more rows of drop wires --in order to enable the broken warp thread to be automatically located and taken up.
A warp stop motion commonly used on weaving machines consists of a row of drop wires resting on the warp threads, so that when a warp thread break occurs, the corresponding drop wire makes an electrical contact or mechanical interlock, thus causing the machine to be stopped.
Dutch patent application No. 8600372--which corresponds to the U.S. Pat. No. 4,791,967 to Vandeweghe, et al., issued on Dec. 20, 1988 --describes a method of automatically locating the fallen drop wire, which is then gripped and raised in order to make it visibly stand out from the row of drop wires, thus enabling the weaver to see at a glance where a thread break needs to be repaired. Dutch patent application No. 8601819 which corresponds to U.S. Pat. No. 4,815,498 to Gryson et al issued Mar. 28, 1989, also describes a method for turning the fallen drop wire through an angle so that the neighboring drop wires are forced apart, thus forming a local opening in the unbroken warp threads, and so facilitating rethreading of the drop wire which is presented in this way.
Although the abovementioned patent documents are aimed at automating the process of warp thread repair, they do not offer any solution to the problem of dealing with the broken warp thread, which is usually still threaded through the fallen drop wire, either by removing it and replacing it with a new one or by tying it in again. The problem is mainly that the broken warp thread which remains threaded through the fallen drop wire first has to be located, which is fairly difficult to automate since the warp thread which was under tension contracts when it breaks and gets crossed over neighboring threads.
SUMMARY OF THE INVENTION
The present invention concerns a device for separating the broken warp thread at the warp stop motion from the warp sheet on a weaving machine, thus providing a solution to the problem described above. Further, the warp thread which is thus separated is also brought into the correct position with respect to the remaining warp threads, in other words not crossed over the neighboring threads.
To this end, the invention essentially involves a device for extracting the sagging loop--formed in the broken warp thread as a result of the drop wire falling--from the warp stop motion, back from the fallen drop wire: optionally, the fallen drop wire may first be raised before extracting the broken warp thread in this way.
In a preferred embodiment the loop is extracted from the warp stop motion back from the fallen drop wire by means of at least one airstream which exerts a force on the broken warp thread, starting at the point where the fallen (or raised) drop wire is located. Depending on the variant, the airstream may be provided by suction or blower nozzles.
In yet another embodiment, the force is exerted by mechanical means, for example grippers or hooks.
The device according to the present invention should preferably be used in combination with the system described in Dutch patent application No. 8601819 and the aforementioned U.S. Pat. No. 4,815,498, in which as well as being raised the fallen drop wire is also turned through an angle in order to facilitate the freeing of the broken warp thread. The effect of turning the drop wire in this way is to draw the neighboring warp threads away from the broken warp thread.
The present invention also concerns a device which essentially uses one or more suction nozzles, blower nozzles or mechanical means which operate in conjunction with the drop wire.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of describing the characteristics of the invention, the following preferred embodiments are described with reference to the accompanying drawings, by way of example only and without being limitative in any way, where:
FIG. 1 represents a cross section of a warp stop motion, equipped with suction nozzles, at the point of the broken warp thread;
FIGS. 2 to 8 illustrate the operation of the device; FIG. 2 is a plan view (looking down on the warp sheet) and FIGS. 3 to 8 show the various stages of the method, in a cross section of the warp stop motion;
FIG. 9 shows an elevation view in partial cross-section of a particular embodiment of a suction nozzle, such as may be used in the device according to the invention;
FIG. 10 shows schematically and in an elevational, partial cross-section view a device which uses blower nozzles mounted above the warp sheet;
FIG. 11 schematically shows a variant of the embodiment in FIG. 10, in which the blower nozzles are mounted under the warp sheet;
FIGS. 12 and 13 show yet another variant which uses a hook to move the sagging loop.
FIGS. 14 and 15 elevational and end views in partial cross-section show a particular embodiment of a suction nozzle or extraction tube (FIG. 15 being taken in the direction of arrow F15 in FIG. 14).
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a cross section of a warp stop motion consisting essentially of a number of rows of drop wires 1 to 4 which are suspended on the warp threads of the warp sheet 5, and which when they fall make an electrical contact with one the electrodes 6 to 9 respectively. The warp sheet 5 is led over supporting elements 10 to 14 on either side of the rows of drop wires 1 to 4.
In FIG. 1 a broken warp thread 15 is shown such that the corresponding drop wire 16 has fallen. Also in FIG. 1 there is a gripping device 17, more particularly as described in Dutch patent application No. 8601819, which manipulates the fallen drop wire 16.
The actual mechanism of the invention consists, in the embodiment illustrated, of a series of suction nozzles 18 to 21 which can move under control of an appropriate control system C which comprises a transport system as well as an activation and control device for the nozzles 18 through 21 in such a way that each suction nozzle 18 to 21 can be presented opposite one of a particular row of drop wires 1 to 4. The operation of the device according to the invention, using the method outlined above, is described below with the aid of the successive figures.
In FIG. 1 a warp thread break has occurred, in particular in warp thread 15. Here it should be noted that as a result of the drop wire 16 falling a sag 22 has been formed in the warp thread 15. The fallen drop wire 16 is located and gripped by the gripping device 17.
In the next step, the fallen drop wire 16 is gripped by its end 23, turned and raised by gripping device 17, as shown in FIG. 2. At the same time the suction nozzles 18 to 21 are lowered by control system C towards the warp sheet 5, almost right up to the supporting elements 11 to 14, as shown in FIG. 3.
Obviously, the result of raising the fallen drop wire 16 will be that where previously there was a sag 22 in the warp thread 15 there will now be a free-hanging loop 24. At this stage, shown in FIG. 2, the suction nozzle 19 is activated by control system C, with the result that the warp thread 15 is drawn taut and perhaps also partly sucked in. As shown in FIG. 4, the suction nozzles 18 to 21 are now moved upwards by control system C, with the result that said loop 24 is displaced over a short distance, arriving over the supporting element 12, since the suction nozzle 19 drags the warp thread 15 towards it.
Control system C, of course, includes suitable control actuators or motors for the raising and lowering of the suction nozzles 18 to 21 sequentially or simultaneously and appropriate associated mechanisms known to those skilled in the art for connecting the actuators or motors to the nozzles. The actuators or motors in turn may be controlled via an appropriate central master control that governs operation of the motors, as well as the transport means 41 to be described below. The activation of the suction applied by each nozzle also may be controlled through the master control in a manner well known to those skilled in weaving machinery. The specific apparatus by which this control is achieved does not form a part of the present invention and may be implemented by any appropriate devices known to those skilled in weaving machinery technology.
When the nozzles arrive in their highest position, suction nozzle 19 is deactivated and suction nozzle 20 is activated (the activation and deactivation times may overlap slightly). The series of suction nozzles is once more presented to the warp sheet 5, resulting in a situation as shown in FIG. 5. The warp thread 15 is then moved along by the action of suction nozzle 20, so that the loop is farther displaced to nozzle 20, as shown in FIG. 6.
As shown in FIGS. 7 and 8, the above sequence is then be repeated for the last suction nozzle 21 so that the loop 24 is drawn out of the warp stop motion, away from the fallen drop wire 16. A hooking or gripping mechanism 25 may be positioned in proximity to the last suction nozzle 21 in order to take over the warp thread 15 from the suction nozzle 21, so that the latter may be deactivated. Said hooking or gripping mechanism 25 may then be used for further manipulation of the warp thread 15: however such manipulation is outside the scope of this invention. On commencement of the operation according to the method of the invention, it may be advantageous to first activate the nozzle 18 beside the fallen drop wire 16 opposite to the direction in which the loop 24 will be transported, in order to raise the warp thread 15 and so facilitate the transfer of said loop 24 between the other suction nozzles 19 to 21.
Clearly, other variations of the system described also possible. In one important variant, there is only one suction nozzle, which is first lowered beside the fallen drop wire 16, then activated and raised so as to draw the loop 24 with it, and subsequently deactivated and positioned over the following row of drop wires. This sequence is repeated until the suction nozzle arrives outside the warp stop motion, at which point the abovementioned hooking or gripping mechanism 25 can take over the thread.
It also clear that in addition to the suction nozzles, the device must include the necessary transport, activation, deactivation and control functions necessary for the cycle to be carried out automatically.
The loop 24 can of course be carried either to side 26 or side 27 of the warp stop motion; in the latter case, there must be another suction nozzle 28 at the other side 27 of the warp stop motion.
In a variant, the operating cycle of the suction nozzles 18 to 21 is as follows. When a warp break is detected, all the suction nozzles 18 to 21 are lowered by control system C. The suction nozzle nearest the fallen drop wire 16 is activated and raised so that the broken warp thread 15 is raised with it; in the accompanying figures, the suction nozzle concerned would be nozzle 19. When the suction nozzle 19 arrives in its raised position, it is deactivated and the next suction nozzle 20, which is still in the lowered position, is activated and then raised. This process is repeated in a similar way until the loop 24 has been carried out of the warp stop motion.
In yet another operating cycle which may be used in the method according to the invention, only the suction nozzle 19 is lowered towards the fallen drop wire 16 and then raised, taking the broken warp thread 15 with it when it is raised.
The other suction nozzles are then activated and deactivated successively, so that the loop 24 is passed from one to the other until it arrives outside the warp stop motion, either on side 26 or on side 27, in other words going directly from the stage shown in FIG. 4 to the stage shown in FIG. 6, without moving the suction nozzles up and down.
In order to prevent the warp thread 15 remaining stuck inside a suction nozzle after it has been deactivated, due to the stiffness of the thread, thus preventing the loop 24 from being passed from one nozzle to another, positive pressure can be applied to the first nozzle when one nozzle is deactivated and the next activated, thus making sure that the loop 24 is released. A warp thread which gets stuck in a nozzle can also be freed by some mechanical device, e.g. rings or tubes 29 mounted concentrically on the suction nozzles 18 to 21 and which move up and down.
The suction nozzles 18 to 21, and also nozzle 28 if provided, can also be mounted underneath the warp sheet 5 instead of above it.
In the variant shown in FIG. 10, the method of the invention is accomplished by using a succession of airjets at various points to displace the loop 24 in the broken warp thread 15, starting at the fallen drop wire 16 and progressing to one of the sides of the warp stop motion, in this case side 26. To this end the suction nozzles 18 to 21, and nozzle 28 if provided, are replaced by blower nozzles 30 to 34. No up and down motion is necessary if such blower nozzles are used. The operation of the device may be simply deduced from FIG. 10, and is more or less analagous to the method using suction nozzles.
It is possible to provide extraction tubes 35 to 39 mounted opposite the blower nozzles 30 to 34, in order to promote evacuation of the airstream from whichever blower nozzles are activated. The extraction tubes may also operate as suction nozzles, so that there is a combined action of blower and suction nozzles. The extraction tubes can be activated by the control system C as well.
In the variant shown in FIG. 11, the blower nozzles 30 to 33, and also blower nozzle 34 if provided, are mounted underneath the warp sheet 5. This has the advantage that they can be mounted on the same transport mechanism 41 as the rotatable gripper device 17.
As shown in FIGS. 12 and 13, the loop 24 can also be transported out of the warp stop motion by means of hooking or gripping devices controlled by control system D. In the variant illustrated, the suction nozzles are replaced by hooks 42 to 45, and also hook 46 if provided, which move up and down when activated by control system D, thus raising the loop 24, starting at the fallen drop wire 16. The particularity of this method is that, as shown in the two figures, it is not necessary for the fallen drop wire 16 to be presented and raised by a special gripping device 17, since the corresponding drop wire will be raised by the action of gripper 43 in FIG. 13.
The motion of the hooks must of course be controlled in such a way that they operate separately one after the other so that they carry the loop 24 in the warp thread 15 with them. In order to avoid unwanted effects on the loop 24, it is also possible for a guide 47 for the broken warp thread to be lowered. Clearly, suitably controlled gripping or clamping devices may be used instead of the hooks 42 to 45. The hooking, gripping or clamping devices may of course also be mounted under the warp sheet 5.
In a preferred embodiment as shown in FIG. 14 the suction nozzles 18 to 21 or the suction nozzle 28 may be provided with a sieve-shaped element 48 which prevents the broken warp thread 15 being sucked completely into the suction nozzles 18 to 21 or 28. In the same way the extraction tubes 35 to 39 may also be provided with a sieve-shaped element 48 which prevents the broken warp thread 15 being blown completely into the extraction tubes 35 to 39.
As shown in FIG. 15 the sieve-shaped element 48 may be provided with holes 49 whereby the diameter of the holes 49 is less than the diameter of the warp thread 15 in order to prevent the warp thread being sucked into the holes 49.
The present invention is in no way limited to the variants described by way of example and shown in the accompanying figures: on the contrary, such a method and device for extracting a broken warp thread from the warp sheet in weaving machines may be made in all sorts of variants while still remaining within the scope of the invention.
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A device for removing a broken warp thread from a warp stop motion includes a plurality of extraction elements that may include nozzles, hooks, grippers and the like that lift a slack loop of broken warp thread at a fallen drop wire associated with the broken warp thread and move the loop to a position outside the stop motion by passing the loop sequentially from one nozzle, etc. to the next in a single direction until the loop is outside the stop motion, where it can be gripped by a thread holder for further manipulation.
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BACKGROUND OF THE INVENTION
This invention relates to the field of automatic transmissions for motor vehicles. More particularly, the invention pertains to a kinematic arrangement of gearing, clutches, brakes, and the interconnections among them in a power transmission.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a transmission according to a first embodiment of the present invention which produces eight forward and one reverse speed ratios.
FIG. 2 is a table showing the proposed tooth numbers for the gears of the transmission illustrated in FIG. 1 .
FIG. 3 is a table indicating the states of the clutches and resulting speed ratio of the transmission in FIG. 1 when the gears have the number of teeth indicated in FIG. 2 .
FIGS. 4-6 are schematic diagrams of alternative embodiments which differ from the embodiment of FIG. 1 with respect to the structure of the torque converter assembly.
FIGS. 7-8 are schematic diagrams of alternative embodiments which differ from the embodiment of FIG. 1 with respect to the structure of the first planetary gear set and its connections to other components.
DETAILED DESCRIPTION OF THE INVENTION
A transmission according to a first embodiment of the present invention is illustrated in FIG. 1 . The transmission contains four simple planetary gear set assemblies 20 , 30 , 40 , and 50 . Each simple planetary gear set assembly has a sun gear, a ring gear with an internal mesh, a planet carrier, and a set of planet gears supported for rotation on the carrier and meshing with both the sun gear and ring gear. A recommended number of gear teeth for each of these gears is shown in FIG. 2 .
Gearbox input shaft 10 is driven by the vehicle's engine via torque converter assembly 100 . The third sun gear 42 , is fixed to gearbox input shaft 10 . The first carrier 26 is connected to the second sun gear 32 . The second carrier 36 is connected to the third ring gear 44 . The first ring gear 24 , third carrier 46 , and fourth ring gear 54 are mutually connected. A gearbox output shaft 12 drives the vehicle wheels, preferably via a driveshaft, a differential assembly, and rear axle shafts. Gearbox output shaft 12 is fixed to the fourth carrier 56 and the second ring gear 34 . A transmission case 14 provides support for the gear sets, input shaft, and output shaft.
Clutches 60 and 62 and brakes 64 , 66 , 68 , and 70 are preferably hydraulically actuated friction clutches which releasably connect two elements when hydraulic pressure is applied and disconnect those elements when the hydraulic pressure is released. Clutch 60 releasably connects gearbox input shaft 10 to the first sun gear 22 . Clutch 62 releasably connects gearbox input shaft 10 to the first ring gear 24 , third carrier 46 , and fourth ring gear 54 . Brake 64 releasably connects the first sun gear 22 to the transmission case 14 . Brake 66 releasably connects the fourth sun gear 52 to the transmission case 14 . Brake 68 releasably connects the first carrier 26 and second sun gear 32 to the transmission case 14 . Brake 70 releasably connects the second carrier 36 and the third ring gear 44 to the transmission case 14 . One way clutch 72 is a passive device which allows the second carrier 36 and third ring gear 44 to rotate freely in a positive direction but prevents rotation in the opposite direction.
Torque converter assembly 100 comprises an impeller 104 that is driven by the transmission input shaft 102 , stator 108 , and turbine 106 . The stator 108 is connected to the transmission case 14 by a one way clutch 110 . When the turbine is substantially slower than the impeller, the one way clutch holds the stator stationary and it provides a reaction torque to create torque multiplication between the impeller and turbine. The one way clutch overruns when the turbine speed is near or greater than the impeller speed. Lock-up clutch 112 connects the turbine to the impeller eliminating the hydrodynamic losses of the torque converter. In FIG. 1 , the turbine is connected to gearbox input shaft 12 via a spring 114 . This spring isolates the gearbox and driveline from the torque pulses produced by the engine while transmitting the average torque. A torque converter assembly with a spring in this location is commonly called a turbine damper.
The transmission ratio is selected by applying hydraulic pressure to two of the clutches and brakes as indicated in FIG. 3 .
The transmission is prepared for forward motion in first gear by applying brake 66 . While the vehicle is at rest, turbine 106 , gearbox input shaft 10 , and all gear set components are stationary. The engine drives impeller 104 , which circulates fluid toroidally among the impeller, stator, and turbine. This fluid flow pattern produces a torque on the turbine shaft and gearbox input shaft 10 . One way clutch 72 provides a reaction at ring gear 44 . Clutch 66 provides another reaction at sun gear 52 . Thus, a multiple of the input torque is transferred to output shaft 12 , accelerating the vehicle.
In this condition, one way clutch 72 will overrun if an attempt is made to transmit power in the opposite direction. If engine braking behavior is desired, it is necessary to also apply friction brake 70 . Optionally, one way clutch 72 may be omitted and friction brake 70 applied for both directions of power transfer.
Lock-up clutch 112 may be applied any time the speed of gearbox input shaft 10 is within the engine's operating range. Preferably, it is applied as soon as possible and remains engaged as long as possible in order to minimize transmission parasitic losses.
To shift to second gear, brake 68 is progressively engaged, maintaining brake 66 fully applied. As the torque capacity of brake 68 increases, one way clutch 72 will overrun. If one way clutch 72 is omitted, brake 70 must be progressively released as brake 68 is engaged.
To shift from second to third gear, brake 64 is progressively engaged while brake 68 is progressively released. To shift from third to fourth gear, clutch 60 is progressively engaged while brake 64 is progressively released. To shift from fourth to fifth gear, clutch 62 is progressively engaged while clutch 60 is progressively released. Brake 66 is maintained in the fully applied state through all of these transitions.
To shift from fifth to sixth gear, clutch 60 is progressively engaged while brake 66 is progressively released. Sixth gear is a direct drive gear. To shift from sixth to seventh gear, brake 64 is progressively engaged while clutch 60 is progressively released. To shift from seventh to eighth gear, brake 68 is progressively engaged while brake 64 is progressively released. Clutch 62 is maintained in the fully applied state through all of these transitions.
Downshifting to a lower gear is accomplished by reversing the steps described above for the corresponding upshift.
The transmission is operated in reverse by applying clutch 60 and brake 70 .
FIGS. 4 , 5 , and 6 illustrate alternate embodiments that differ from the above embodiment with respect to the construction and function of torque converter assembly 100 . These embodiments are operated in the same fashion as the previous embodiment.
In the embodiment of FIG. 4 , a relatively narrow shaft 116 runs through the center of the gearbox inside gearbox input shaft 10 , which is hollow. Shafts 116 and 10 are connected to each other as far from the input end of the transmission as feasible. The diameter of shaft 116 is selected just large enough to withstand the maximum anticipated turbine torque (with an appropriate safety factor). As a result of its small diameter and relatively long length, shaft 116 has considerable torsional compliance and provides isolation from engine pulses (which was accomplished by spring 114 in the embodiment of FIG. 1 ). In this embodiment, turbine 106 is connected to shaft 116 as opposed to shaft 10 . The remaining components and their interconnections are identical to the embodiment of FIG. 1 .
The embodiment of FIG. 5 also uses a narrow shaft 116 to provide isolation from engine pulses. In this embodiment, however, the turbine is connected to gearbox input shaft 10 and lock-up clutch 112 releasably connects transmission input shaft 102 to shaft 116 . Shaft 116 may be designed to withstand engine torque as opposed to turbine torque which is typically much higher. As a result, it has more compliance and provides better isolation.
In the embodiment of FIG. 6 , lock-up clutch 112 is located within the gearbox portion and releasably connects the narrow shaft 116 to gearbox input shaft 10 . Turbine 106 is connected to gearbox input shaft 10 . Shaft 116 is connected to transmission input shaft 102 . The fluid that actuates clutch 112 may be fed through output shaft 12 .
FIGS. 7 and 8 illustrate alternate embodiments which differ with respect to the previous embodiments with respect to the construction of the first gear set and its connections. Torque converter assembly 100 is not shown in these Figures. Any of the variations of torque converter illustrated in FIGS. 1 , 4 , 5 , and 6 and described above could be utilized with the gearbox structures illustrated in FIGS. 7 and 8 . The embodiments illustrated in FIGS. 7 and 8 are operated in the same fashion as the embodiment illustrated in FIG. 1 which is described above.
A transmission according to another embodiment of the present invention is illustrated in FIG. 7 . The transmission contains one compound planetary gear set assembly 80 and three simple planetary gear set assemblies 30 , 40 , and 50 . The compound planetary gear set assembly has a sun gear, a ring gear with an internal mesh, a planet carrier, an inner set of planet gears supported for rotation on the carrier and meshing with the sun gear, and an outer set of planet gears supported for rotation on the carrier and meshing with both one of the inner planet gears and the ring gear.
The third sun gear 42 , is fixed to gearbox input shaft 10 . The first ring gear 84 is connected to the second sun gear 32 . The second carrier 36 is connected to the third ring gear 44 . The first carrier 86 , third carrier 46 , and fourth ring gear 54 are mutually connected. Output shaft 12 is fixed to the fourth carrier 56 and the second ring gear 34 . A transmission case 14 provides support for the gear sets, input shaft, and output shaft.
Clutch 60 releasably connects gearbox input shaft 10 to the first sun gear 82 . Clutch 62 releasably connects gearbox input shaft 10 to the first carrier 86 , third carrier 46 , and fourth ring gear 54 . Brake 64 releasably connects the first sun gear 82 to the transmission case 14 . Brake 66 releasably connects the fourth sun gear 52 to the transmission case 14 . Brake 68 releasably connects the first ring gear 84 and second sun gear 32 to the transmission case 14 . Brake 70 releasably connects the second carrier 38 and the third ring gear 44 to the transmission case 14 . One way clutch 72 allows the second carrier 36 and third ring gear 44 to rotate freely in a positive direction but prevents rotation in the opposite direction.
A transmission according to another embodiment of the present invention is illustrated in FIG. 8 . The transmission contains one compound planetary gear set assembly 90 and three simple planetary gear set assemblies 30 , 40 , and 50 . The third sun gear 42 , is fixed to gearbox input shaft 10 . The first ring gear 94 is connected to the second sun gear 32 . The second carrier 36 is connected to the third ring gear 44 . The first sun gear 92 , third carrier 46 , and fourth ring gear 54 are mutually connected. Output shaft 12 is fixed to the fourth carrier 56 and the second ring gear 34 . A transmission case 14 provides support for the gear sets, input shaft, and output shaft.
Clutch 60 releasably connects gearbox input shaft 10 to the first carrier 96 . Clutch 62 releasably connects gearbox input shaft 10 to the first sun gear 92 , third carrier 46 , and fourth ring gear 54 . Brake 64 releasably connects the first carrier 96 to the transmission case 14 . Brake 66 releasably connects the fourth sun gear 52 to the transmission case 14 . Brake 68 releasably connects the first ring gear 94 and second sun gear 32 to the transmission case 14 . Brake 70 releasably connects the second carrier 38 and the third ring gear 44 to the transmission case 14 . One way clutch 72 allows the second carrier 36 and third ring gear 44 to rotate freely in a positive direction but prevents rotation in the opposite direction.
A transmission embodiment according to this invention contain four epicyclic gearing assemblies, each with three members that rotate around a common axis. In each epicyclic gearing assembly, the speeds of the three elements are linearly related. The second rotating elements is constrained to rotate at a speed which is a weighted average of the speeds of the first and third elements. The weighting factors are determined by the configuration of the epicyclic gearing assembly and the ratios of the numbers of gear teeth. In FIG. 1 , all four epicyclic gearing assemblies are simple planetary gearsets. In FIGS. 7 and 8 , one of the epicyclic gearing assemblies is a compound planetary gearset. Other types of epicyclic gearing assemblies, such as coplanar gear loops as described in U.S. Pat. Nos. 5,030,184 and 6,126,566, are known and may be substituted without departing from the present invention.
In accordance with the provisions of the patent statutes, the preferred embodiment has been described. However, it should be noted that alternate embodiments can be practiced otherwise than as specifically illustrated and described.
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A multiple speed power transmission comprising: four epicyclic gearing assemblies each having first, second, and third rotating elements with specified interconnections, an input shaft connected to one of the rotating elements, an output shaft, two rotating clutches releasably connecting the input shaft to rotating elements, and four brakes selectively holding rotating elements against rotation. Clutches and brakes are applied in combinations of two to produce eight forward ratios and one reverse ratio.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/294,260 filed Jan. 12, 2010 entitled “Interactive On Site Stain Removal System and Method of Using” which is hereby incorporated by reference in its entirety to the extent not inconsistent.
FIELD OF THE INVENTION
[0002] The present invention generally relates to a system and method for facilitating the proper and effective removal stains for fabrics and similar materials. More particularly, the present invention pertains to a touchscreen based system which provides instructions for removing an identified stain from a selected fabric type using a set of color-coded stain removal agents.
BACKGROUND
[0003] In the dry cleaning industry, spotting boards became the standard equipment used for stain removal in the early 1940's. Spotting boards are still popular today and are typically used by professionals, such as dry-cleaners, for removing stains in fabrics, such as clothing and outerwear. Spotting boards primarily uses three sources to aid in removing stains. First, a vacuum system can be used to suck or remove agents away from the fabric. Second, steam can be used for flushing a wet agent such as ammonia away from the fabric. Finally, air can be used for drying the fabric after being wetted with water or solvents, for example. There are problems, however, with successfully removing stains. For example, there are many different stains which require certain specific procedures for successful removal from a fabric. In addition, there are many different types of fabrics, and the procedure for removing a stain from one type of fabric may not be the same for one fabric as it is for another. Furthermore, it can be difficult for even a trained operator to remember how a particular stain is removed from a particular fabric.
[0004] This presents a problem for those in the stain removal industry as it can be difficult to train and teach new employees how to remove stains from fabrics due to these complexities. Furthermore, mistakes made by combining the wrong stain removal agents or applying the wrong agent to a delicate fabric can ruin or destroy the item. Proper chemistry and procedures have to be used in order to successful remove stains. Most spotting boards do not provide instructions for removing stains, and even if they do, the instructions are often out of date, inaccurate or inconvenient for the operator to follow.
[0005] In an effort to alleviate this problem, training schools have developed throughout the country to train operators off-site. However, the knowledge and techniques demonstrated at these schools must be memorized by the student and are often difficult to reference. Most educational information published in books, video training tapes, or visual displays are limited in nature due to availability, the complexities thereof and length for describing the procedures. The operator has to rely on memorization through viewing or reading and then return to the workstation where the spotting board is located to apply the procedures.
[0006] Further, hiring someone with little or no experience to follow and learn these procedures requires training and resources before the person becomes experienced in the stain removal procedures. Owners of dry cleaning facilities normally will train some one by using one-on-one or show-and-tell techniques on the job. However, problems arise when the owner or experienced operator is not available for instructions. This can reduce productivity and cause backlog.
[0007] Therefore, the need has arisen for an on-site and interactive system that can be used by experienced or inexperienced operators to facilitate the successful removal stains from any type of fabric without lengthy training, voluminous memorization, or advanced chemical knowledge.
SUMMARY
[0008] According to one exemplary embodiment of the present invention, an interactive on-site training tool is provided for assisting with the removal of a stain from a cloth or garment. The method allows the operator to access all the necessary information to remove stains without the need for professional assistance and without leaving the workstation.
[0009] Another exemplary embodiment of the present invention includes a system including a touchscreen display for using in displaying procedures for removing selected stain types from selected fabric types, wherein the displayed procedures include reference to stain removal agents and/or tool through color-coded identifying information which corresponded to color-color labels affixed to the stain removal agents and tools.
[0010] This summary is provided to introduce a selection of concepts in a simplified form that are described in further detail in the detailed description and drawings contained herein. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. Yet other forms, embodiments, objects, advantages, benefits, features, and aspects of the present invention will become apparent from the detailed description and drawings contained herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective of one form of the present invention configured for use and installed on a spotting board.
[0012] FIG. 2 is a plan view of one set of stain removal agents provided in conjunction with one form of the present invention.
[0013] FIG. 3 is a plan view of one set of the labels provided in conjunction with another form of the present invention which are suitable for application to the container of stain removal agents to be utilized.
[0014] FIG. 4 is a diagrammatic view of a computer system suitable for implementing one form of the present invention.
[0015] FIG. 5 is a flowchart illustrating the various tracks implemented in one form of the Stain Removal Application according to one form of the present invention.
[0016] FIG. 6 is a screen shot of a representative home screen displayed by the Stain Removal Application according to one form of the present invention.
[0017] FIG. 7 is a screen shot of a representative stain removal screen displayed by the Stain Removal Application according to one form of the present invention.
DETAILED DESCRIPTION
[0018] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates.
[0019] In a dry-cleaning facility or other stain-removal setting, a number of different personnel are tasked with removing stains. This requires that each posses the skills and knowledge necessary to successfully remove various stains for the many different types of fabrics commonly encountered both quickly and without damaging the fabric. The present disclosure, through reference to the accompanying figures, describes a system and associated method for removing stains that provides color-coded stain removal agents along with an interactive reference for ascertaining and carrying out the proper stain removal procedure.
[0020] The system and method for facilitating proper stain removal described herein shall be illustrated as implemented via computer software and hardware, with appropriate components and devices.
[0021] FIG. 1 is a perspective of one form of the present invention configured for use and installed on a spotting board. The illustrated system 10 includes a spotting board 11 . Spotting board 11 is a traditional spotting board common in the art, and it shall be appreciated that other types of spotting boards, spotting cabinets, or the like having a different shape, size, and/or configuration may be utilized in combination with the present invention. Spotting board 11 includes a base 12 , upper platform 14 , and a lower platform 16 . Upper platform 14 is typically a large, flat workspace constructed primarily of a smooth water-resistant material such as stainless steel, glass, or the like. As illustrated, upper platform 14 may be in the form of a traditional ironing board to enable a variety of different garment types to be laid flat, such as a sleeve board. In this form, upper platform 14 also includes a stain-removal agent storage bin 15 where stain-removal-agents may be stored for subsequent use during the current task. Similarly, lower tray 16 is also a large, flat workspace, but it is often constructed from a metal frame covered with a selected fabric. In addition, lower platform 16 often takes on a different shape from upper platform 14 to provide versatility. Furthermore, a sleeve board 17 is provided above or adjacent to upper platform 16 . Sleeve board 17 is typically of a similar construction to upper platform 16 , but having a smaller size and shape adapted for use when removing stains from the sleeves of garments.
[0022] Base 12 typically includes user controls, such as foot pedals 18 , which enable the user to operate steam 20 , vacuum 22 , and air 24 which all have corresponding sources contained within or connected to base 12 . Steam source 20 generates steam which may also be emitted from the spotting gun 23 for use in working stains from a fabric. Vacuum source 22 generates a suction force within vacuum zone 21 of upper platform 14 for use in removing agents from a fabric. Finally, air source 24 generates a stream of compressed air of the like which is emitted from the spotting gun 23 for use in working stains from a fabric. It shall be appreciated that the illustrated steam, vacuum, and air sources may be connections to external steam, vacuum, and air sources or generators. Additionally, alternate controls may be utilized for controlling the use of vacuum source 20 , air source 22 , and steam generator 24 .
[0023] Exemplary spotting boards, such as the one illustrated in FIG. 1 , include the “Model 44SP” and “Model 44SPG” spotting boards provided by FORENTA L. P. of 2300 W. Andrew Johnson Hwy #A, Morristown, Tenn. 37814. It shall be appreciated that other spotting boards manufactured by FORENTA or other suppliers would be suitable for use with the system and method described herein. Furthermore, it shall be appreciate that the present invention may be utilized independent of a specialize spotting board.
[0024] According to the illustrated form, system 10 also includes a display 30 mounted in a position so as to be before a user standing at spotting board 11 and within convenient reach of the user. Display 30 is connected to or includes an integrated computer (not shown) for purposes of presenting an interactive stain removal application to the user and, in the event display 30 is a touchscreen, receiving the user's input. Turning to the details of display 30 , the display, in this form, is a flat panel monitor, such as an LCD panel, OLED panel, plasma display, surface-conduction electron-emitter display, or the like. However, in alternate forms, display 30 may be any other type of display, including a CRT monitor or the like. In the illustrated form, display 30 is a touch screen display, such as a capacitive or resistive touch screen. Furthermore, the display 30 is preferably between approximately 6″ and 24″ in size when measured diagonally across its visible screen. In a more preferred form, display 30 is between approximately 8″ and 15″ in size. For purposes of non-limiting example, display 30 may be a model KTLC-12W-USB/B touch screen monitor supplied by KEYTEC, INC. of 520 Shepherd Drive, Garland, Tex. 75042, USA. It shall be appreciated that other monitors manufactured by KEYTEC or other suppliers would be suitable for use with the system and method described herein.
[0025] Additionally, system 10 , as shown in FIG. 1 , includes a set of stain removal agents 26 (partially illustrated). These agents are utilized to ease the stain removal process by chemically modifying the stain or otherwise affecting the stain to enable proper removal. Common stain removal agents include acids, alkalis, oils, solvents, digesting agents, acids, detergents, and bleaches, just to name a few representative examples. Often times, more than one specific type of each stain removal agent is included. Furthermore, two different stain removal agents often have complex scientific names which can be easily mistaken for one another, such as perchloroethylene and trichloroethylene, leading to undesired results.
[0026] Turning to FIG. 2 , one form of the set of stain removal agents 26 provided in conjunction with the display 30 and stain removal application is illustrated. The stain removal agents 26 , according to this form, are provided in bottles 27 , such as plastic squeeze bottles, having a selected tip or top, for applying the agent to the fabric. Each bottle 27 includes a unique label 28 which includes identifying indicia 29 . According to the form illustrated, the identifying indicia 29 may be a color code, which may comprise a coloring of the entire label, a portion of the label, an image, the text, the chemical name, or any combination of these or the like, wherein the color is then associated with a selected stain removal agent or stain removal agent type. In alternate form, readily identifiable shapes or other quickly identifiable indicia may be utilized. It shall be appreciated that any color coded bottle, dispenser, or applicator may be utilized without departing from the spirit of the invention. For example, refillable plastic squeeze bottles may be provided, with each bottle a label identifying a selected stain removal agent. These bottles 27 may be provided empty or full of the selected agent.
[0027] Alternatively, as illustrated in FIG. 3 , the set of stain removal agents 26 (not shown in FIG. 3 ) for use with the display 30 and stain removal application may be separately provided, such as by the user of a third-party vendor. In this form, the system 10 includes a series of labels 28 which are suitable for attachment to a stain removal agent bottle, dispenser, applicator, or the like. Each label 28 similarly includes identifying indicia 29 so that, when affixed to an agent container, they enable a user to readily identify the stain removal agent contained therein according to its identifying indicia 29 . As above, the identifying indicia 29 may be a color coding, such as a colored image, text, or any combination of the like. For example, various stain removal agents of the same class (i.e. bleaches, detergents, etc.) may each have a color code which is a shade of a selected color, which stain removal agents from differing classes having color codes of differing colors altogether. In alternate form, shapes or other quickly identifiable indicia may be utilized. In addition, for purposes of re-filling the stain removal agents' bottles, the labels may also included mixing instructions, as stain removal agents are often sold in concentrated form and must be mixed prior to use. Furthermore, the labels may also included other information, such as safety, legal, or proper disposal information, as required or desired.
[0028] FIG. 4 is a diagrammatic view of computer system 40 of one embodiment of the present invention. Computer system 40 includes a server of personal computer, namely computer 44 . computer 44 is preferably connected to or includes a data store 46 which stores business logic for a Stain Removal Application 48 , such as stain removal processes, stain removal agent information, and demonstrative graphics and videos/animations. System 40 also includes display 30 , which is connected to and driven by computer 44 through operative connection 31 , which may be any combination of HDMI, DVI, DSUB, USB, or the like. While display 30 is illustrated as being a touch screen display powered by a client computer, it should be understood that display 30 may also be in the form of a handheld device, simple display connected to a video source, thin client, tablet computer, or the like. In addition, computer 44 or display 30 may include one or more speakers (not shown) for presenting associated audio to the user generated by Stain Removal Application 48 . Furthermore, it should be understood that while only a single computer and display are illustrated, more or fewer may be utilized in alternative embodiments. For example, in a multi-station implementation, system 40 might include one or more displays driven by one or more computers 44 .
[0029] In the illustrated embodiment, computer 44 of system 40 includes one or more types of memory 50 and one or more processors or CPUs 52 . Memory 50 preferably includes a removable memory device. Processor 52 may be comprised of one or more components configured as a single unit. Alternatively, when of a multi-component form, processors 52 may have one or more components located remotely relative to the others. One or more components of each processor 52 may be of the electronic variety defining digital circuitry, analog circuitry, or both. In one embodiment, each processor 2 is of a conventional, integrated circuit microprocessor arrangement, such as one or more CORE™ processors (including CORE 2 Duo, Core i3, Core i7 and the like) or PENTIUM 4® processors supplied by INTEL Corporation of 2200 Mission College Boulevard, Santa Clara, Calif. 95052, USA. It shall be appreciated that other processors manufactured by INTEL or other suppliers would be suitable for use with the system and method described herein.
[0030] Memory 50 (removable or generic) is one form of a computer-readable device. Memory may include one or more types of solid-state electronic memory, magnetic memory, or optical memory, just to name a few. By way of non-limiting example, memory may include solid-state electronic Random Access Memory (RAM), Sequentially Accessible Memory (SAM) (such as the First-In, First-Out (FIFO) variety or the Last-In-First-Out (LIFO) variety), Programmable Read Only Memory (PROM), Electronically Programmable Read Only Memory (EPROM), or Electrically Erasable Programmable Read Only Memory (EEPROM); an optical disc memory (such as a DVD or CD ROM); a magnetically encoded hard disc, floppy disc, tape, or cartridge media; or a combination of any of these memory types. Also, memory 50 may be volatile, nonvolatile, or a hybrid combination of volatile and nonvolatile varieties.
[0031] While data store 46 is shown as connected to computer 44 , it shall be appreciated that data store 46 can reside in the same or different location(s) and/or be incorporated within computer 44 . For example, data store 46 can reside within memory 50 of computer 44 . As one non-limiting example, data store 46 can exist all or in part either in a database or in one or more files within a computer readable medium that is operatively connected to computer 44 , such as via a network, through an Internet connection, or otherwise. Alternate arrangements may be included which shall be appreciated by those of skill in the computer arts.
[0032] Turning collectively to FIGS. 1-4 , a user may utilize the system 10 of FIG. 1 to perform traditional stain removal methods absent any pre-existing knowledge. The computer 44 and interactive touch screen display 30 which are running and displaying the Stain Removal Application 48 guide the operator through each step to remove a stain at the workstation. As will be described in detail below, the operator may view a video/animated presentation, written and/or audible step-by-step instructions for each stain removal method which is customized to the user-specified stain and fabric types.
[0033] As described above with respect to FIGS. 2 and 3 , all stain removing agents are labeled with identifying indicia, which in this form shall be described as a color coding, along with a content description for the operator to identify. For example, during the presentation the instructions will be for the operator to use the bottle labeled in red for removing blood and another bottle with corresponding indicia for bleaching if necessary.
[0034] The touch screen method is an interactive software based program designed to eliminate errors in stain removal. The requirement for massive memorization of methods and chemicals is no longer required because the procedures are programmed for the operator. Owners and management can now be absent for the workstation and inexperienced operators can perform any stain removal process without supervision. The system guides the operator during each step of the process to successfully remove any stain from any fabric without leaving the workstation.
[0035] Turning to FIG. 5 , a flowchart illustrating the various navigational tracks provided in one form of Stain Removal Application 48 are illustrated. According to the organizational form illustrated, these tracks all individually originate from and return to home screen 70 , but it shall be appreciated that they may be otherwise ordered in series depending upon the desires of the user. The navigational tracks include: Label Bottles 72 , Spotting Schools 74 , Fabric Identification 76 , Select Stain 78 , and Identify Unknown Stain 80 . The Label Bottles track 72 guides the user through the procedures for properly labeling the bottles of stain removal agents with the labels provided with system 10 , according to the form shown in FIG. 3 . In some forms where the system 10 includes pre-labeled agents, this track may be omitted. The Spotting School track 74 provides education information about the agents, tools, and techniques utilized in the stain removal processes suggested in other tracks. Fabric Identification track 76 provides visual and descriptive guidance which will assist a user in properly selecting the fabric type for the garments they are working upon. Select Stain track 78 is the principal focus of Stain Removal Application 48 and guides the user through the process for successfully removing a stain of the selected type, based upon a number of criteria, such as the type of fabric the stain is to be removed from. The Identify Unknown Stain Track 80 assists a user in identifying the type of stain they are working upon, if needed, as in order to obtain the best results the inputs must be as accurate as possible. Finally, the Timer track 82 is always available allowing the user to initiate a timer, which may be used as part of a routine stain removal process or utilized in conjunction with any other track shown in FIG. 5 . Furthermore, the timer functionality may be embedded within the other tracks of accessible in the other tracks, as will be further illustrated below.
[0036] FIG. 6 . is a representative home screen 100 displayed by the Stain Removal Application 48 on display 30 according to one illustrated form. From the home screen 100 , the user may selected one of the many tracks described above. According to this form, the application 48 provides for a series of buttons 102 , 104 , 106 , 108 , and 110 which the user may select to launch the above described track Label Bottles 72 , Spotting Schools 74 , Fabric Identification 76 , Select Stain 78 , and Identify Unknown Stain 80 respectively. Home screen 100 also includes additional options, such as audio and sequence advancing controls 112 and 114 which enable the user to turn sound on or off as well as control whether or not the various screens automatically advance based on timing or must be manually advanced. Home screen 100 also includes a manually configurable general purpose timer for use in stain removal processing or the like.
[0037] Turning to FIG. 7 , a representative stain removal screen 120 which may be displayed by the Stain Removal Application 48 on display 30 according to one illustrated form. For purposes of illustration, stain removal screen 120 would be displayed in response to a user selecting “Blood” as the stain type using button 108 of FIG. 6 . The user may select the type of stain from a list of stains categorized alphabetically. The user may click on the letter “B” for information about how to remove a blood stain. Again, the program can go through a step-by-step description for what chemicals and equipment are necessary for removing the stain. The user may also be given the option, if necessary, to select the type of fabric the stain is in. In a further form, the program may also coordinate with an attached or attached scanner that is capable of identifying the type of stain in a fabric if this information is unknown and returning it to the program for use in selecting a stain removal process.
[0038] Screen 120 includes a multi-step stain removal procedure 122 , which is provided to the user is several discrete steps in sequential order. In addition, the steps which involve the use of a stain removal agent are accompanied by reference to the identifying indicia (e.g. color coding) which are similarly included on the label which is attached to the corresponding stain removal agent bottle. In addition to the written procedure, the Stain Removal Application 48 may provide a video/animated demonstration 124 with one or more steps in the procedure 122 . Also, audio will also be available for users who wish to have the step by step instructions read to them. Furthermore, next to each step in the stain removal procedure 122 in which timing is critical, the Stain Removal Application 48 may provide a timer 126 , which, when selected by the user, begins a countdown which coincides with the recommended treatment time in that step. For instance, if a step calls for soaking the stained area for 15 minutes, the user would immediately be presented with a pre-set timer for 15 minutes. In further form, the user would be able to adjust the timer before starting it in accordance with their preferences.
[0039] As the user progresses through the stain removal procedure 122 , the user may select the next step. Upon doing so, a new series of animation will appear to illustrate the current process until the process is complete and the stain is removed. Alternatively, the steps may automatically advance based upon pre-programmed time estimated to complete the task, which serves to reduce the level of user input required. Furthermore, alongside each written step of the process, an icon, such as icon 128 will be available for the operator to select. The icons will allow the operator to view a specific chemical or video/animated presentation for a specific step. Additionally, screen 120 includes an additional timer button 130 which is typically accessible from any screen in the Stain Removal
[0040] While only the representative example of removing a blood stain is provided in the include figures, numerous additional examples of the procedures for use in removing various stains from various fabric types is provided in Appendix A. Representative type of stains are Adhesive Tape, Albumin, Animal Stain, Apple Stain, Asparagus, Asphalt (Road Tar), Automobile Wax, Avocado, Banana, Beer, Beets, Berry Stains, Blood, Brandy, Broths, Butter, Cakes, Candle Wax, Candy, Carbon Paper, Cat Urine, Catsup, Caviar, Cheese or Sauce, Chewing Gum, Chlorine, Chocolate, Cider, Clam Chowder, Coffee, Cola Beverage, Color Changes, Cooking Oil, Cough Syrup, Crayons, Deodorants—Underarm, Dog Urine, Egg, Eye Drops, Flowers, Foods, Fruits, Furniture Wax or Polish, Gasoline, Gin and Tonic, Ginger Ale, Glue—Super, Glue—Elmer, Glue—Rubber, Grape Juice, Grass Stains, Gravy, Grease Spots, Greases, Guacamole, Gutter or Road Salt, Hair Dressing, Hair Dyes, Hand Lotions, Holiday Sauce, Ice Cream, Ink—Ball Point, Ink d Blue/Black, Ink—Red, Jam or Jelly, Ketchup, Kool Aid®, Leather Stains, Lemon Aid, Lipstick, Liquor Drinks, Makeup, Milk Shake, Mascara, Meat Sauces, Medicine, Metallic Stains, Mildew, Milk, Milk Shake, Mouth Washes, Mud, Mustard, Nail Polish, Oil Spots, Oils—Motor, Olive Oil, Orange Juice, Oyster/Clam Chowder, Paints—
[0041] Acrylic, Paints—Latex, Pea Soup, Peanut Butter, Perfumes, Perspiration Stains, Pizza, Plastics, Polish—Shoe, Potatoes or Yams, Ravioli, Rice, Rouge, Rust, Salad Dressings, Saliva, Salsa, Scorch, Shellac, Sherbert—Ice Cream, Shoe Polish, Smoke Odors, Soft Drinks, Soot—Fire, Sour Cream, Soy Milk, Soy Sauce, Spaghetti, Spotting or Sizing Rings, Sugar Carmelized, Syrups, Tabasco Sauce, Tar—Road, Tar—Roof, Tea, Tobacco or Chew, Tomato Sauce, Tooth Paste, Turkey Gravy, Urine—Human, Varnish, Venison—Deer Meat, Vomit, Watercolors, Water Rings, Wines, Wood Stains, and Yogurt. Procedures for removing a subset of these stains are provided.
[0042] Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims. All equivalents, changes, and modifications that come within the spirit of the invention as described herein and/or by the following claims are desired to be protected.
[0043] For example, a person of ordinary skill in the computer software art will recognize that the client and/or server arrangements, user interface and display content, and/or data layouts as described in the examples discussed herein could be organized differently on one or more computers to include fewer or additional options or features than as portrayed in the examples and still be within the spirit of the invention.
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A interactive system for removing stains is provided. The system includes a software program loaded onto an all-in-one touch sensitive display. The program displays step-by-step stain removal instructions and educational information about the stains, fabrics, methods and tools used in the stain removal process. The program can be advanced by the touch of the finger to the screen or the by selecting the auto-play option. The stain removal process is aided by incorporating color labeled bottles of stain removal agents which match color coded text and images displayed in the instructional menus. The user experience is further enhanced by the use of photos and animations depicting fabrics and stains for identification and animations detailing the stain removal process.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a novel process for preparing 3-methyltetrahydrofuran, which is a useful substance as a comonomer of polytetramethylene ether glycol which is a raw material of elastic fibers called spandex fibers, or as a solvent for a specific use purpose.
2. Description of the Related Arts
As preparation methods of 3-methyltetrahydrofuran, various methods have heretofore been disclosed, and for example, there are a method which comprises the hydrogenation of citric acid (EP Disclosure No. 277562) and another method which comprises the hydrogenation of 4-hydroxy-2-methylbutane-1,2-epoxide (U.S. Pat. No. 3,956,318). However, these starting materials are less easily available, and therefore these methods are industrially impractical. In addition, a method which comprises the hydrogenation of methylmaleic acid or methylsuccinic acid (Japanese Patent Publication No. 9463/1974) has also been disclosed, but this starting material is scarcely available and what is worse, conditions for the hydrogenation are also severe. These inconveniences make its industrial practice difficult.
Furthermore, there is a method which comprises partially hydrogenating 1,4-butynediol to form 2-buten-,1,4-diol, hydroformylating and hydrogenating the thus formed 2-buten-1,4-diol to obtain 2-methyl-1,4-butanediol (U.S. Pat. No. 3,859,369), and then dehydrating/cyclizing this product in the presence of an acid catalyst to obtain 3-methyltetrahydrofuran. However, this method has some drawbacks. For example, the selectivity of 2-buten-1,4-diol by the partial hydrogenation of 1,4-butynediol is not sufficiently high, and the yield of the desired hydroformylation product of an internal olefin such as 2-buten-,1,4-diol is not sufficiently high, either.
In addition, a method has been disclosed which comprises the hydrogenation of β-formyl isobutyrate to obtain 3-methyltetrahydrofuran or 2-methyl-1,4-butanediol (Japanese Patent Application Laid-open No. 219981/1994). β-formyl isobutyrate which is a starting material in this method can be synthesized in a known manner such as the hydroformylation of a methacrylic acid ester [Bull. Chem. Soc. Japan, Vol. 50, p. 2351 (1977)], but the production of an α-isomer whose boiling point is close to that of β-formyl isobutyrate is not avoidable. Thus, a large amount of energy is required for its separation, and for this reason, the disclosed method is not considered to be industrially advantageous.
Under such circumstances, the present invention has been developed to solve the problems in the above-mentioned various manufacturing methods of 3-methyltetrahydrofuran, and an object of the present invention is to provide a process for preparing 3-methyltetrahydrofuran by an industrially advantageous procedure.
SUMMARY OF THE INVENTION
The present inventors have intensively researched with the intention of solving the above-mentioned problems. As a result, it has been found that the object of the present invention can be achieved by first synthesizing methylsuccinic acid diester from a methacrylic acid ester, carbon monoxide and a lower aliphatic alcohol as materials, and then hydrogenating and simultaneously dehydrating/cyclizing this diester to obtain 3-methyltetrahydrofuran. The present invention has been completed on the basis of this found knowledge.
That is to say, the present invention provides a process for preparing 3-methyltetrahydrofuran which comprises a step 1 of reacting a methacrylic acid ester with carbon monoxide and a lower aliphatic alcohol to synthesize a methylsuccinic acid diester, and a step 2 of hydrogenating and dehydrating/cyclizing the methylsuccinic acid diester which is the product of the step 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Next, a process of the present invention will be described in detail.
A methacrylic acid ester which is a starting material in the present invention can be manufactured industrially in large quantities as a monomer of polymethacrylates, and so it is inexpensively available. Carbon monoxide which is another material can be mass-produced as a water gas or an iron manufacturing gas, and so, needless to say, it is easily available. Furthermore, a lower aliphatic alcohol can be recovered after the hydrogenation reaction of a methylsuccinic acid diester in a step 2, and in principle, it is not consumed. As understood from the above, according to the process of the present invention, the materials which are all inexpensively available can be used, and so 3-methyltetrahydrofuran can be prepared in a high selectivity. In consequence, the process of the present invention has an industrially extremely high significance. The preparation process of 3-methyltetrahydrofuran according to the present invention can schematically be shown by the following reaction formulae ##STR1## wherein R and R' are each an alkyl group; [I] is a methylsuccinic acid diester; and [II] is 3-methyltetrahydrofuran. Here, R is preferably an alkyl group having 1 to 8 carbon atoms, and R' is preferably an alkyl group having 1 to 8 carbon atoms.
The reaction of the methacrylic acid ester with carbon monoxide and the lower aliphatic alcohol in the step 1 of the present invention can be carried out under various conditions, but preferably, the reaction is done in the presence of an element belonging to any of the group 8 to 10 of the periodic table, i.e., a catalyst containing an element belonging to any of the group 8 to 10 of the periodic table, or its compound. The methacrylic acid ester which can be used in this reaction is usually an alkyl methacrylate (wherein an alkyl group has 1 to 8 carbon atoms), and typical examples of the alkyl methacrylate include methyl methacrylate, ethyl methacrylate, propyl methacrylate, isopropyl methacrylate and butyl methacrylate. They are all usable from the viewpoint of reactivity, but in view of easy availability, methyl methacrylate is suitable. Furthermore, the lower aliphatic alcohol is usually an aliphatic alcohol having 1 to 8 carbon atoms, and typical examples of the lower aliphatic alcohol include methanol, ethanol, n-propanol, iso-propanol and n-butanol.
A practical system in the step 1 of the present invention may suitably be selected in compliance with various situations, but a homogeneous liquid phase system is preferable. In this homogeneous liquid phase system, the methacrylic acid ester as the material is mixed with the lower aliphatic alcohol and the catalytic component, and the mixture is then treated at a predetermined temperature for a predetermined period of time under an increased pressure of carbon monoxide to accomplish the above-mentioned step 1. No particular restriction is put on a molar ratio of the lower aliphatic alcohol to the methacrylic acid ester, but this ratio is preferably in the range of 0.1 to 50 mol, more preferably 0.5 to 10 mol. In addition, carbon monoxide is consumed as the reaction material, and it simultaneously plays the role of highly maintaining the activity of an element belonging to any of the group 8 to 10 of the periodic table or its compound which can be used as the catalyst. In this step 1, therefore, the reaction is carried out under an increased pressure of usually 1 to 300 kg/cm 2 (gauge pressure), preferably 5 to 200 kg/cm 2 (gauge pressure). Carbon monoxide which can be used in the process of the present invention is never required to be highly pure, and so carbon monoxide containing methane, hydrogen, nitrogen or the like can also be used without any problem, so long as the partial pressure of carbon monoxide can be secured. Examples of the element belonging to any of the groups 8 to 10 of the periodic table which can be used as the catalyst include iron, cobalt, nickel, ruthenium, rhodium, palladium, osmium, iridium and platinum, and they can be used as the catalyst singly or in the form of a mixture of two or more thereof. Of these compounds enumerated above, cobalt and ruthenium are particularly suitable as the catalytic component. The compound containing the element in the groups 8 to 10 of the periodic table which can be used as the catalyst can be used in the form of a halide, a salt of an organic acid or an inorganic acid, a carbonyl compound or a phosphine coordination compound, but the carbonyl compound is particularly suitable. The amount of the element in the groups 8 to 10 of the periodic table which can be used as the catalyst in the present invention is usually in the range of 0.1 to 200 mmol, preferably 1 to 50 mmol with respect to 1000 ml of the reaction solution.
Furthermore, in order to increase a reaction rate, a suitable promotor can be added to the system. Examples of a compound which can be used as the promotor include tertiary amines, tertiary phosphine compounds, and organic and inorganic halides, and they may be used singly or in a combination of two or more thereof.
Typical examples of the tertiary amines include trimethylamine, triethylamine, N,N,N',N'-tetramethylethylenediamine, pyridine, N,N-dimethylaminopyridine and lutidine.
Typical examples of the tertiary phosphine compounds include triphenylphosphine, tributylphosphine, tricyclohexylphosphine, bis(diphenylphosphino)ethane, bis(diphenylphosphino)propane and bis(diphenylphosphino)butane.
Typical examples of the organic halides include tetramethylammonium iodide, tetramethylammonium bromide, tetramethylammonium chloride, methyltriphenylphosphonium iodide, methyltriphenylphosphonium bromide, methyltriphenylphosphonium chloride, methyl iodide, methyl bromide, ethyl iodide and ethyl bromide.
Typical examples of the inorganic halides include lithium iodide, lithium bromide, lithium chloride, sodium iodide, sodium bromide, sodium chloride, potassium iodide, potassium bromide, potassium chloride, magnesium iodide, magnesium bromide and magnesium chloride.
The combination and the amount of these promotors can be decided in compliance with the selected catalyst.
In the practice of the process of the present invention, it is possible to use a reaction solvent. As the reaction solvent, the reaction material itself can utilized as the reaction solvent, but no particular restriction is put on a kind of the reaction solvent, so long as it is stable in the reaction system and does not disturb the desired reaction. Thus, the reaction solvent can be selected from the group consisting of aliphatic hydrocarbons, aromatic hydrocarbons, ethers, ketones, esters and amides. A reaction temperature in the process of the present invention is usually in the range of 50° to 350° C., preferably 100° to 250° C.
The methylsuccinic acid diester which is a reaction product in the step 1 of the present invention is separated from the catalytic component by an operation such as distillation or extraction if necessary, and it is then fed to the following hydrogenation and dehydration/cyclization reaction (the step 2).
The hydrogenation and the dehydration/cyclization reaction in the step 2 of the present invention can be allowed to proceed under various conditions, but it is preferable that they proceed in the presence of a catalyst. The suitable catalyst contains at least one selected from the group consisting of copper, copper compounds, metals in the groups 7 to 10 of the periodic table, and metallic compounds thereof. More specifically, examples of the principal effective component of the catalyst for the reaction in the step 2 include copper, cobalt, nickel, iron, rhenium, palladium, ruthenium, platinum and rhodium. Furthermore, a promotor can effectively be used, and the suitable promotor is a solid acidic component containing chromium, molybdenum, manganese, barium, magnesium, silicon or aluminum. The catalyst which is particularly suitable for the reaction in the step 2 is a catalyst usually called copper-chromite containing copper as the principal component and containing manganese or barium as the promotor component. The hydrogenation and the dehydration/cyclization reaction in the step 2 of the present invention can be carried out at a reaction temperature of about 100° to 300° C. under a reaction pressure of about 20 to 200 kg/cm 2 (gauge pressure), depending upon the selected catalytic component and the reaction conditions. In the case that the particularly suitable copper-chromite is used as the catalyst in the step 2 of the present invention, the reaction temperature is suitably in the range of 180° to 280° C., and the reaction pressure is suitably in the range of 50 to 200 kg/cm 2 (gauge pressure). Hydrogen which can be used in the reaction is preferably pure hydrogen, but hydrogen containing methane, nitrogen or the like is also usable.
As the catalyst for use in the hydrogenation reaction in the step 2, a copper-chromium-manganese (or barium) catalyst is preferable, and for example, it can be prepared by the following procedure.
(1) Solid cupric oxide (CuO), chromium oxide (Cr 2 O 3 ) and manganese dioxide (MnO 2 ) [or barium oxide (BaO)] are mixed with one another, and graphite or the like is further added as a lubricant. After sufficient mixing, the mixture is molded in a usual manner, and the molded article is calcined at a high temperature, crushed to a suitable size, and then used.
(2) Aqueous ammonia is added to an aqueous solution containing dissolved ammonium bichromate, and another aqueous solution in which cupric nitrate (or cupric sulfate) and manganese nitrate (or manganese sulfate) or barium nitrate are dissolved is then added dropwise to the above-mentioned aqueous solution with stirring. The resulting precipitate is washed with water, dried, and then calcined at a temperature of about 350° C. in air. The thus calcined powder obtained in this manner can directly be used for the reaction, but a suitable binder and lubricant can be added to this calcined powder, and they can sufficiently be mixed, molded, and then used.
A weight ratio of the respective components contained in the copper-chromium-manganese (or barium) catalyst obtained in the manner of the above-mentioned (1) or (2), i.e., CuO:Cr 2 O 3 :MnO 2 (or BaO) is preferably in the range of 20-85:15-75:1-15. The catalyst may be used in the form of powder or tablets, and the optimum form of the catalyst can be selected in compliance with its use purpose. Prior to use in the reaction, the catalyst can be subjected to a suitable activation treatment such a treatment in a hydrogen atmosphere at about 200° C. In the practice of the reaction in the step 2 of the present invention, the amount of hydrogen is 4 mol or more, preferably 6 to 60 mol per mol of the ester supplied for reaction.
In the present invention, the reaction solution containing 3-methyltetrahydrofuran prepared by the hydrogenation and the dehydration/cyclization reaction is subjected to a usual distillation operation to separate and purify 3-methyltetrahydrofuran, whereby desired 3-methyltetrahydrofuran can easily be obtained.
According to the present invention, the treatments in the respective steps proceed in high yields, and what is better, 3-methyltetrahydrofuran can efficiently be obtained from the inexpensive starting materials. Accordingly, the present invention has an industrially extremely high merit.
Next, the present invention will be described in more detail with reference to examples, but the scope of the present invention should not be limited to these examples.
(Step 1)
EXAMPLE 1
In a 100-ml stainless steel autoclave equipped with a thermometer and a pressure gauge were placed 3.0×10 -2 mol of methyl methacrylate, 0.2 mol of methanol, 1.0×10 -4 mol of Ru 3 (CO) 12 as a catalyst and 5.0×10 -4 mol of methyltriphenylphosphonium iodide (Ph 3 PMeI) as a promotor. The reactor was sufficiently purged with a carbon monoxide gas, and the carbon monoxide gas was filled into the reactor up to 20 kg/cm 2 (gauge pressure). Next, the reactor was immersed in an oil bath maintained at 165° C., and a reaction solution was then stirred by a magnetic stirrer, whereby reaction was carried out for 4 hours. The reaction solution was analyzed by gas chromatography, and as a result, it was apparent that the conversion of methyl methacrylate was 54%, and the selectivity of dimethyl methylsuccinate was 88.0% and the selectivity of methyl isobutyrate was 4.0%.
EXAMPLE 2
The same procedure as in Example 1 was repeated except that 1.5×10 -3 mol of Co 2 (CO) 8 as a catalyst and 3.0×10 -3 mol of pyridine as a promotor were used and carbon monoxide was filled up to a pressure of 50 kg/cm 2 (gauge pressure). As the results of analysis, the conversion of methyl methacrylate was 40%, and the selectivity of dimethyl methylsuccinate was 80.5% and the selectivity of methyl isobutyrate was 3.2%.
(Step 2)
EXAMPLE 3
A stainless steel reaction tube having an inner diameter of 15 mm and a length of 300 mm was used as a hydrogenation reactor, and 10 g of a copper-chromite catalyst (G-99C, made by Nissan Gardler Co., Ltd.) having a uniform size of 10 to 20 mesh was filled into the reaction tube. Next, the catalyst was reduced at 150° to 200° C. with a nitrogen-hydrogen mixing gas containing 0.5 to 5% by volume of hydrogen in a usual manner under such conditions as not to form hot spots.
The catalytic component was separated and the dimethyl methylsuccinate was isolated in a usual manner (distillation under reduced pressure) from the reaction solution obtained in Example 1. Next, 70 parts by weight of the xylenes (a mixture of xylene isomers and ethylbenzene) was added to 30 parts by weight of this dimethyl methylsuccinate to prepare a feed material for hydrogenation and dehydration/cyclization reaction. The feed gas to the hydrogenation reactor was switched to pure hydrogen, and in this case, pressure was 160 kg/cm 2 (gauge pressure), the space velocity (SV) of the purge gas was 500 hr -1 , and the temperature of the catalyst layer was 230° C. The reaction material was fed to the reaction tube through its upper portion at a feed rate of 3.3 g per hour. After cooling, the reaction product was subjected to gas-liquid separation, and the resulting liquid phase portion was then analyzed by gas chromatography. After 5 hours from the start of the reaction, the reaction product was collected for 1 hour, and then analyzed. As a result, the yield of 3-methyltetrahydrofuran was 95.2%, and that of 2-methylbutanediol was 0.4%.
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A process for preparing 3-methyltetrahydrofuran is herein disclosed which comprises reacting a methacrylic acid ester with carbon monoxide and a lower aliphatic alcohol to obtain a methylsuccinic acid diester, and hydrogenating and dehydrating/cyclizing this methylsuccinic acid diester. According to this process, 3-methyltetrahydrofuran can efficiently be obtained from inexpensive starting materials.
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FIELD OF THE INVENTION
[0001] The present invention is related to animal feed, particularly to poultry and swine feed.
DESCRIPTION OF RELATED ART
[0002] It is generally known in the art that color affects feeding behavior of animals. Several scientific and anecdotal studies have demonstrated that color is a stimulus for feed consumption, both alone and in combination with other factors. However, despite the body of knowledge on the effects of color and colored feed on feeding behaviour, attempts at efficiently incorporating color into animal feed, particularly on a large scale, especially in a feed mill, have been largely unsuccessful. Thus, there remains a need for colored animal feed, ways to color animal feed efficiently, and large-scale processes for coloring animal feed, especially in a feed mill.
SUMMARY OF THE INVENTION
[0003] According to a first aspect of the invention, there is provided a concentrate for preparing a colored animal feed comprising: from about 1 wt % to about 15 wt % of a physiologically acceptable feed consumption enhancing food-coloring agent compatible with animal feed ingredients; from about 2 wt % to about 20 wt % of a physiologically acceptable electrolyte compatible with animal feed ingredients; and, balance a physiologically acceptable carrier, all weights based on weight of the concentrate.
[0004] According to a second aspect of the invention, there is provided a process for preparing colored animal feed, the process comprising: providing a concentrate having from about 1 wt % to about 15 wt % of a physiologically acceptable feed consumption enhancing food-coloring agent compatible with animal feed ingredients, from about 2 wt % to about 20 wt % of a physiologically acceptable electrolyte compatible with the animal feed ingredients and balance a physiologically acceptable carrier, all weights based on weight of the concentrate; mixing the concentrate with animal feed ingredients; and, further processing the mixture into colored animal feed.
[0005] According to a third aspect of the invention, there is provided a process for preparing colored animal feed, the process comprising: providing a concentrate having from about 1 wt % to about 15 wt % of a physiologically acceptable feed consumption enhancing food-coloring agent compatible with animal feed ingredients, from about 2 wt % to about 20 wt % of a physiologically acceptable electrolyte compatible with the animal feed ingredients and balance a physiologically acceptable carrier, all weights based on weight of the concentrate; mixing the concentrate with animal feed ingredients at a mixer in a feed mill where most of the animal feed ingredients are mixed; and, further processing the mixture into colored animal feed.
[0006] According to a fourth aspect of the present invention, there is provided a process for preparing colored animal feed, the process comprising: mixing animal feed ingredients to form a mash; applying a concentrate to the mash before pelletizing the mash, the concentrate having from about 1 wt % to about 15 wt % of a physiologically acceptable feed consumption enhancing food-coloring agent compatible with the animal feed ingredients, from about 2 wt % to about 20 wt % of a physiologically acceptable electrolyte compatible with the animal feed ingredients and balance a physiologically acceptable carrier, all weights based on weight of the concentrate; pelletizing the mash to form colored pellets; and, further processing the colored pellets into colored animal feed.
[0007] According to a fifth aspect of the present invention, there is provided a process for preparing colored animal feed, the process comprising: mixing animal feed ingredients to form a mash; pelletizing the mash to form pellets; applying a concentrate to the pellets to form colored pellets, the concentrate having from about 1 wt % to about 15 wt % of a physiologically acceptable feed consumption enhancing food-coloring agent compatible with the animal feed ingredients, from about 2 wt % to about 20 wt % of a physiologically acceptable electrolyte compatible with the animal feed ingredients and balance a physiologically acceptable carrier, all weights based on weight of the concentrate; and, further processing the colored pellets into colored animal feed.
[0008] According to a sixth aspect of the invention, there is provided a colored animal feed comprising: about 30-40 wt % corn, about 10-30 wt % wheat, about 10-15 wt % soya bean, about 5-10 wt % canola, about 0.05-0.25 wt % of a physiologically acceptable mineral, about 0.01-0.05 wt % of a physiologically acceptable enzyme, a physiologically acceptable feed consumption enhancing food-coloring agent and a physiologically acceptable electrolyte, all weights based on weight of the animal feed.
[0009] According to a seventh aspect of the invention, there is provided a method for enhancing consumption of animal feed by an animal, the method comprising: mixing a concentrate with a physiological acceptable diluent to form a mixture, the concentrate having from about 1 wt % to about 15 wt % of a physiologically acceptable feed consumption enhancing food-coloring agent compatible with animal feed ingredients, from about 2 wt % to about 20 wt % of a physiologically acceptable electrolyte compatible with animal feed ingredients and balance a physiologically acceptable carrier, all weights based on weight of the concentrate; applying the mixture to animal feed to form colored animal feed; drying the colored animal feed; providing the colored animal feed to the animal; and, allowing the animal to eat the colored animal feed.
[0010] According to a eighth aspect of the invention, there is provided a method of increasing weight gain of an animal, the method comprising: preparing a colored animal feed from a concentrate, the concentrate having from about 1 wt % to about 15 wt % of a physiologically acceptable feed consumption enhancing food-coloring agent compatible with the animal feed ingredients; from about 2 wt % to about 20 wt % of a physiologically acceptable electrolyte compatible with the animal feed ingredients; and, balance a physiologically acceptable carrier, all weights based on weight of the concentrate; and, feeding the colored animal feed to the animal.
Concentrates:
[0011] Food-coloring agents used in concentrates of the present invention are physiologically acceptable insofar as they do not cause undue adverse reactions in an animal at amounts typically consumed by the animal eating a feed prepared using the concentrate. Furthermore, the food-coloring agent is compatible with animal feed ingredients insofar as the coloring agent does not react with other feed ingredients to unduly produce undesirable side-products. Preferably, the food-coloring agent can be mixed with the animal feed ingredients in a generally uniform manner. Preferably, the food-coloring agent is approved for use in animal feeds by the pertinent regulatory body of the state in which the feed is to be used.
[0012] The color of the food-coloring agent is one that enhances consumption of animal feed by the animal. Preferably, the color is red or blue, more preferably red. Colors can have different shades, tones and/or tints and the shades, tones and tints of a color included in the scope of that color. Some shades of red include, for example, scarlet, crimson, vermilion, carmine, maroon, burgundy, ruby, rose, madder, rouge, brick, blood red, blush, fire engine red, cinnabar, russet, rust, Venetian red, flame, Indian red and tomato. Some shades of blue include, for example, azure, cerulean, cobalt, cornflower blue, denim, dodger blue, International Klein blue, midnight blue, navy blue, periwinkle, powder blue, Prussian blue, royal blue, steel blue and ultramarine blue. A particularly preferred example of a red food-coloring agent is FD & C Red #40 dye. Mixtures of food-coloring agents may be used.
[0013] The food-coloring agent is present in the concentrate in an amount of from about 1 wt % to about 15 wt % based on the weight of the concentrate. Preferably, the amount of food-coloring agent is from about 2 wt % to about 10 wt %. An amount of from about 3 wt % to about 7 wt % is of particular note.
[0014] Electrolytes used in concentrates are physiologically acceptable insofar as they do not cause undue adverse reactions in an animal at amounts typically consumed by the animal eating a feed prepared using the concentrate. Furthermore, the electrolyte is compatible with animal feed ingredients insofar as the electrolyte does not react with other feed ingredients to unduly produce undesirable side-products. Preferably, the electrolyte can be mixed with the animal feed ingredients in a generally uniform manner. Electrolytes may be selected for their ability to help disperse or dissolve the food-coloring agent in the carrier and/or other animal feed ingredients to help ensure a more homogeneous dispersal of the coloring agent in the feed.
[0015] Some examples of electrolytes are salts (e.g. alkali metal salts, alkaline earth metal salts, halide salts, phosphates, sulphates, nitrates, etc.), sugars (e.g. sucrose, dextrose, fructose, mannose, etc.) and mixtures thereof. Preferred examples of electrolytes are sodium chloride, potassium chloride, magnesium chloride, magnesium sulphate, dextrose and mixtures thereof.
[0016] The electrolyte is present in the concentrate in a total amount of from about 2 wt % to about 20 wt % based on the weight of the concentrate. Preferably, the amount of electrolyte is from about 3 wt % to about 15 wt %. An amount of from about 4 wt % to about 10 wt % is of particular note.
[0017] In general, electrolytes help correct dehydration and electrolyte loss in animals during periods of stress caused by placement and/or movement of the animals. Standard electrolyte mixtures may be used in the preparation of the concentrate. For poultry and swine, for example, electrolyte mixtures listed in the Compendium of Medications for Poultry , Poultry Industry Council, Guelph, Ontario 2001 may be used.
[0018] The concentrate may contain other animal feed ingredients, particularly micro ingredients, if desired.
[0019] A physiologically acceptable carrier forms the balance of the concentrate. Physiologically acceptable carriers are capable of forming relatively homogeneous dispersions or solutions with the food-coloring agent and electrolytes, and do not cause undue adverse reactions in an animal ultimately eating the carrier. Carriers are preferably liquid. More preferably, the carrier is water. Preferably, the carrier is purified. Carriers may be purified by any known technique. For example, liquid carriers may be purified by distillation, reverse osmosis, filtration, ion exchange chromatography, etc. Liquid carriers may also serve to “activate” the coloring agent since some coloring agents require the presence of a liquid medium in order for the color to be homogeneously distributed throughout the resultant feed at the end of a milling process.
[0020] Concentrates may be prepared by mixing the coloring agent, electrolytes and carrier, together with any other desired ingredients, to form a generally homogeneous blend or solution.
[0021] Concentrates of the present invention are surprisingly advantageous in that they can be used at any number of feed processing steps to successfully prepare colored animal feed, especially on a large scale in a feed mill. Such versatility permits tailoring of feed processing to meet the needs of a particular operation.
Colored Animal Feed and Processes for Preparation Thereof:
[0022] Animal feeds typically contain a wide variety of ingredients to provide a well-balanced diet. Feeds may also contain pharmaceutical and/or nutraceutical ingredients to provide enhanced health for the animals. The nature and proportion of the ingredients in the feed depend on many factors, for example, the type of animal, the age of the animal, nutritional requirements of the animal, individual feed producer preference and the cost of ingredients. Feed compositions may change from week to week due to such factors. Concentrates of the present invention may be used to produce colored feed of any composition.
[0023] Concentrates of the present invention are particularly advantageous in preparing colored pre-starter and starter feeds. Preferably, concentrates are used to produce feed for swine and poultry (e.g. chickens (layers, broilers, roasters, etc.) and turkeys). Concentrates are more particularly advantageous for preparing colored pre-starter and starter feeds for poultry and swine, especially poultry.
[0024] A typical feed contains macro ingredients, micro ingredients and liquid ingredients. Macro ingredients are typically used in a feed milling process in relatively large amounts and in dry form. Micro ingredients are typically used in relatively small amounts and in dry form. Macro ingredients may include, for example, grains (e.g. wheat, barley, canola, oats, flax, etc.), rolled corn, soya bean meal, protein meals of various types, some minerals sources, fillers, etc. Micro ingredients may include, for example, vitamins, some minerals, enzymes, amino acids, salts, antibiotics, probiotics, organic acids, buffers, etc. Liquid ingredients may include, for example, fats, greases, methionine, etc. Feed compositions are well within the ability of one skilled in the art to produce and the exact feed composition produced by any one feed supplier is often proprietary.
[0025] In a typical feed milling process, the various ingredients are stored in tanks and fed through feed lines to a main mixing tank. Some of the ingredients, for example the micro ingredients, may be pre-mixed in batches and then fed to a main mixer. Other ingredients, for example grains, may be ground before being fed into the mixer. Other pre-mixing processing steps may be used as desired or required. A carrier, for example water, may be used when needed to ensure that ingredients are carried into and mixed in the mixer. The ingredients may be mixed in the main mixer, preferably in a batch of 0.5-3 metric tonnes, to form a mash. The mash is pelletized, and expanded if desired. Pellets are then distributed into containers for bulk shipping. The mill is flushed after each feed order is made in compliance with Hazard Analysis Critical Control Points (HACCP) or like regulations.
[0026] Concentrates may be advantageously employed at any of a number of stages of the process to impart color to the feed. In one embodiment, the concentrate may be added to the mixer and mixed together where most of the other feed ingredients are mixed. The concentrate may be added to the mixer by any convenient means, for example by feeding from a storage tank or by pouring from a pail. In another embodiment, the concentrate may be added to the mash after mixing of the ingredients but before pelletizing, for example when the mash is expanded. In yet another embodiment, the concentrate may be added to the feed after pelletizing but before distribution into containers. The concentrate may be used in any amount that imparts sufficient color to the feed. For example, the concentrate is preferably used in an amount of from about 5-20 kg concentrate per 1000 kg feed (0.5-2 wt %), more preferably 7-15 kg per 1000 kg (0.7-1.5 wt %), for example 12 kg per 1000 kg (1.2 wt %).
[0027] In still yet another embodiment, the concentrate may be applied to feed in a barn or other animal feeding location. Preferably, the concentrate is diluted with an appropriate amount of diluent and applied directly to the feed. The diluent is preferably the same as the carrier used in the concentrate (e.g. water). The volume ratio of diluent:concentrate is preferably in a range of from about 200:1 to about 10:1, more preferably from about 150:1 to about 25:1. Application may be accomplished by any suitable technique, for example, spraying, pouring, dipping, etc. Spraying is preferred as it permits more even application of the color. The colored animal feed is allowed to dry before providing the colored feed to the animals.
Methods of Use of Colored Animal Feed:
[0028] Colored animal feed is useful for enhancing feed consumption by animals and for increasing weight gain of animals. It is believed that the color attracts animals to the feed thereby encouraging them to eat more. This increases the likelihood of survival of the animal as well as overall weight gain of the animal.
[0029] Colored animal feed has been found to be particularly useful for new born and young animals. Particularly in the first 7 days of the animal's life, a small increase in weight will lead to better survivability and a much heavier shipping weight. This increases profitability of the animal growing operation. Therefore, enhancing feed consumption and increasing weight gain in the first 7 days is particularly important. Colored animal feed prepared in accordance with the present invention is particularly useful in the first 7 days of the animal's life.
[0030] Colored animal feed prepared in accordance with the present invention is particularly useful for enhancing feed consumption and weight gain of poultry and swine, more particularly of poultry. Poultry includes, for example, chickens (e.g. layers, broilers, roasters, etc.) and turkeys.
[0031] In respect of broiler chickens, for example, it has been shown in the art that anatomic changes in the digestive tract during the first days of life are remarkable. Broilers achieve a maximum relative weight of the digestive organs when they are between 3 and 8 days of age. The highest increase in volume of villi in the duodenum occurs when the birds are 4 days old and in the jejunum and ileum when they are 10 days old. If the birds don't achieve the maximum development of the villi in the duodenum in the first week and the jejunum and ileum in the second week, they are likely to have difficulty in developing good digestion and absorption capacities during their lives.
[0032] For optimal results, all other factors that affect the health of the animals should be controlled to industry standard. These include, for example, ventilation, cleanliness of living area, feeder placement, availability of fresh water, temperature, humidity, light, etc. Such factors are well known to one skilled in the art.
[0033] Further features of the invention will be described or will become apparent in the course of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] In order that the invention may be more clearly understood, a preferred embodiment thereof will now be described in detail by way of example, with reference to the accompanying drawings, in which:
[0035] FIG. 1 is a schematic diagram of a feed milling operation; and,
[0036] FIG. 2 shows results for the effect on weight gain of broiler chicks of red colored feed prepared by a spray method.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Example 1
Preparation of Concentrates
[0037] A concentrate (12 kg) for coloring feed red was prepared by mixing the ingredients listed in Table 1 in a pail until a homogeneous mixture was formed:
[0000]
TABLE 1
Ingredient
Amount (g)
Purpose
FD & C Red #40 dye
500.0
Red colorant
Sodium chloride
300.00
Electrolyte
Potassium chloride
15.0
Electrolyte
Magnesium chloride
7.5
Electrolyte
Magnesium sulphate
7.5
Electrolyte
Dextrose
400.0
Electrolyte
Distilled water
10,770.0
Carrier
Total:
12,000.0
Example 2
Feed Compositions
[0038] A suitable red colored broiler chicken starter feed composition is provided in Table 2. This composition may be prepared in a feed mill in accordance with the process described in Example 3 below.
[0039] Limestone is a source of calcium. Mono-Dical Ca16/P21 is a source of phosphate. Alimet is a source of methionine. FF Broiler Micro Premix is a mixture of vitamins and minerals. Soda bicarb is sodium bicarbonate acting a pH buffer. Col-CI70 is choline chloride. Corn-soy enzyme is a mixture of glucanase and xylanase.
[0000]
TABLE 2
Ingredient
Amount (kg)
Corn Fine Rolled 8.0% CP
494.37
Soya Bean Meal (SBM) 47.5% CP
123.45
Canola Meal 37% CP
100.00
Meat and Bone Meal 50% CP
100.00
Wheat HRS Western 13% CP
75.00
Wheat Shorts 16% CP
71.60
Concentrate of Example 1
12.00
Poultry Fat
10.00
Limestone B2 Grade
4.10
Salt white mixing
2.40
Mono-Dical Ca16/P21
2.00
Alimet 88%
1.68
FF Broiler Micro (1 kg) Premix
1.25
Lysine-HCl
0.75
Soda bicarb - BP
0.50
Copper sulphate (25)
0.40
Chol-Cl70
0.30
Corn-soy enzyme
0.20
Total:
1000.00
Example 3
Process for Preparing Feed Compositions
[0040] Referring to FIG. 1 , the composition as described in Example 2 may be prepared in a feed mill as follows.
[0041] Corn, wheat HRS and wheat screenings are stored in external bins 1 , 2 , 3 respectively and fed to grinder 25 through lines 101 , 102 , 103 respectively where they are ground separately. Ingredients from grinder 25 are fed through line 121 and distributed to bins 4 , 5 , 6 in central storage area 30 of the feed mill where each ground ingredient is stored separately. Soya bean meal, canola meal, wheat shorts and meat and bone meal are stored in bins 7 , 8 , 9 , 10 respectively in central storage area 30 . Limestone, salt and mono dical are stored in bins 11 , 12 , 13 respectively in central storage area 30 . FF Broiler Premix, lysine, soda bicarb and copper sulphate are stored in bins 14 , 15 , 16 , 17 respectively. Another micro ingredient may be stored in bin 18 , if desired. Barrels 23 , 24 for storing, respectively, corn-soy enzyme and phytase, if desired, are proximal to the micro ingredients. The concentrate of Example 1 is stored in tank 19 , Alimet in tank 20 , choline chloride in tank 21 and poultry fat in tank 22 .
[0042] Dry ingredients in central storage area 30 are fed in the amounts listed in Table 2 on to scales 31 , 32 and then to main mixer 40 . Micro ingredients are weighed on micro scale 35 and then fed to mixer 40 through line 124 . Liquid ingredients in tanks 18 , 19 , 20 , 21 are fed into mixer 40 through lines 125 , 126 , 127 , 128 .
[0043] Mixing of the ingredients in mixer 40 produces a red colored mash which is fed through line 130 to conditioner 50 . Steam and water added at the conditioner intensifies the red color. The mash is then fed to expander 52 and pelletizer 54 where red colored pellets are formed from the mash. Expander 52 improves pellet quality, improves nutrient digestibility and reduces microbial levels. Red colored pellets are transferred from pelletizer 54 to cooler 60 and then through line 150 to post pelleting application system 70 . Fat from tank 22 through line 140 , corn-soy enzyme from barrel 23 and phytase, if desired, from barrel 24 are applied to the pellets at post pelleting application system 70 . From the post pelleting application system finished feed is transferred to bins in bulk shipping storage area 80 . Bulk feed from bulk shipping storage area 80 may be loaded into trucks, rail cars, shipping containers, etc.
Example 4
Methods of Use of Colored Feed
[0044] The effect of red colored feed on weight gain of broiler chicks in an industrial scale setting was examined.
Spray Method:
[0045] A sprayable red colored dye solution was prepared by mixing 50 ml of a 15% (w/v) concentrate solution of red dye with 7 litres of distilled water to form a homogeneous solution. A broiler chicken starter feed having a composition as listed in Table 3 was prepared in a process similar to the one described in Example 3.
[0000]
TABLE 3
Ingredient
Amount (kg)
Corn Fine Rolled 8.0% CP
506.37
Soya Bean Meal (SBM) 47.5% CP
123.45
Canola Meal 37% CP
100.00
Meat and Bone Meal 50% CP
100.00
Wheat HRS Western 13% CP
75.00
Wheat Shorts 16% CP
71.60
Poultry Fat
10.00
Limestone B2 Grade
4.10
Salt white mixing
2.40
Mono-Dical Ca16/P21
2.00
Alimet 88%
1.68
FF Broiler Micro (1 kg) Premix
1.25
Lysine-HCl
0.75
Soda bicarb - BP
0.50
Copper sulphate (25)
0.40
Chol-Cl70
0.30
Corn-soy enzyme
0.20
Total:
1000.00
[0046] The feed was spread on paper in brooding areas on 16 floors of six barns. On each floor in each barn the feed was spread evenly on the paper to provide about 50-70 grams of feed per bird (about 3 days supply). On 10 floors of the six barns, the feed was sprayed evenly with the sprayable red colored dye solution described above using a backpack sprayer. Each barn had one floor of feed that remained uncolored. The dye solution was allowed to dry and the barn conditions between each floor in a barn were optimized and standardized in accordance with Horizon Poultry Excellence Program Standard Operating Procedures. On each floor, newly hatched broiler chicks were tipped onto the paper and allowed to feed themselves. From Day 3 onward, birds on all floors in all barns were fed the same feed containing no red colored dye.
[0047] Bird weights were taken three times per day from six different areas on each floor each day. For each weighing, 10 birds were randomly selected from each of the six areas on each floor of each barn. Average daily weights were calculated for each floor of each barn. Results are illustrated in FIG. 2 and weights at Day 0, Day 7 and Day 20 are summarized in Table 4.
[0000]
TABLE 4
Feed
Day 0
Day 7
Weight
Day 20
Weight
Color
Weight (g)
Weight (g)
gain (g)
Weight (g)
gain (g)
A
Regular
46.00
142.00
96.00
637.00
591.00
B
Red
43.00
150.17
107.17
693.50
650.50
C
Red
42.67
125.00
82.33
508.00
465.33
D
Regular
42.67
125.00
82.33
496.00
453.33
E
Red
42.67
130.00
87.33
512.00
469.33
F
Red
42.43
135.00
92.57
—
—
G
Regular
42.43
124.00
81.57
—
—
H
Regular
43.52
124.00
80.48
—
—
I
Red
43.52
130.00
86.48
—
—
J
Red
43.52
138.00
94.48
—
—
K
Regular
43.50
132.00
88.50
—
—
L
Red
43.50
139.00
95.50
—
—
[0000]
Barn
Floor
Sex of Bird
A
Griffith
Floor 1
pullets
B
Griffith
Floor 2
pullets
C
Lynch 1
Floor 1
cockerals
D
Lynch 1
Floor 2
cockerals
E
Lynch 1
Floor 3
cockerals
F
Lynch 2
Floor 1
pullets
G
Lynch 2
Floor 2
pullets
H
Berlett 2
Floor 1
cockerals
I
Berlett 2
Floor 2
cockerals
J
Berlett 2
Floor 3
cockerals
K
Bell 1
Floor 1
pullets
L
Bell 1
Floor 2
pullets
[0048] Inspection of FIG. 2 and Table 4 shows that broiler chicks, whether male (cockerals) or female (pullets), consistently gain more weight after 7 days when fed red colored starter feed rather than regular, uncolored starter feed of the same nutrient composition. The increased weight gain in the first 7 days was magnified over 20 days even though all birds received the same feed from Day 3 onward.
[0049] FIG. 2 also provides idealized performance data for male (cockerel) and female (pullet) Ross 308 broilers. Weight gain profiles for broiler chicks fed red colored starter feed compare favourably with the idealized data. Data collected from the Griffith barn shows weight gains exceeding the idealized data for female broiler chicks fed red colored feed. In FIG. 2 , the shaded numbers are from days that weights were not taken due to either extreme heat or other emergencies on the farm. The data entered for these dates have been calculated by taking the (previous day+following day)/2.
Milling Method:
[0050] Regular and red colored broiler chicken starter feeds were prepared in separate milling processes, both processes following a procedure similar to the one described in Example 3. For the red colored feed, a concentrate as described in Example 1 was added in the main mixer by pouring 12 kg of the concentrate into the mixer using a pail. The compositions of the regular and red colored feeds are provided in Table 5.
[0000]
TABLE 5
Regular Feed
Red Colored Feed
Ingredient
Amount (kg)
Amount (kg)
Corn Fine Rolled 8.0% CP
506.37
494.37
Soya Bean Meal (SBM) 47.5% CP
123.45
123.45
Canola Meal 37% CP
100.00
100.00
Meat and Bone Meal 50% CP
100.00
100.00
Wheat HRS Western 13% CP
75.00
75.00
Wheat Shorts 16% CP
71.60
71.60
Poultry Fat
10.00
10.00
Limestone B2 Grade
4.10
4.10
Salt white mixing
2.40
2.40
Mono-Dical Ca16/P21
2.00
2.00
Alimet 88%
1.68
1.68
FF Broiler Micro (1 kg) Premix
1.25
1.25
Lysine-HCl
0.75
0.75
Soda bicarb - BP
0.50
0.50
Copper sulphate (25)
0.40
0.40
Chol-Cl70
0.30
0.30
Corn-soy enzyme
0.20
0.20
Red concentrate of Example 1
0.00
12.00
Total:
1000.00
1000.00
[0051] The feed was spread on paper in brooding areas on five floors of two barns. On each floor in each barn feed was spread evenly on the paper to provide about 50-70 grams of feed per bird (about 3 days supply). Each barn had one floor of regular feed. One barn had two floors of red colored feed and the other barn had one floor of red colored feed. The barn conditions between each floor in a barn were optimized and standardized in accordance with Horizon Poultry Excellence Program Standard Operating Procedures. On each floor, newly hatched cockerel broiler chicks were tipped onto the paper and allowed to feed themselves. From Day 3 onward, birds on all floors in all barns were fed the same uncolored feed.
[0052] Bird weights were taken three times per day from six different areas on each floor each day. For each weighing, 10 birds were randomly selected from each of the six areas on each floor of each barn. Average daily weights were calculated for each floor of each barn. Results are summarized in Table 6.
[0000]
TABLE 6
Smith 1
Smith 1
Smith 1
Smith 2
Smith 2
Floor 1
Floor 2
Floor 3
Floor 1
Floor 2
Regular
Red
Red
Regular
Red
Weight (g)
Weight (g)
Weight (g)
Weight (g)
Weight (g)
Day 0
46.00
46.00
46.00
42.00
42.00
Day 1
54.00
55.50
54.00
53.33
53.17
Day 2
65.00
67.00
66.67
63.50
64.50
Day 3
77.50
81.50
81.17
74.83
75.17
Day 4
90.83
96.17
95.67
90.67
93.00
Day 5
107.17
112.00
111.50
98.17
104.67
Day 6
117.50
123.83
127.00
119.83
117.17
Day 7
136.00
143.00
147.17
135.50
137.00
Day 8
152.75
161.25
162.25
Day 9
176.50
195.75
184.25
Day 10
195.00
215.50
208.25
[0053] In both barns, birds fed red colored starter feed for the first 3 days of life showed increases in weight at 7 days over birds fed uncolored feed. The results demonstrate that a milling process using a concentrate of the present invention is effective at providing bulk colored feed that can improve weight gain in an animal.
[0054] From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent to the structure.
[0055] It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations. This is contemplated by and is within the scope of the claims.
[0056] Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
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Colored animal feeds, especially red and blue feeds, promote weight gain in animals, particularly poultry and swine. Colored feeds particularly promote weight gain in the first seven days leading to much improved weight at shipping. A concentrate having from about 1 wt % to about 15 wt % of a physiologically acceptable feed consumption enhancing food-coloring agent compatible with animal feed ingredients, from about 2 wt % to about 20 wt % of a physiologically acceptable electrolyte compatible with animal feed ingredients, and balance a physiologically acceptable carrier can be conveniently used to prepare colored animal feed on an industrial scale at any of various points in the milling or post-milling process.
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FIELD OF THE INVENTION
[0001] The present invention relates to a concrete mold supporting system and a method for constructing a concrete building through the use of the mold supporting system, and more particularly to a height-adjustable concrete mold supporting system and a method for constructing concrete floors and walls whereby a concrete building of precise size and configuration can be easily constructed with enhanced cost-effectiveness.
DESCRIPTION OF THE RELATED ART
[0002] Referring first to FIGS. 1 a to 1 d showing a conventional concrete building construction method by way of example, reinforcements 12 are disposed above a base member 10 , and then wet concrete is applied up to a predetermined reference level 14 . When the concrete is aged or dried so that a concrete floor body 16 is constructed, a fixing frame 18 for square timbers is disposed on the concrete floor body 16 by means of a plurality of pads such as pieces of plywood. Thereafter, a concrete wall mold 22 is uprightly mounted on the fixing frame 18 , and then concrete is applied into and allowed to dry in the concrete wall mold 22 .
[0003] When the concrete has been dried, the concrete wall mold 22 is detached to expose the hardened concrete wall body 24 . Then again, another base member 10 is disposed on the concrete wall body 24 , and then repeated is the above process including the steps of disposing reinforcements, and constructing the concrete floor body 16 and the concrete wall body 24 . This results in a concrete building with a plurality of stories.
[0004] However, in the conventional method of constructing a concrete building as described above, since the concrete is applied to the reference level based on an rough estimation by a workers eye-sight, the size and surface configuration of the concrete floor body tends to vary bitterly depending on the individual workers judgement and skill. Moreover, since the fixing frame is disposed by interposing pads thereunder with reference to a highest point of the concrete floor body, it is very difficult to dispose the fixing frame in an exact horizontal level.
[0005] In addition, the thickness of the concrete floor body becomes larger than the designed dimension, so that the height of each story of the concrete building is increased. There may be also a problem in that a crack or a declination may be generated in the concrete building due to an increased load and an increased stress.
[0006] Further, when the concrete is applied into the concrete wall mold, the concrete may leak out of the clearance between the concrete floor body and the fixing frame, which must be eliminated by a separate task. In the conventional method, the clearance between the concrete floor body and the fixing frame is blocked by sheets of plywood, etc. However, it has been very difficult to completely block the clearance, which means the conventional method fails to completely prevent the leakage of the concrete. Also, the conventional method requires considerable work force and expense for detaching and disposing the fixing frame, the pads, and the concrete wall mold.
SUMMARY OF THE INVENTION
[0007] Accordingly, in view of the problems inherent in the related art, it is an object of the present invention to provide a concrete mold supporting system and a method for constructing concrete floors and concrete walls that assures precise and cost-effective construction of a concrete building with great ease.
[0008] In accordance with one aspect, the invention provides a height-adjustable concrete mold supporting system for use in constructing concrete floors and walls of a concrete building, the system comprising: a bracket detachably disposed on a base member; first and second screw shafts vertically assembled with the bracket; first and second height adjusting tubes into which the first and the second screw shafts are movably inserted; a mounting board supported by the first and the second height adjusting tubes; and means for fixing the first and the second height adjusting tubes to the first and the second screw shafts to determine an adjusted space between the bracket and the mounting board.
[0009] In accordance with another aspect, the invention provides a method for constructing a concrete building through the use of a height-adjustable concrete mold supporting device, the method comprising the steps of: a) attaching the concrete mold supporting device on a base floor; b) adjusting the height of the concrete mold supporting device into alignment with a target reference plane; and c) removably clamping a concrete mold on the concrete mold supporting device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The above objects, and other features and advantages of the present invention will become more apparent after a reading of the following detailed description when taken in conjunction with the drawings, in which:
[0011] [0011]FIGS. 1 a to 1 d are sectional views illustrating a conventional method for constructing concrete floors and concrete walls of a concrete building;
[0012] [0012]FIG. 2 is an exploded perspective view of a height-adjustable concrete mold supporting system according to an embodiment of the present invention;
[0013] [0013]FIG. 3 is a side elevational section view of the mold supporting system shown in FIG. 2;
[0014] [0014]FIG. 4 is a view similar to FIG. 3 but showing the inventive system which is fixedly attached at its bottom end to a base floor and removably holds concrete mold parts at its top end;
[0015] [0015]FIGS. 5 a to 5 d are partially enlarged sectional views illustrating a method for constructing concrete floors and concrete walls of a concrete building according to the present invention; and
[0016] [0016]FIG. 6 is a partially cut-away sectional view of a concrete building constructed by use of the system and method of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0017] A preferred embodiment of the present invention will be described in detail hereinafter with reference to the accompanying drawings.
[0018] It can be appreciated in FIGS. 2 and 3 that a concrete mold supporting system 30 according to the invention includes a bottom anchor bracket 32 which has a fixed plate 34 and a supporting plate 36 assembled above the fixed plate 34 . The fixed plate 34 has a plurality of engaging protuberances 34 b fixed on and protruding upward from the upper surface of the fixed plate 34 , each of which has a through hole 34 a vertically extending through the engaging protuberance 34 b . Preferably, the fixed plate 34 may be formed from material such as rubber or resin, which is capable of insulating heat conduction.
[0019] The supporting plate 36 has a plurality of engaging holes, each of which has a plurality of engaging snaps 36 a arranged around each engaging hole. Each of the engaging protuberances 34 b of the fixed plate 34 is inserted through each engaging hole and fixedly held by the engaging snaps 36 a.
[0020] At an upper surface of the supporting plate 36 are formed first and second elongated holes 36 b and 36 c aligned in line with each other, through which first and second screw shafts 38 and 40 are respectively inserted. The first and the second screw shafts 38 and 40 respectively have first and second shaft heads 38 a and 40 a received under the first and the second elongated holes 36 b and 36 c . First and second nuts 42 and 44 are respectively fitted around the first and the second screw shafts 38 and 40 , and are screwed to abut on upper surfaces of the first and the second elongated holes 36 b and 36 c , thereby maintaining the first and the second shaft heads 38 a and 40 a to abut on lower surfaces of the first and the second elongated holes 36 b and 36 c . Therefore, the main portions of the first and the second screw shafts 38 and 40 are disposed vertically above the first and the second elongated holes 36 b and 36 c.
[0021] Further, the concrete mold supporting system 30 includes first and second height adjusting tubes 46 and 48 respectively having first and second tube holes 46 a and 48 a into which are inserted the first and the second screw shafts 38 and 40 . Inner diameters of the first and the second tube holes 46 a and 48 a are larger than outer diameters of the first and the second screw shafts 38 and 40 . The first and the second height adjusting tubes 46 and 48 respectively have first and second adjusting screw holes 46 b and 48 b penetrating through the cylindrical walls of the first and the second height adjusting tubes 46 and 48 . First and second adjusting screws 50 and 52 are respectively screwed through the first and the second adjusting screw holes 46 b and 48 b up to the outer surfaces of the first and the second screw shafts 38 and 40 , so as to firmly hold the first and the second screw shafts 38 and 40 in the first and the second height adjusting tubes 46 and 48 . Lower ends of the first and the second height adjusting tubes 46 and 48 are held by third and fourth nuts 54 and 56 screwed around the first and the second screw shafts 38 and 40 .
[0022] The first and the second height adjusting tubes 46 and 48 respectively have first and second assembling screw holes 46 c and 48 c formed at upper ends thereof to hold thereon a top mounting board 62 with a bearing surface. The mounting board 62 has first and second recesses 62 a and 62 b through the bottom of which are formed first and second recess holes 62 c and 62 d respectively. First and second assembling screws 58 and 60 are screwed through the first and the second recess holes 62 c and 62 d into the first and the second assembling screw holes 46 c and 48 c so that the mounting board 62 is firmly held on the first and the second height adjusting tubes 46 and 48 . The first and the second assembling screws 58 and 60 are completely screwed against the bottoms of the first and the second recesses 62 a and 62 b so that they do not protrude above the first and the second recesses 62 a and 62 b . The second assembling screw 60 has a center screw hole 60 a formed longitudinally through the center axis thereof.
[0023] The mounting board 62 has a holding protuberance 62 e formed at one end thereof. A clamp 66 is detachably assembled on the mounting board 62 by a bolt 64 . The clamp 66 has first and second bolt holes 66 a and 66 b aligned with each other. The bolt 64 is inserted through the first and the second bolt holes 66 a and 66 b and then screwed into the center screw hole 60 a so as to firmly assemble the clamp 66 with the mounting board 62 .
[0024] As shown in FIG. 4, the bottom bracket 32 of the inventive system 30 is fixed onto a base member 68 by driving nails 70 through the through holes 34 a of engaging protuberances 34 b into the base member 68 . Then, in a state that the first and the second adjusting screws 50 and 52 and the third and the fourth nuts 54 and 56 are released, the height of the first and the second height adjusting tubes 46 and 48 is so adjusted that the upper surface of the mounting board 62 becomes level with a predetermined reference level 72 .
[0025] When the upper surface of the mounting board 62 is level with the reference level 72 , the first and the second adjusting screws 50 and 52 are tightly screwed into the first and the second adjusting screw holes 46 b and 48 b so that the first and the second height adjusting tubes 46 and 48 are fixed to the first and the second screw shafts 38 and 40 . Thereafter, the third and the fourth nuts 54 and 56 are firmly tightened on the first and the second screw shafts 38 and 40 against the lower ends of the first and the second height adjusting tubes 46 and 48 to aid the supporting or the fixing of the first and the second height adjusting tubes 46 and 48 .
[0026] Hereinafter, described will be a method for constructing concrete floors and walls of a concrete building according to the present invention, with reference to FIGS. 5 a through 5 d and 6 .
[0027] At first, as shown in FIG. 5 a , the concrete mold supporting system 30 is fixedly secured on the base floor or member 68 in such a manner that the top bearing surface of the mounting board 62 is flush with the reference level 72 as described above with regard to FIG. 4. When it becomes necessary to adjust the distance between the bottom bracket 32 and the top mounting board 62 , the first and the second screw shafts 38 and 40 are moved along the first and the second elongated holes 36 b and 36 c of the supporting plate 36 after the first and the second nuts 42 and 44 are released. Then, the first and the second nuts 42 and 44 are tightened again.
[0028] Thereafter, as shown in FIG. 5 b , concrete reinforcing members 74 , e.g., elongated steel bars, are disposed between the base member 68 and the reference level 72 , and then, as illustrated in FIG. 5 c , wet concrete is injected or applied between the upper surface of the base member 68 and the reference level 72 . The concrete is allowed to be hardened for a sufficient period of time so that a concrete floor body 78 is constructed consequently. When the concrete has been applied up to the reference level 72 , the inventive mold supporting system 30 is buried into the concrete floor body 78 with only the upper surface of the mounting board 62 being exposed to the outside.
[0029] A fixing frame 76 of square shape and a wall-forming mold 80 , as concrete mold parts, are so fixed to the mold supporting system as to be firmly held by the holding protuberance 62 e of the top mounting board 62 which serves as a clamp. When the fixing frame 76 has been fixed on the upper surface of the mounting board 62 , the lower surface of the fixing frame 76 is flush with the reference level 72 .
[0030] As clearly shown in FIGS. 5 d and 6 , the wall-forming mold 80 includes an inner plate 80 a disposed on the upper surface of the fixing frame 76 and an outer plate 80 b spaced a predetermined distance apart from the inner plate 80 a . The lower end of the inner plate 80 a is placed on the upper surface of the fixing frame 76 , and the bolt 64 is tightened through the first and the second bolt holes 66 a and 66 b of the clamp 66 into the center screw hole 60 a of the second assembling screw 60 , so that the clamp 66 is fixedly assembled on the mounting board 62 with clamping the concrete wall mold 80 on the fixing frame 76 .
[0031] When the wall-forming mold 80 has been completely assembled, wet concrete is injected into the inner space of the wall-forming mold 80 and allowed to dry therein, so that a concrete wall body 82 is constructed. At the end of hardening process of the wall body 82 , the fixing frame 76 and the wall-forming mold 80 are removed. By reiterating the process of forming the concrete floor body 78 and the concrete wall body 82 as described above, a concrete building having a plurality of stories can be constructed.
[0032] Although the combination of tube and screw shaft is illustrated and described hereinabove as an example of the height-adjustor of the inventive mold supporting system, the invention shall not be limited thereto and other types of height-adjusting mechanism, for instance, pantograph lifter may equally be employed in place of the illustrated screw-type height adjustor.
[0033] It will be understood by those skilled in the art that various changes and modifications may be made to the illustrated embodiment without departing from the true scope of the present invention.
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Disclosed are a height-adjustable concrete mold supporting system and a method for constructing concrete floors and concrete walls, by which a concrete building can be easily and precisely constructed with enhanced cost-effectiveness. The system has a bottom bracket detachably disposed on a base member. First and second screw shafts are vertically assembled with the bracket. The first and the second screw shafts are movably inserted into first and second height adjusting tubes. A top mounting board is supported by the first and the second height adjusting tubes. The first and the second height adjusting tubes are fixed to the first and the second screw shafts so as to determine an adjusted space between the bracket and the mounting board.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a support fixture for musical instruments. More particularly, the invention relates to an improved support mechanism incorporating a spin-lock type mechanism which permits easy assembly while providing a sturdy and durable arrangement.
2. Description of Related Art
Particularly for instrument stands used by school aged children, musical instrument equipment must be simple in form, easy to assembly, and must hold the instrument firmly in place. Instruments are assembled and disassembled several times weekly (sometimes several times daily), thus the instrument stand must be dependable and capable of withstanding use through countless cycles of assembly and disassembly.
Various arrangements are known for supporting small instruments, i.e. percussion, keyboards, etc., such that their playing surfaces can be easily reached by the performer. In particular, bracket arrangements for tom-toms, having several degrees of freedom, are useful particularly in multiple drum sets. Such arrangements are illustrated in U.S. Pat. Nos. 3,535,976, 4,543,446 and 4,796,508. These arrangement include a ball clamped into a socket, with a rod attached to and projecting from the ball to support a drum. Such devices offer both vertical and rotational freedom of movement.
Prior to the present invention, many percussion instruments were attached to stands by a threaded screw. FIG. 1, which structure will be discussed in greater detail below, illustrates this prior art arrangement. With this type of stand children have to balance the instrument onto a threaded screw and twist either the instrument or the stand to complete the assembly. Often, the result is an incomplete assembly; the instruments loose their balance and fall, the threads do not align and cross thread; the instruments are inadequately tightened and wobble, and/or the instruments are spun propeller-style with such force that the screws break. The need therefore exists for a musical instrument stand, particularly for use by young children, which overcomes the drawbacks of the prior art.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a musical instrument stand which is easy to assemble and which holds an instrument firmly in place.
It is also the object of the invention to provide an assembly arrangement particularly suited for an educational environment and for small children.
The invention provides a bracket fitted onto a musical instrument and a stand for receiving the instrument and bracket. The bracket is preferably mounted on the center of gravity of the instrument. The bracket and stand assembly are provided with a mating coupling in the form of a spin-lock mechanism. During assembly the instrument and bracket are positioned on the stand, then rotated relative to one another to lock the assembly together. A tightening nut may also be provided to encure a secure fastening arrangement.
These and other objects and advantages of the invention will appear more fully from the following description made in conjunction with the accompanying drawings wherein like reference characters refer to the same or similar parts throughout the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of the prior art drum support utilizing a threaded screw.
FIG. 2 is top left perspective view of the drum support of the invention.
FIG. 3 is bottom right perspective view of part of the drum support of the invention.
FIG. 4 is a top view of the wing-type key member of the invention.
FIGS. 5 is an enlarged side view of the wing-type key member of the invention.
FIG. 6 is a top view of the receiving unit of the invention.
FIG. 7 is a cross sectional front view of the receiving unit of the invention taken along line VII--VII of FIG. 6.
FIG. 8 is a cross sectional side view of the receiving unit of the invention taken along line VIII--VIII of FIG. 6.
FIGS. 9a, 9b and 9c illustrate in sequence the operation of the locking mechanism of the invention.
FIG. 10 is a partial bottom of the locking assembly illustrating the locked position whereby the locking arms 24a, 24b abut the delimiting tangs 21 after a 90 degree rotation of the rod 4 relative to the receiving section 18.
FIG. 11 is a cross sectional side view of the locking assembly taken along line XI--XI of FIG. 10.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is an exploded view of the prior art drum support discussed above wherein a stand base 2, generally formed as a tripod, is provided with a telescopically adjustable rod 4 approximately 5/8 inch in diameter having a reduced threaded end portion 6. The adjustable rod 4 is secured at varying heights via the clamp 2a. For the conventional arrangement, a frame mounting plate 8 is formed with a nut 8a which threadingly receives the reduced threaded end portion 6 of the rod 4. The frame mounting plate 8 is designed for affixation to a musical instrument, i.e. percussion bars 10 mounted on frame member 9, in the form of a xylophone in FIG. 1.
With reference to FIGS. 2 and 3, the instrument stand of the invention similarly comprises a stand base 2 provided with a telescopically adjustable rod 4 of suitable dimensions whereby the desired height of the rod 4 is adjustably arranged via the clamp 2a. As opposed to the reduced threaded end portion 6 of the prior art arrangement, the adjustable rod 4 of the preferred embodiment is provided with a wing-type key member 16 which locks to the receiving unit 18 assembled to the frame 19. As with the conventional arrangement of FIG. 1, the embodiment of FIGS. 2 and 3 illustrate a percussion instrument in the form of a xylophone with percussion bars 10.
FIGS. 4 and 5 provide a top view and an enlarged view of the wing-type key assembly 16 nonrotatably provided on the rod 4. Specifically, the wing-type key assembly 16 is formed with a wing nut 22 threadingly provided on a threaded end portion 4a of the rod 4. The wing-type key assembly 16 further includes a reduced diameter shaft 4b having one end connected to the threaded end portion 4a so as to share a common longitudinal axis a--a. Connected to the reduced diameter shaft 4b are a pair of vertically oriented, oppositely positioned locking arms 24a, 24b extending at right angles relative to the axis a--a.
The locking arms 24a, 24b are positioned in an adjacent spaced relation to the upper surface 22a of the wing nut 22 so as to form the interspace 26 therebetween. The width W of the interspace is adapted to vary as the wing nut 22 is rotated about the threaded end portion 4a. It is noted a limiting plate may be provided between the wing nut 22 and the locking arms 24a, 24b to limit the minimum value of the width W.
FIGS. 6-8 illustrate various views of the receiving unit 18. The receiving unit 18 is formed as a frame mounting plate with a cylindrical recessed section 19 with a substantially cylindrical side wall 19a and a front wall 19b. As with the conventional arrangement shown in FIG. 1, the receiving unit 18 is adapted to be assembled to a frame for the musical instrument, for example by screw which pass through screw holes 18a to affix the unit 18 to the frame (see FIG. 1).
The cylindrical recessed section 19 comprises a central passage 20 generally formed as an elongated opening slightly larger in dimension than the reduced diameter shaft 4b and vertically oriented, oppositely positioned locking arms 24a, 24b such that the shaft 4b and the locking arms 24a, 24b are adapted to pass through the central passage 20. The passage of the wing-type locking device of rod 4 into the central passage 20 is limited by the wing nut 22 such that the upper surface 22a of the wing nut abuts against the front wall 19b of the receiving unit 18.
The recessed section 19 is further formed with delimiting tangs 21 which extend into the recess in a direction opposite the front wall 19b. The tangs 21 may be formed by crimping a portion of the front wall 19b if the receiving unit 18 is formed of steel, aluminum or other malleable material. It is noted however that the receiving unit 18 may also be formed of a polymer material such as plastic with suitable strength to ensure a stable locking device.
The operation of the locking mechanism of the invention will now be described with reference to FIGS. 9a, 9b, and 9c. It is noted that the frame and musical instrument have been omitted from the drawings for clarity. For assembly, the end of the rod 4 comprising the reduced diameter shaft 4b and vertically oriented, oppositely positioned locking arms 24a, 24b is inserted into the central passage 20 in the direction of arrow A and with the orientation illustrated in FIG. 9a. When the upper surface 22a of the wing nut 22 abuts the front wall 19b of the recessed section 19, the percussion assembly which is affixed to the receiving unit 18, and the rod 4 with associated stand base 2 are rotated relative to one another approximately 90 degrees to a locked position. Specifically, the receiving unit 18 is rotated in a counter-clockwise direction when viewed from the bottom as shown by arrow B in FIG. 9b. In the locked position, the locking arms 24a, 24b abut the delimiting tangs 21 to prevent further relative rotation of the receiving unit 18 and the rod 4. Next, the assembly is placed in the secured position by rotating the wing nut 22 in the clockwise direction shown by arrow C in FIG. 9c. The wing nut 22 moves relative to the rod 4 in the direction of the front wall 19b due to its threading engagement with the reduced threaded end 4a. Thus, the wing-type key member 16 is tightened by the wing nut 22 to clamp the receiving unit 18 to the rod 4 in an easily assembly and surely fastened manner.
FIG. 10 illustrates the locked position whereby the locking arms 24a, 24b abut the delimiting tangs 21 after a 90 degree rotation of the rod 4 relative to the receiving section 18. FIG. 11 illustrates the dimensional relationship of the locking arms 24a, 24b to the recessed section 19 wherein it is understood that the recessed section 19 if formed with a depth d substantially equal to the thickness of the locking arms 24a, 24b in the longitudinal direction of the rod 4. With this arrangement, the wing-type key member does not interfere with the arrangement or function of the musical instrument supported by the stand. In order to provide further stability in the locking assembly of the invention the rod 4 may be provided with a washer-like member 5 formed to be received in a close fitting manner in the central passage 20 when in the locked and secured positions.
While the invention has been shown and described with reference to specific embodiments, it is understood that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. For example, while a 90 degrees rotation of the rod 4 relative to the receiving unit 18 was described above, it is understood that any degree of rotation is encompassed by the invention so long as the associated parts are locked together. Moreover, while two locking arms are described above, it is understood that any number may be provided to attain a suitable connection. The wing nut arrangement has also been set forth above by way of example only. It is understood that the wing nut 22 may be omitted entirely from the foregoing embodiment, or may comprise a clamping member rather than a threaded member to attain the secured position.
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A support fixture for musical instruments, and more particularly, an improved support mechanism is provided incorporating a spin-lock type mechanism which permits quick and easy assembly while providing a sturdy and durable arrangement. The assembly mechanism of the invention is particularly suited for musical instruments stands to be used by small children.
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FIELD OF THE INVENTION
[0001] This invention generally relates to water systems and valves used therein.
BACKGROUND OF THE INVENTION
[0002] There has long been need for leak detection in the water supply systems used to serve the common household. Complicated systems to help shut off water for an appliance or full house water system have been developed. However, conventional water supply systems tend to focus on systems to shut off the flow of water once a leak is detected. With the advent of the so-called smart home, it would be desirable to have a water supply system that includes a water valve with the capability to communicate the status of the valve, the fluid flowing through the valve, for example the overall flow of water in the house. Such a water valve could provide significant advantages with respect to the detection and/or prevention of leaks in the water supply system.
[0003] Embodiments of the invention provide such a water valve. These and other advantages of the invention, as well as additional inventive features, will be apparent from the description of the invention provided herein.
BRIEF SUMMARY OF THE INVENTION
[0004] In one aspect, embodiments of the invention provide a valve that includes a valve housing with a valve inlet and valve outlet, and a valve member disposed between the valve inlet and valve outlet. The valve member is movable between an open and closed position. The valve has one or more electronic sensors disposed in the valve housing, and a wireless RF transmitter electrically coupled to the one or more electronic sensors. The wireless RF transmitter is configured to wirelessly communicate information from the one or more electronic sensors.
[0005] In a particular embodiment, the one or more electronic sensors include a flow meter. The flow meter may be one of a Hall-effect sensor configured to provide a signal to the wireless RF transmitter, and a reed switch configured to provide a signal to the wireless RF transmitter. In other embodiments, the one or more electronic sensors include a temperature sensor. Additionally, the one or more electronic sensors may include a position sensor configured to determine a position of the valve member. Also, the one or more electronic sensors could include a valve inlet pressure sensor and a valve outlet pressure sensor.
[0006] In certain embodiments, the wireless RF transmitter is configured to communicate wirelessly with a mobile electronic device, the mobile electronic device including an application that allows the user to receive information from the wireless RF transmitter. In more particular embodiments, the wireless RF transmitter is configured to receive commands from the mobile electronic device, and to transmit the commands to an actuator that controls a position of the valve member. Alternatively, the wireless RF transmitter may be configured to communicate wirelessly with a computer having software that allows the user to receive information from the wireless RF transmitter. More specifically, the wireless RF transmitter may be configured to receive commands from the computer, and to transmit the commands to an actuator that controls a position of the valve member. In a particular embodiment, the wireless RF transmitter is powered by a rechargeable battery. In some embodiments, the communications protocol for the wireless RF transmitter is Bluetooth or ZigBee.
[0007] The valve may further comprise an electrically-controlled actuator configured to position the valve member, where the electrically-controlled actuator is coupled to the wireless RF transmitter. The electrically-controlled actuator may be configured to be controlled remotely from a computer or mobile electronic device. In a further embodiment, the computer and mobile electronic device are each programmed to provide an alarm signal to the user when the information from the one or more sensors indicates one of a malfunction of the valve, and a leak in a piping system connected to the valve.
[0008] In another aspect, embodiments of the invention provide a valve system that includes a remote electronic device having an electronic display, and a valve. The valve has a valve housing with a valve inlet and valve outlet, and a valve member disposed between the valve inlet and valve outlet. In some embodiment, the valve member is movable between an open and closed position. The valve includes one or more electronic sensors disposed in the valve housing, a wireless RF transmitter electrically coupled to the one or more electronic sensors, and configured to wirelessly communicate information from the one or more electronic sensors. The remote electronic device is configured to receive, via the wireless RF transmitter, the information from the one or more electronic sensors, and to display the information on the electronic display.
[0009] In certain embodiments, the remote electronic device is one of a desktop PC, a laptop PC, a notebook PC, a tablet computer, and a smart phone. In a particular embodiment, the valve is a check valve of a sump pump, and the one or more electronic sensors include a flow meter. The valve may further comprise an electrically-controlled actuator configured to position the valve member, where the electrically-controlled actuator is coupled to the wireless RF transmitter. Further, the remote electronic device may be programmed to control the electrically-controlled actuator via the wireless RF transmitter. Additionally, the remote electronic device may be programmed to automatically close the valve when the information from the one or more electronic sensors indicates that there is a malfunction in the valve, or that there is a leak in a piping system connected to the valve. In other embodiments, the remote electronic device is programmed to automatically provide an alarm signal when the information from the one or more electronic sensors indicates that there is a malfunction in the valve, or that there is a leak in a piping system connected to the valve.
[0010] In a particular embodiment, the valve is a supply valve for a water supply system, and wherein the remote electronic device is programmed to cause the supply valve to close when the one or more sensors indicate a leak in the water supply system. The one or more electronic sensors may be one of a flow meter, a valve inlet pressure sensor, a valve outlet pressure sensor, a temperature sensor, and a position sensor configured to determine a position of the valve member. Alternatively, the one or more electronic sensors may be one of a Hall-effect sensor flow meter configured to provide a signal to the wireless RF transmitter, and a reed switch flow meter configured to provide a signal to the wireless RF transmitter.
[0011] Other aspects, objectives and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:
[0013] FIG. 1 is a schematic cross-sectional view of an RF signal-emitting valve, according to an embodiment of the invention;
[0014] FIG. 2 is a schematic diagram showing an exemplary valve system with the RF signal-emitting valve of FIG. 1 , according to an embodiment of the invention; and
[0015] FIG. 3 is a schematic diagram showing a sump pump with the RF signal-emitting valve of FIG. 1 , according to an embodiment of the invention.
[0016] While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[0017] FIG. 1 is a schematic cross-sectional view of an RF signal-emitting valve 100 , according to an embodiment of the invention. The RF signal-emitting valve 100 has a valve housing 101 , an inlet 102 and an outlet 104 . A valve member 106 is positionable between an open position and a closed position. The valve member 106 is positioned by an electric actuator 108 .
[0018] In general, the RF signal-emitting valve 100 includes at least one electronic sensor. In the particular embodiment of FIG. 1 , the RF signal-emitting valve 100 includes multiple electronic sensors. An inlet pressure sensor 110 , configured to measure fluid pressure, is located at the inlet 102 , while outlet pressure sensor 112 is located at the outlet 104 . A flow meter 114 , configured to measure the flow rate of a fluid flowing through the valve 100 , is also positioned proximate the outlet 104 . A temperature sensor 116 , configured to measure a temperature of fluid flowing through the valve 100 . A position sensor 118 , configured to sense a position of the valve member 106 , is located proximate the valve member 106 . The position sensor 118 may be a linear variable differential transformer, for example, though other types of electronic position sensors including, but not limited to, capacitive displacement sensors, inductive non-contact displacement sensors, and Hall-effect sensors may also be used. In particular embodiments of the invention, the electric actuator 108 and the aforementioned electronic sensors may be powered by a battery 120 , such as a lithium-ion battery for example. The battery 120 may be attached to an exterior surface of the valve housing 101 . In other embodiments, the electric actuator 108 and electronic sensors may be powered via an external power supply, such as utility-supplied power.
[0019] The electric actuator 108 and the aforementioned electronic sensors are connected to a wireless RF signal emitter 122 , which is configured to receive information from each of the electronic sensors, and to wirelessly transmit that information to a remote electronic device, such as a desktop or laptop personal computer, tablet computer, or smart phone. The remote electronic device has a display and is programmed such that a user can monitor a status of the valve 100 , or monitor various parameters of a fluid flowing through the valve 100 . In certain embodiments, the user can send commands via the remote electronic device to the electric actuator 108 through the wireless RF signal emitter 122 , allowing remote control of the valve member 106 .
[0020] FIG. 2 is a schematic diagram of a valve system 200 that includes the RF signal-emitting valve 100 , according to an embodiment of the invention. The valve system 200 of FIG. 2 is used in a water supply system such as would be used to supply water to a residence. In the embodiment shown, water from a utility flows through the RF signal-emitting valve 100 to appliances or faucets throughout the residence. The RF signal-emitting valve 100 wirelessly communicates with a remote electronic device such as a personal computer 202 (desktop, laptop, notebook, etc.) or mobile electronic device 204 , such as a tablet computer or a smart phone. The personal computer 202 includes specific hardware and software to facilitate two-way communication with the RF signal-emitting valve 100 , and to facilitate the display of information received from the RF signal-emitting valve 100 with information from the one or more electronic sensors. Similarly, the mobile electronic device 204 includes an application to facilitate two-way wireless communication with the RF signal-emitting valve 100 , and to facilitate the display of information received from the RF signal-emitting valve 100 with information from the one or more electronic sensors. The personal computer 202 and mobile electronic device 204 are also programmed to transmit commands to the RF signal-emitting valve 100 , allowing the user to remotely control functions, such as opening and closing, of the RF signal-emitting valve 100 . The communication protocol used by the RF signal-emitting valve 100 may be one of the Bluetooth and ZigBee protocols, though other suitable communication protocols may be used.
[0021] In certain embodiments, the user of the remote electronic device will be programmed to provide a visual and/or digital display of the parameters determined by the one or more electronic sensors. Consequently, the user is able to determine if the fluid flow through the valve is above normal, below normal, or at the level expected. Depending on the reading, the user can be alerted to a possible leak in the piping system connected to the RF signal-emitting valve 100 , or alerted to a malfunction in the RF signal-emitting valve 100 . In particular embodiment, the remote electronic device is programmed to alert the user, via an audio or visual alarm for example, when the parameters received, from the RF signal-emitting valve 100 , are outside of a predetermined threshold range, thus indication a possible leak in the aforementioned piping system, or of a malfunction in the valve 100 . In a more particular embodiment, the remote electronic device is programmed to automatically command the electric actuator 108 to close the RF signal-emitting valve 100 , when the parameters received, from the RF signal-emitting valve 100 , are indicative of a possible leak in the aforementioned piping system, or of a malfunction in the valve 100 .
[0022] FIG. 3 is a schematic diagram showing a sump pump 300 that includes the RF signal-emitting valve 100 , according to an embodiment of the invention. The RF signal-emitting valve 100 is located inside of the sump 302 and connected to the sump pump 300 . Thus, the one or more electronic sensors in the RF signal-emitting valve 100 are indicative of a flow through the valve 100 , and, therefore, operation of the sump pump 300 . The user is thus able to remotely monitor the operation of the sump pump 300 from the display of the remote electronic device. Additionally, the remote electronic device may be programmed to automatically alert the user, via an audio or visual alarm for example, when the information received from the RF signal-emitting valve 100 is indicative of a leak in the piping system attached to the sump pump 300 , or of a malfunction in the sump pump 300 .
[0023] All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
[0024] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[0025] Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
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A valve includes a valve housing with a valve inlet and valve outlet. A valve member is disposed between the valve inlet and valve outlet. The valve member is movable between an open and closed position. The valve has one or more electronic sensors disposed in the valve housing. The one or more electronic sensors may include an electronic flow meter, a temperature sensor, pressure sensor, and/or a position sensor. A wireless RF transmitter is electrically coupled to the one or more electronic sensors. The wireless RF transmitter is configured to wirelessly communicate information from the one or more electronic sensors.
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FIELD OF THE INVENTION
[0001] This invention relates generally to log home construction and in particular, to panelized log home construction.
BACKGROUND OF THE INVENTION
[0002] Log cabins have been used as shelter for hundreds of years. The earliest methods of constructing these shelters utilized round logs notched near the corners to provide structural integrity to the completed building as the logs were stacked. Still used today, this method of construction is extremely labor intensive, difficult to fabricate, often drafty, and requires a high level of maintenance.
[0003] Stacking round logs results in a relatively small surface area of log to log contact. In order to produce a continuous wall with a reasonable level of thermal and structural integrity, an adhesive material is packed into the horizontal space between logs, a process know as chinking. These walls are referred to as “chinked walls”. Chinked walls require continuous maintenance as the chinking is lost over time and must be replaced.
[0004] To reduce or eliminate the necessity for chinking, improved methods of log cabin construction have been developed. One such method involves logs with flattened sides and square notches. When stacked, the flat sides are closer together than rounded sides, minimizing the need for chinking.
[0005] The next evolution in log cabin construction utilized a scribing of one log of a wall to approximately match the contour of the log upon which it rested, thereby bringing the logs into more intimate contact. This intimate contact required only minimal chinking, or alternatively, caulking.
[0006] Additional developments to create better structural integrity and increased thermal efficiency have included flattened tops and bottom log surfaces to further increase contact surface area, and the addition of one or more tongues in one of the log faces to cooperate with and fit within corresponding grooves in the flat face of an adjacent log.
[0007] While these improvements have contributed to more structurally sound, energy efficient structures, other problems still remain. For example, logs which comprise the log structure tend to shrink in width even if they have been kiln dried prior to placement. This shrinkage, reported to be as much as 1 inch per log, contributes to increased draftiness and water leakage. Additionally, stacked logs settle as they shrink, reducing the overall height of the wall and thereby affecting the position of any structures supported by the wall. Such structures may include doors and windows which become out of square and roof trusses which become uneven.
[0008] Still another problem inherent in log cabins built by the above identified construction methods is the difficulty to effectuate major repairs to a wall section damaged by, for example, a fire or flood. Cutting out and replacing a section of damaged wall with acceptable cosmetic results is both labor and time intensive, with resultant high repair costs.
[0009] One construction method used to overcome both the shrinkage and wall section replacement problems is to utilize a wall panel comprising horizontal sections of logs stacked between and held in place by two upright support elements. Such an arrangement provides a means for supporting a load above the upper edge of the wall panel regardless of vertical movement between the upper edge of the uppermost horizontal log and the load and allows for relatively easy replacement of a damaged wall panel section.
[0010] One example of such a wall panel is U.S. Pat. No. 5,265,390 to Tanner. Tanner's wall panel comprises a base plate, a plurality of horizontally placed wooden logs independently held between a pair of standards and at least one jack mounted on the upper edge of each wall panel. The logs mate with one another without being fixed together so that each log can move separately relative to the standards.
[0011] While Tanner's wall panel presents advantages over non-panelized construction methods, problems still remain. Chief among them are the requirement to assemble the wall panel onsite. Accordingly, there is still a continuing need for improved methods to construct log cabins. The present invention fulfills this need, and further provides related advantages.
BRIEF SUMMARY OF THE INVENTION
[0012] The present invention relates to panelized log home construction. In a first embodiment, a wall panel comprises a plurality of logs of predetermined length stacked on top of each other. A tongue is machined into each log end such that when stacked a wall tongue is formed from the aligned log tongues. A rod channel runs through the stacked logs for receiving a tension/lifting rod. A first end of the tension/lifting rod comprises a rod lifting attachment for lifting and a second end permits adjustment of the tensioning force. Optional protective channels fixedly cover each wall tongue and optional wall utility channels receive wires and pipes, as required.
[0013] In a second embodiment, a pair of posts fixedly attached to a foundation slidably receive the wall panels. Machined into each post is at least one wall receiving groove sized to slidably receive and cooperate with the wall tongue. An optional protective groove covering fixedly covers each wall receiving groove to lessen the possibility of post breakage upon wall panel insertion.
[0014] According to a third embodiment, a method of constructing a wall panel comprises the steps of stacking a plurality of logs of predetermined length on top of each other; machining a tongue into each log end such that when stacked a wall tongue is formed from the aligned log tongues; fabricating a rod channel through each log such that when stacked a rod channel runs through the wall panel to receive a tension/lifting rod, a first end of the tension/lifting rod comprising a rod lifting attachment for lifting and a second end permitting adjustment of the tensioning force; and placing a predetermined tensioning force on the stacked walls. Optionally, a protective tongue covering is fixedly attached to each wall tongue and optionally a utility channel is machined into each log such that when stacked, a wall utility channel is formed for receiving wires and pipes, as required.
[0015] According to a fourth embodiment, a log home comprises a plurality of wall panels and posts in a predetermined arrangement.
[0016] According to a fifth embodiment, a method of repairing a damaged wall panel comprises the steps of removing an effective amount of wall panel cover structure to permit the damaged wall panel to be slidable removed; slidably inserting a replacement wall panel; and repairing the wall panel cover structure, wherein the wall panel comprises a plurality of logs of predetermined length stacked on top of each other; a tongue is machined into each log end such that when stacked a wall tongue is formed from the aligned log tongues; a rod channel runs through the stacked logs for receiving a tension/lifting rod, a first end of the tension/lifting rod comprising a rod lifting attachment for lifting and a second end permitting adjustment of the tensioning force; and a pair of posts fixedly attached to a foundation to slidably receive the wall panels, wherein each post includes at least one wall receiving groove sized to slidably receive and cooperate with the wall tongue.
[0017] One advantage of the panelized log home construction of the present invention is the ability to easily and relatively inexpensively remove a panel section to repair major damage caused by, for example, fire or flood.
[0018] Another advantage is that the wall panel may be constructed off-site under controlled climatic conditions and then easily transported to the construction site.
[0019] Still another advantage is the reduced on-site construction time with concomitant cost savings on labor.
[0020] Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is an oblique view of a panelized wall.
[0022] FIG. 2 is an oblique view of a log.
[0023] FIG. 3 is an oblique view of a panelized wall system.
[0024] FIG. 4 is a cross sectional view of a portion of a panelized wall.
[0025] FIG. 5 is a front view of a panelized wall system.
[0026] FIG. 6 is a top view of a post retaining two panelized walls.
[0027] FIG. 7 is a top view of a corner post.
[0028] FIG. 8 is a cross sectional view of ship lapped stacked posts.
[0029] FIG. 9 is a cross sectional view of a panelized wall system in place.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The present invention will be described in relation to log homes. However, it should be appreciated that the materials described are not limited to wood. Any material suitable for construction may be substituted, for example, metal such as steel and aluminum, composites, extruded wood replacement materials and the like. Furthermore, the present invention is not limited to any particular wood shape or size, nor to any particular building shape. The dimensions described below are used merely as exemplars.
[0031] Turning now to the figures, and more specifically FIGS. 1-3 , wall panel 2 of the present invention comprises a plurality of logs 4 cut to a finished face dimension plus the depth of wall receiving groove 52 , cut into each of two posts 48 , described in detail below. Tongue 6 is machined into each end of log 4 such that when stacked wall tongue 84 is formed from aligned log tongues 6 . Optionally, but preferably, log 4 has a second tongue 10 machined into a first horizontal surface 12 and a cooperating groove 16 machined into a second horizontal surface 14 , such that when logs 4 are stacked, second tongue 10 and groove 16 cooperate in a known manner.
[0032] At least one rod channel 20 is drilled into log 4 from first horizontal surface 12 to second horizontal surface 14 to receive tension/lifting rod 22 in stacked logs 4 . Preferably two rod channels 20 are drilled at equal distance from the centerline of log 4 . Optional utility channel 24 is drilled at a predetermined location so that when logs 4 are stacked, wall utility channel 26 is formed to receive, for example, electrical conduit, water pipe, gas pipe or combinations thereof. If required, utility slot 28 , is cut into log 4 to receive, for example, an electrical box (not shown). Utility channel 24 may be cut horizontally into log 4 , as required.
[0033] Turning to FIG. 4 , logs 4 are assembled into a wall panel by stacking and fixing one log 4 on top of another. Seal 30 is placed between each fixedly stacked log 4 . In a preferred embodiment, logs 4 are fixedly attached by running adhesive bead 32 along either side of second tongue 10 , and seal 30 is created by running insulation bead 34 on top of second tongue 10 prior to stacking. Insulation bead 34 is formed of material that does not interfere with the adhesive process, for example, a high expansion insulation material, rubber gasket, or felt. To provide additional fixation, each log 4 is attached to the log 4 on which it rests with, for example, log screw 36 , preferably, a 10″ log screw at 12″ centers. This stacking process is repeated until the design height of panel 2 is obtained.
[0034] Shown in FIG. 5 , logs 4 may be stacked onto tension/lifting rod 22 as wall panel 2 is being assembled by inserting tension/lifting rod 22 into successive rod channels 20 ; tension/lifting rod 22 may be inserted into wall rod channel 38 formed by stacked rod channels 20 after wall panel 2 has been assembled; or wall panel 2 may be assembled partly with tension/lifting rod 22 inserted after log 4 stacking and partly with logs 4 stacked after tension/lifting rod 22 is in place, dependant on assembly physical space limitations. Tension/lifting rod 22 is, for example, a ½ inch to ⅝ inch diameter threaded high tensile steel rod. Rod lifting attachment 62 , for example, eye loop 64 is threaded onto the lifting end 23 .
[0035] To provide adjustable tension, tension/lifting rod non-lifting end 66 is, for example, threaded into nut 40 welded onto plate 68 . Second nut 41 is threaded onto lifting end 23 and countersunk into uppermost log 4 . Tension/lifting rod 22 is tightened to an effective force to create an effective seal and minimize cracking of logs 4 . As required, electrical conduit, electrical wire, and/or pipe (not shown) is installed in wall utility channel 26 , and electric box (not shown) installed in utility slot 28 . Either bottom log 4 of wall panel 2 or base log 70 ( FIG. 3 ) is countersunk to receive nut 40 and plate 68 , thereby allowing panel 4 to rest flush upon base log 70 . The interface of wall panel 2 and base log 70 also receives seal 30 and adhesive bead 32 in the manner described above.
[0036] Turning to FIG. 6 , optionally, in a preferred embodiment protective tongue covering 42 , for example, a steel channel, shaped to intimately receive wall tongue 84 is installed over wall tongues 84 . Protective tongue covering 42 is installed by, for example, drilling holes to receive ¼″ by 4″ screws 50 at 8″ centers. Screws 50 have tapered heads to maintain a flush or smooth finish to protective tongue covering 42 . Prior to installation, seal 30 is placed under protective tongue covering 42 in the manner described above.
[0037] Returning to FIG. 3 , panel openings 44 , for example, window and door openings, are cut and framed into wall panel 2 as wall panel 2 is assembled. Alternatively, panel openings 44 may be cut and framed after wall panel 2 has been assembled. Panel openings 44 are framed by installation of, for example, jacks 46 , preferably 2×4 inch jacks, adjusted to the rough opening of the window or door unit (not shown) to be installed.
[0038] It should be appreciated that prefabricated wall panels 2 may be constructed off site under controlled climatic conditions, thereby providing better quality control, tighter tolerances, and reduction in on site labor costs. Tension/lifting rods 22 and optional protective tongue covering 42 also serve to keep wall panel 2 from bowing as it is raised from a horizontal storage or transport position.
[0039] Turning now to FIGS. 6 and 7 , post 48 is fabricated with at least one wall receiving groove 52 machined along its length. Intermediate post 54 ( FIG. 6 ) has two wall receiving grooves 52 machined into opposite sides, while corner post 56 ( FIG. 7 ) has two wall receiving grooves machined into, for example, 90 degree sides. In a preferred embodiment, corner post 56 is fabricated from a minimum of 8″×8″ cut stock.
[0040] Optionally, but preferably, protective groove insert 58 , for example, a steel covering shaped to intimately receive protective tongue covering 42 is installed within wall receiving groove 52 . Groove insert 58 is installed by, for example, drilling holes to receive ¼″ by 4″ screws 50 at 8″ centers. Screws 50 have tapered heads to maintain a flush or smooth finish to receiving groove 52 . Prior to installation, seal 30 is placed under groove insert 58 , in the manner described above.
[0041] Turning again to FIG. 3 , posts 48 are conventionally fastened to foundation 76 , for example, with L lags (not shown), preferably, ¼″×6″ L lags or with dowels 74 , or combinations thereof. Depending on local building codes, posts 48 may be fastened directly to foundation 76 , or alternatively to sill plate 78 which has been fastened to foundation 76 .
[0042] After installation of posts 48 , wall panel 2 is raised by rod lifting attachments 62 and aligned such that tongue 6 (preferably protected by protective tongue covering 42 ) aligns with post groove 60 (preferably protected by post groove insert 58 ) and slidably lowered into place. Although wall panel 2 may rest directly upon foundation 76 or sill plate 78 (as required by local code), in a preferred embodiment, at least one base log 70 , countersunk to receive tension/lifting rod nut 40 , is mounted to foundation 76 or sill plate 78 (as required by local code) prior to placement of wall panel 2 . Thereafter, wall panel 2 is slidably mounted as described above and rests upon base log 70 .
[0043] Once wall panel 2 is in place, rod lifting attachment 62 is removed. If desired, tension/lifting rod 22 may be cut flush with counter sunk second nut 41 . However, it is preferable to bore out the bottom log 4 of a second stacked wall panel 2 , or the top plate 86 , for example, a lentil log, as applicable, to accept the extended tension/lifting rod 22 . In this manner, rod lifting attachment 62 may be reattached if wall panel 2 needs to be subsequently removed.
[0044] Maximum wall panel 2 dimensions are limited only by the ability to transport, lift and position wall panel 2 . Wall panels 2 may be stacked utilizing, for example, dowels 74 or pins, and adhesive bead 32 with a through lag bolt or screw (not shown) from the opposite side of post 48 installed into stacked wall panel 2 . Posts 48 may be likewise stacked using for example, dowels 74 or pins, and adhesive bead 32 . As shown in FIG. 8 , when staked, bracket 78 is mounted within and to span mating post wall receiving grooves 52 , using, for example, screws. Optionally, posts may be mated using s shiplap joint 82 . Once wall height has been established, top plate 86 ( FIG. 3 ) is constructed using known construction methods, supported by posts 48 .
[0045] Turning to FIG. 9 , wall panel 2 or base log 70 , as required by local code, rests on only a portion of sill plate 78 . In a preferred embodiment, floor joist 90 is supported by at least a portion of remaining sill plate 78 . In this manner, floor joists 90 , floor decking 92 , and insulation 94 may be constructed after wall panels 2 have been placed. Drip edge 88 , is constructed between sill plate 78 and foundation 76 .
[0046] A plurality of wall panels 2 and posts 48 placed in a predetermined pattern form the log home (not shown). By utilizing the panelized log home construction of the present invention, onsite framing time has been reduced from six to seven months down to five to ten days. Similarly, the time required to replace a damaged wall section has been dramatically reduced.
[0047] To repair a damaged wall section, the roof and overlying floor (if present) are cut away a sufficient amount to allow wall panel 2 to be lifted out after cutting the appropriate adhesive bead 32 and replaced with an undamaged or repaired wall panel 2 . If a repaired wall panel 2 is used, a replacement tongue 6 is added, if required. Rafters and joists that have been cut away to provide lifting access are repaired using known “sistering” or similar construction techniques, followed by repair of the floor and roof.
[0048] Although the present invention has been described in connection with specific examples and embodiments, those skilled in the art will recognize that the present invention is capable of other variations and modifications within its scope. For example, in the exemplar, protective tongue covering 42 and protective groove covering 58 are utilized to prevent breakage of post 48 during installation of wall panel 2 . However, depending on the strength of construction materials used, one or both could be omitted.
[0049] These examples and embodiments are intended as typical of, rather than in any way limiting on, the scope of the present invention as presented in the appended claims.
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The present invention relates to panelized log home construction. In a first embodiment, a wall panel comprises a plurality of logs of predetermined length stacked on top of each other. A tongue is machined into each log end such that when stacked a wall tongue is formed from the aligned log tongues. A rod channel runs through the stacked logs for receiving a tension/lifting rod. A first end of the tension/lifting rod comprises a rod lifting attachment for lifting and adjustment of the tensioning force. Optional protective coverings fixedly cover each wall tongue and optional wall utility channels receive wires and pipes, as required. A pair of posts fixedly attached to a foundation slidably receive the wall panels. Machined into each post is at least one wall receiving groove sized to slidably receive and cooperate with the wall tongue. An optional protective groove insert fixedly covers each wall receiving groove to lessen the possibility of post breakage upon wall panel insertion.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the field of oil and gas well stimulation, and more particularly, to isolating segments of a subterranean cased or open hole well for stimulating and/or testing purposes. The invention is particularly well-suited for stimulating horizontal wellbores that extend through a naturally fractured reservoir.
2. Description of the Related Art
The field of oil and gas well stimulation sometimes involves wells with multiple horizontal laterals in a vertical well that are drilled to facilitate production from a formation. Some of the well laterals are substantially long, up to several thousand feet, and it is desirable to stimulate these horizontal well sections to increase their production. There are a number of stimulation methods, such as acidizing and fracturing. The typical way to stimulate the horizontal sections of a wellbore is to fill the entire horizontal wellbore with the desired stimulation fluid, increase the fluid pressure, and hope that the fluid encounters and enhances the formation's natural fractures. However, according to recent studies this method of stimulating a long horizontal section of a well only effectively treats the initial interval (e.g. the first one-thousand feet or so) of that section. It is desirable to enhance the natural fractures in the formation all the way to the end of the horizontal well, but current methods do not effectively provide for this. In order to effectively fracture a long horizontal well, the well needs to be isolated into sections which can each be independently stimulated.
One way to isolate horizontal sections of a well in anticipation of fracturing is to use inflatable packers. Inflatable packers can be maneuvered into a desired section of the horizontal well and set to isolate the section. However, inflatable packers have a limited pressure containing capacity, often not enough to facilitate fracture of a formation, and therefore they have a high tendency to fail and add significant downtime to the completion operation.
There is another tool, the Wizard Packer from Dresser, that allows isolation of a horizontal well into preset lengths to facilitate stimulation of the formation, but it requires sending darts into the sections to open sliding sleeves which allow the treating fluid to enter into the isolated section. Despite the isolation, there is sometimes still no stimulation within the preset segment if one or more of the interval sections does not contain a natural fracture to enhance. There is no way to adjust the isolated length and effectively stimulate a new length without removing and resetting the entire system. The Wizard Packer is often prohibitively expensive, and is not retrievable. The Wizard Packer is fairly long in length and rigid, such that it often cannot negotiate small radius turns in a wellbore. There is a need for a less expensive, more maneuverable tool to isolate sections of the horizontal lateral at any length without removing the tool from the wellbore since the time and expense for each entry and withdrawal of a tool from a well is significant. The location of the natural fractures within a wellbore may not be known, and presetting the isolated lengths allows no flexibility for moving and adjusting the sections to find natural fractures to enhance.
In addition, there is no effective method of testing the sections of a horizontal wellbore for their respective production levels following stimulation.
The present invention is directed to overcoming, or at least reducing the effects of, one or more of the problems set forth above.
SUMMARY OF INVENTION
In one aspect of the present invention, a FracShield assembly for isolating and stimulating single or multiple sections of a substantially horizontal or vertical wellbore in a single trip is provided. The assembly according to one embodiment comprises a mandrel with a topsub, a plurality of anchoring hydraulic buttons, a packing element, and a sealing cup. The sealing cup is housed within a removable protective sheath. The assembly is self-sealing upon the application of pressure within the isolated well segment and is designed primarily to facilitate fracturing a horizontal well when a pressurized fluid is introduced into the isolated section. The assembly is deployed by pumping a ball or dart through the work string and the mandrel of the assembly, which seats in the protective sheath until the pressure within the mandrel reaches a level necessary to shear the holding pins and jettison the sheath from the tool. Upon removal of the sheath, the sealing cup, which is radially outward biased, creates a seal with the inner circumference of the wellbore. The device may include a second seal that is also pressure activated to further contain significant pressure during the stimulation of the well. After stimulating a particular section of the wellbore, the assembly is pulled uphole and reset to stimulate another section of the wellbore. Thus, the assembly permits stimulating multiple zones of the wellbore in a single trip.
According to another embodiment, the assembly exhibits a plurality of slip-on-cone-type anchoring slips. The slips begin to traverse the cone when the pressure on the sealing cup reaches a predetermined level, and the slips continue to move longitudinally and radially along the cone until they anchor themselves in the wall of the wellbore. The slip assembly for gripping the wall of the wellbore in this embodiment can move relative to the mandrel in cases of contraction of the work string to which the mandrel is connected, or in other circumstances. The movement of the slip assembly is controlled by a control collet which includes several collet fingers initially engaged with a shoulder.
The device can be used for production testing of isolated well segments as well. When a well is completed, the tool can be used to isolate segments of the well to facilitate testing each interval for its respective production level.
One embodiment of the device is a single trip multiple-zone isolation tool for stimulating or testing a wellbore that includes a mandrel with a bore therethrough, multiple hydraulically actuated buttons that are arranged radially about the outer diameter of the mandrel for gripping the wall of the wellbore, and a sealing cup coaxially arranged about the mandrel wherein the the sealing cup is radially biased to extend to the diameter of the wall of the wellbore. The mandrel is adapted for connection to a jointed pipe or coiled tubing, the sealing cup is covered by a protective sheath during tool run-in, and the hydraulically actuated buttons are operable in response to hydraulic pressure to move radially outward to engage the wall of the wellbore. As the hydraulic pressure increases, the sealing force of the sealing cup against the wall of the wellbore also increases causing the portion of the wellbore adjacent to the tool to become isolated. The protective sheath is attached to the mandrel by multiple releasable means to ensure the sheath remains in place until it is desirable to jettison it from the end of the tool. These releasable means may include shear screws, collet fingers, or an interlock system. The interlock system may be unlocked by internal hydraulic pressure, allowing the sheath to be jettisoned from the tool.
In one embodiment the tool exhibits a secondary seal comprising a packing element that is predisposed to buckle under the application of longitudinal force and seal against the wall of the wellbore. This packing element returns to its pre-buckle condition upon the removal of longitudinal force. The hydraulically actuated buttons or slips return to their run-in positions when internal pressure is substantially equalized with annular pressure.
The present invention is directed to methods of stimulating a wellbore. The method for stimulating a subterranean well comprises: a) running an isolation tool on a jointed pipe or coiled tubing into the well and positioning the tool adjacent a first interval of interest; the isolation tool comprising a mandrel having a bore therethrough, a plurality of hydraulically actuated buttons or slip-on-cone-type anchoring slips arranged about the mandrel for gripping the wall of the wellbore, and a sealing cup coaxially arranged about the mandrel wherein the sealing cup is radially biased to extend to the wall of the wellbore with the sealing cup initially covered by a protective sheath; b) pressurizing the jointed pipe or coiled tubing to jettison the protective sheath circumscribing a sealing cup from the end of the tool and actuate the hydraulically actuated buttons or slip-on-cone-type anchoring slips into engagement with the wall of the wellbore; c) isolating the interval of interest with a seal formed by the sealing cup against the wellbore wall; d) stimulating the isolated interval by hydraulic fracturing or acidizing; e) placing a plug downhole of the tool; f) substantially equalizing the internal pressure of the work string and tool with the annular pressure to release the tool from the wall of the wellbore; g) moving the tool uphole a desirable distance, resetting the hydraulically actuated buttons or slips, and forming a seal with the sealing cup by pressurizing the jointed pipe or coiled tubing; h) stimulating the new interval; i) substantially equalizing the internal pressure of the tool with the annular pressure to release the tool from the wall of the wellbore; and j) repeating the steps (g)-(i) until all the intervals of interest are stimulated.
The method of stimulating a subterranean well may also comprise the steps of: a) running the isolation tool on a jointed pipe or coiled tubing into the well and positioning the tool adjacent a first interval of interest, wherein the isolation tool comprises a mandrel having a bore therethrough, a hydraulically actuated button or slip assembly arranged about the mandrel for gripping the wall of the wellbore, a sealing cup coaxially arranged about the mandrel wherein one end of the sealing cup is radially biased to extend to the wall of the wellbore, and wherein the sealing cup is initially covered by a protective sheath; b) releasing the protective sheath from the tool to expose the sealing cup; c) actuating the slip assembly to engage the wall of the wellbore; d) isolating the interval by forming a seal against the wellbore wall with the sealing cup; e) stimulating the interval; f) placing a plug downhole of the tool; g) releasing the tool from the wall of the wellbore; h) moving the tool uphole and positioning the tool adjacent a new interval and repeating steps (c)-(h) until all intervals of interest have been stimulated. This method may alternatively include only steps (a)-(e) without any repetition.
The present invention is also directed toward methods for testing a subterranean well. The method for testing a subterranean well may comprise: a) running the isolation tool on a jointed or coiled tubing into the well and positioning the tool adjacent the first interval of interest, the isolation tool comprising a mandrel having a bore therethrough, a plurality of hydraulically actuated buttons arranged about the mandrel for gripping the wall of the wellbore and a sealing cup coaxially arranged about the mandrel wherein the sealing cup is radially biased to extend to the wall of the wellbore with the sealing cup initially covered by a protective sheath; b) pressurizing the jointed pipe or coiled tubing to actuate the anchoring hydraulically actuated buttons to engage the wall of the wellbore and to jettison the protective sheath circumscribing a sealing cup from the end of the tool; c) isolating the interval of interest with a seal formed by the sealing cup against the wellbore wall; d) reducing work string pressure and allowing production fluids from the formation to flow through the interior passageway of the tool and to the jointed pipe or coiled tubing string; e) measuring production from the isolated interval, f) substantially equalizing the internal pressure of the jointed pipe or coiled tubing with the annular pressure to release the tool from the wall of the wellbore; g) moving the tool uphole a desirable distance and reducing annular pressure to allow the hydraulically actuated buttons to actuate and the sealing cup to again seal; h) measuring production from the new interval or combined intervals; i) substantially equalizing the internal pressure on jointed pipe or coiled tubing with the annulus pressure to release the tool from the wall of the wellbore; and j) repeating steps (g)-(i) until the entire interval of interest is tested.
The method for testing a subterranean well may also comprise: a) running the isolation tool on a jointed or coiled tubing into the well and positioning the tool adjacent the first interval of interest, the isolation tool comprising a mandrel having a bore therethrough, a plurality of slip-on-cone-type anchoring slips arranged about the mandrel for gripping the wall of the wellbore and a sealing cup coaxially arranged about the mandrel wherein the sealing cup is radially biased to extend to the wall of the wellbore with the sealing cup initially covered by a protective sheath; b) pressurizing the jointed pipe or coiled tubing to jettison the protective sheath circumscribing the sealing cup from the end of the tool; c) actuating the slip-on-cone-type anchoring slips; d) isolating the interval of interest with a seal formed by the sealing cup against the wellbore wall; e) reducing jointed pipe or coiled tubing pressure and allowing production fluids from the formation to flow through the interior passageway of the tool and to the production tubing; f) measuring production from the isolated interval, g) substantially equalizing the internal pressure of the work string with the annular pressure to release the tool from the wall of the wellbore; h) moving the tool uphole a desirable distance and reducing annular pressure to allow the sealing cup to seal and the slips to actuate again; i) measuring production from the new interval or combined intervals; j) substantially equalizing the internal pressure on the jointed pipe or coiled tubing with the annular pressure to release the tool from the wall of the wellbore; and k) repeating steps (h)-(j) until the entire interval of interest is tested.
The testing method may also comprise the steps of: a) running an isolation tool on a jointed pipe or coiled tubing into said well and positioning the tool adjacent a first interval of interest, wherein the isolation tool comprises a mandrel having a bore therethrough, a slip assembly arranged about the mandrel for gripping the wall of the wellbore and a sealing cup coaxially arranged about the mandrel wherein one end of the sealing cup is radially biased to extend to the wall of the wellbore and wherein the sealing cup is initially covered by a protective sheath; b) releasing the protective sheath from the tool to expose the sealing cup; c) actuating the slip assembly to engage the wall of the wellbore; d) isolating the interval by forming a seal against the wellbore wall with the sealing cup; e) testing the interval; f) releasing the tool from the wall of the wellbore; g) moving the tool uphole and positioning the tool adjacent a new interval and repeating steps (c)-(g) until all intervals of interest have been tested.
The methods for stimulating a subterranean may include hydraulic fracturing and acidizing of the formation. The stimulating and testing method may include placing a plug at each interval, this plug may be a sand plug, and chemical plug, a mechanical plug, or other plug known in the art. The stimulating and testing method may also include pressurizing the annulus of the wellbore to help facilitate the release of the tool from the walls of the wellbore.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features and aspects of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:
FIGS. 1A-1 to 1 A- 4 depicts a crossection of a FracShield device in accordance with one embodiment of the present invention.
FIGS. 1B-1 to 1 B- 4 depicts the FracShield just after the protective sheath has been jettisoned from the tool.
FIGS. 1C-1 to 1 C- 4 depicts the FracShield fully deployed and under the application of pressure.
FIG. 2 depicts a top crossectional view of the hydraulically actuated button slips assembly.
FIG. 3 depicts a second crossectional view of the hydraulically actuated button slips assembly.
FIGS. 4A-1 to 4 A- 4 depicts an alternative embodiment of the FracShield in the run-in position.
FIGS. 4B-1 to 4 B- 4 depicts the alternative embodiment just after the protective sheath has been jettisoned from the tool.
FIGS. 4C-1 to 4 C- 4 depicts the alternative embodiment of the FracShield fully deployed and under the application of pressure.
FIG. 5 depicts a bottom view of the slip ring in the alternative embodiment.
FIG. 6 depicts a top view of the cone assembly of the alternative embodiment without the anchoring slips in place.
FIG. 7 depicts a top view of the control collet of the alternative embodiment.
FIG. 8 depicts one embodiment of the invention in a wellbore after the sheath has been jettisoned from the tool.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Illustrative embodiments of the invention are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, that will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
Turning now to the drawings, and in particular to FIGS. 1A-1 to 1 C- 4 , a preferred embodiment of the FracShield assembly is illustrated in a wellbore 5 in accordance with the present invention. Beginning at the top of the tool, an internally threaded topsub 12 is attached to an externally threaded receptacle 100 . The topsub is designed such that a jointed work string of drill pipe or tubing can be attached to the top of the device. Alternatively, the topsub may be adapted to be connected to a coiled tubing work string. Disposed within topsub 12 are a plurality of O-rings 16 which act as seals. The topsub position relative to receptacle 100 is secured by a plurality of set screws 20 , for example four set screws spaced about the circumference of the topsub may be used. Receptacle 100 comprises the housing of the tool anchoring assembly. The anchoring assembly includes a plurality of hydraulically actuated buttons 104 that are disposed within receptacle 100 . Hydraulically actuated buttons 104 , shown in FIGS. 1A-2 to 1 C- 2 , are radially arranged about the outer diameter of the tool. Each of the hydraulically actuated buttons include a geometric pattern of gripping teeth 106 comprising the outer surface of the hydraulically actuated buttons. The tooth geometry may be adjusted depending on the conditions of the rock formation and/or casing in which the tool is to be anchored. The outer surfaces of hydraulically actuated buttons 104 are flush with or recessed within the outer diameter of receptacle 100 in the tool run-in position as illustrated in FIG. 1A-2. Each hydraulically actuated button 104 has a button strap 114 extending across the diameter of the button, the strap being secured at both ends by a bolt 118 . Button strap 114 constrains the force of a plurality of springs 108 which are located in holes 112 in hydraulically actuated button 104 . The springs 108 are disposed between button strap 114 and the bottom of hydraulically actuated button 104 . FIGS. 2 and 3 illustrate a crossectional view of the hydraulically actuated buttons assembly (springs not shown for clarity). The springs are radially inward biased with the tendency of each to retract the slips into receptacle 100 . Buttons 104 are hydraulically actuated by fluid manipulation through the work string when it becomes necessary to anchor the tool in a desired position within a wellbore.
The inner surface of receptacle 100 comprises a button sleeve 123 that is threadedly attached to the receptacle opposite the connection to the topsub 12 . The button sleeve exhibits a plurality of small slots 120 cut into its outer diameter to permit fluid pressure communication to hydraulically actuated buttons 104 while minimizing any admission of solid particles. The fluid path reaches slot 120 after negotiating a gap 122 at the distal end of button sleeve 123 which also limits solid particle entry. As the fluid pressure increases, the pressure is communicated to hydraulically actuated button 104 which overcome the restraining spring force and move in a radially outward direction until they contact a wall 7 of the wellbore and anchor the tool in place.
Receptacle 100 is threaded both internally and externally at its lower end. The internal threading of the receptacle attaches about the outer diameter of a mandrel 14 . The position of the receptacle relative to the mandrel is secured by a plurality of set screws 124 . Mandrel 14 exhibits a passageway 22 therethrough, said passageway providing for the introduction of fluid through the device and into the isolated section of the well for stimulation of the formation. Passageway 22 is also formed by the inner diameters of button sleeve 123 and top sub 12 at the upper end of the tool. The external threading of the receptacle attaches to an upper gage ring 47 . The threaded upper gage ring 47 is bonded to the upper side of an elastomeric packing element 51 . In an alternative embodiment, the packing element might be polymeric. A lower gage ring 52 is similarly bonded to the lower side of packing element 51 . Both of the gage rings include a retainer 54 for holding packing element 51 in place. Packing element 51 is predisposed to buckle in a radially outward direction upon the application of longitudinal force. As more wellbore pressure downhole of the FracShield assembly is applied to the work string, packing element 51 seals against wellbore 5 . FIGS. 1C-2 and 4 C- 2 show packing element 51 in the buckled position creating a seal against the wellbore. Packing element 51 is a backup seal to a sealing cup 70 , which is discussed below. In an alternative embodiment, packing element 51 is not a part of the assembly.
Lower gage ring 52 is threadedly connected to a retainer 62 . Retainer 62 houses a plurality of upper shear screws 64 and exhibits an internal counterbore. Disposed between the retainer and the mandrel is a pick up ring 68 which prevents relative downward movement of retainer 62 with respect to mandrel 14 . Retainer 62 makes a threaded connection to a sealing cup 70 that is immediately below the retainer. Sealing cup 70 is radially outward biased such that when protective sheath 60 is jettisoned from the bottom of the device, sealing cup 70 moves radially outward and forms a seal with the wall of wellbore 5 . In the preferred embodiment sealing cup 70 might comprise a highly abrasion-resistant nitrile rubber, possibly with the addition of internal reinforcement, or some other polymeric material conducive to the wear resulting from moving the device in open hole without the protective sleeve.
In a preferred embodiment, protective sheath 60 is primarily held in a position circumscribing sealing cup 70 by an assembly of collet fingers 72 and an interlock sleeve 77 . An end 61 of protective sheath 60 may abut a notch 58 in lower gage ring 52 in the run-in position as shown in FIGS. 1A-3 and 4 A- 3 . A plurality of shear screws 74 secure the interlock sleeve in position relative to the mandrel. Collet fingers 72 and interlock sleeve 77 ensure that the sheath cannot be separated from the tool except by hydraulic actuation. This feature is desirable when, for example, the tool becomes stuck during insertion, particularly in an open hole wellbore. Sheath 60 protects sealing cup 70 from damage as the assembly is run into the wellbore. When the tool is going through a tight section of the wellbore there may be significant frictional forces on sheath 60 that would tend to force it from the end of the device. If sheath 60 were to come off, the tool could not be advanced down the wellbore without risking damage to sealing cup 70 because of its natural outward bias. The collet fingers and interlocking sleeves, combined with multiple shear screws, ensure a robust design such that a mechanical force alone cannot release the sheath, the force must be accompanied by hydraulic actuation that releases the interlock. The second set of shear screws 64 are included in the present embodiment to further secure sheath 60 over sealing cup 70 . Upper shear screws 64 prevent gage rings 47 & 52 and packing element 51 from moving up relative to the mandrel. The gage rings or packing element may have a tendency to move relative to the mandrel if, for example, one of them comes into contact with the wall of the wellbore during insertion of the assembly. The restricted movement of these elements prevents the premature activation of packing element 51 .
The lower end of the protective sheath houses a ball seat assembly 76 . The ball seat assembly is designed to receive a ball 78 when it becomes desirable to jettison sheath 60 from over sealing cup 70 . A ball is dropped from the surface and circulated down the jointed pipe or coiled tubing. The ball continues to be circulated through the interior of the tool until it rests on and makes a seal with ball seat assembly 76 . As internal pressure is increased, a conduit 75 facilitates fluid communication with interlock sleeve 77 such that an upward force is transmitted to the interlock sleeve. When the internal pressure reaches a predetermined value, interlock sleeve 77 , which is a toroidal piston, shears shear screws 74 and uncovers collet fingers 72 . After collet fingers 72 have been uncovered, upper shear screws 64 shear, allowing ball seat 76 and protective sheath 60 to be jettisoned longitudinally downward relative to the mandrel as shown in FIG. 8 . The sheath is left in the wellbore, as it is not necessary to retrieve it following the fracturing operation. It will also be understood that other types of sealing devices, such as a dart, may be used as a suitable alternative to ball 78 .
Operation of the FracShield may be illustrated as follows. The FracShield is run into a cased or open hole wellbore on a work string and positioned adjacent to the interval of interest. The work string may include jointed pipe, tubing, or coiled tubing. While the shield is being inserted, hydraulically actuated buttons 104 of anchoring assembly 102 are flush with or recessed within the outer diameter of receptacle 100 to allow the tool to be inserted without hindrance from teeth 106 of the hydraulically actuated buttons creating friction against the wall of the wellbore. If the FracShield encounters resistance to movement within the wellbore due to a tight spot or some other hindrance, the tool facilitates fluid circulation either down the tubing, through the tool, and up the annulus; or down the annulus, through the tool, and up the tubing to help release the tool from the tight spot.
Once the tool has been positioned adjacent to the first interval of interest, a ball is deployed and circulated down through the work string. The ball continues to circulate through the interior of the tool and eventually lands on ball seat assembly 76 of protective sheath 60 . The ball makes a seal with seat 76 and the pressure inside the work string is increased. When the pressure inside the tool reaches a predetermined level, interlock sleeve 77 shears shear screws 74 and uncovers collet fingers 72 . The uncovered collet fingers release, and the internal pressure forces sheath 60 to jettison from the end of the tool. The amount of pressure required to jettison the sheath will be a function of the number of shear screws used and the shear strength of the screws. By way of example, the sheath may be jettisoned when the internal pressure exceeds 1000 psi. FIGS. 1B-1 to 1 B- 4 illustrate the tool immediately after the protective sheath has been jettisoned from the tool. The sheath may remain in the well, as it is intended to be expendable. Sheath 60 may be made, for example, of a degradable material.
With sheath 60 no longer on the tool, sealing cup 70 , which is radially outward biased, immediately expands and makes contact with the walls of the wellbore. Pressurized treating fluid from the work string continues through the interior of the tool and comes into contact with the isolated section of the well. The pressure in the isolated section of the wellbore forces sealing cup 70 to form an even tighter seal with the walls of the well. The higher the pressure, the tighter the seal of the sealing cup with the wellbore. In addition to creating a seal, the pressure on packing cup 70 allows the cup to act like a piston, which pushes back against retainer 62 . Retainer 62 communicates this force to lower gage ring 52 , which may be bonded to packing element 51 . Packing element 51 is then compressed until the force acting on it from lower gage ring 52 reaches a level that causes packing element 51 to buckle. The buckling occurs in a predisposed way such that the packing element moves in a radially outward manner. The packing element continues to buckle until it seals against the wall of the wellbore. FIG. 1C-2 exhibits packing element 51 in the buckled position forming a seal with the wall of the wellbore. The packing element seal is a secondary seal, further ensuring that the pressurized fluid from the work string is not transmitted to other sections of the well. Before the pressure builds to a level high enough to buckle the packing element, however, the pressure inside the tool reaches a predetermined level that actuates hydraulically actuated buttons 104 to extend radially outward until teeth 106 of the slips engage the walls of the wellbore, securing the tool in .position as shown in FIGS. 1C-1 to 1 C- 4 .
With the tool anchored and a double seal accomplished, the isolated wellbore section can be effectively treated. For example, the natural fractures in the formation may be hydraulically fractured and/or acidized to increase their productivity.
When the stimulation treatment for the isolated section is complete, a plug, for example a sand, chemical, or mechanical plug, may be placed in the wellbore adjacent the formation to keep this section of the wellbore isolated from subsequent treatments. Once the plug is in place the pressure in the tubing string is reduced and the tool returns to its deactivated position as shown in FIGS. 1B-1 to 1 B- 4 . Sealing cup 70 relaxes to a less substantial seal with the wellbore wall, packing element 51 which had buckled is returned to the initial position, and hydraulically actuated button slips 104 release their grip and retract into receptacle 100 as the pressure inside the tool decreases. Should the seals and hydraulically actuated buttons remain set after the pressure has been reduced, for example due to friction, the annular space between the tool and the wellbore can be pressurized from the surface to equalize the pressure across the tool and relax the slips and seals. Alternatively, the well could be killed using a kill fluid and all the pressure on the work string bled off, allowing the tool to relax.
After the tool has been returned to the relaxed position as shown in FIGS. 1B-1 to 1 B- 4 , it can be pulled back in the wellbore any desired distance to the next section of the wellbore to be treated. The process of setting the tool and stimulating the newly isolated section of the wellbore is repeated. This process may be repeated as often as necessary until the entire horizontal or vertical section has been treated, after which the tool is retracted from the well and recovered for future use.
The invention may also be used to test isolated sections of the wellbore. To accomplish testing, the tool is connected to a work string, for example a coiled tubing or drill pipe, run into the wellbore, and positioned adjacent the interval to be tested. Protective sheath 60 of the assembly is jettisoned from the tool as described above. Following the deployment of protective sheath 60 , the tool is set in the same manner as described above, except the sealing pressure is provided by the natural pressure of the formation. With the tool set in position and connected to a production tubing string, annular blowout preventors can be closed, annular pressure bled down, and the pressure from the well forces the production fluid through passageway 22 of the mandrel and into the production tubing. Production tests can then be conducted for the isolated well section.
When the production test for the first isolated well section has been completed, the tool is returned to its relaxed position as shown in FIGS. 1B-1 to 1 B- 4 by pressurizing the annulus or killing the well. The tool is then pulled up the wellbore and repositioned above the next interval to be tested. The tool is reset into the position shown in FIGS. 1C-1 to 1 C- 4 with the seals and hydraulically actuated buttons again set in place. As the production test from the newly isolated well section is conducted, a simple calculation will reveal what portion of the measured production is contributed by the segment of well extending from the previous tool position to the current tool position. The process of releasing the tool, repositioning, resetting, and testing is repeated until the desired production information from the various segments within the well is gathered.
FIGS. 4-7 illustrate an alternative embodiment of the FracShield, namely an alternative anchoring assembly and topsub. In the alternative embodiment illustrated as FIGS. 4A-1 to 4 C- 4 , there is a control collet 24 attached to mandrel 14 just below topsub 12 . The topsub position relative to mandrel 14 is secured by a plurality of set screws 20 . The topsub includes external slots 18 to permit fluid bypass. Control collet 24 is disposed about the external diameter of mandrel 14 . Control collet 24 includes a plurality of fingers 26 that extend beyond a shoulder 28 . The shoulder is part of the outer surface of the mandrel and together with fingers 26 of control collet 24 act as a restraint to movement of a slip ring 30 relative to the mandrel. The shoulder 28 restraint is not intended to be absolute. When a force between slip ring 30 and mandrel 14 becomes sufficiently large, control collet fingers 26 are intended to disengage the shoulder and slide down relative to the mandrel. FIG. 7 shows a top view of the control collet assembly with fingers 26 engaging shoulder 28 of the mandrel.
Formed on the inside diameter of control collet 24 is a counterbore 32 which creates a gap between the control collet and the mandrel that can be seen in FIGS. 4A-2 to 4 C- 2 . A groove 38 is cut into the mandrel adjacent control collet counterbore 32 , and a split ring 36 is disposed between the counterbore and groove, making contact between slip ring 30 and mandrel 14 . Split ring 36 limits the movement of slip ring 30 toward the top of the tool. For example, while the tool is being inserted into a wellbore, slip ring 30 may come into contact with the wall of the wellbore and encounter some resistance to further movement. Slip ring 30 is designed for movement relative to mandrel 14 , but during the insertion of the tool no relative movement is desired. Since split ring 36 is in place, further introduction of the assembly into the wellbore while slip ring 30 is encountering resistance against the wall of the wellbore will not result in movement of slip ring 30 and control collet 24 relative to mandrel 14 because slip ring 30 will make contact with split ring 36 and stop any relative movement toward the top of the tool. Control collet counterbore 32 will, however, allow for relative movement of slip ring 30 and assembly toward the bottom of the assembly when such movement is desirable. The circumstances under which the movement of slip ring 30 is desirable are discussed below.
Slip ring 30 , which is adjacent the control collet, includes multiple fluid bypass slots 34 to facilitate fluid bypass through the annular space between slip ring 30 and wellbore 5 . These slots 34 , along with slip ring 30 , are illustrated in FIG. 5 . Slip ring 30 is threadedly attached to the outer diameter of control collet 24 and secured in place by a plurality of set screws 40 . The edge 42 of the slip ring toward the bottom of the tool is slanted, forming an obtuse angle with the outer surface of mandrel 14 . Immediately toward the bottom of the tool and adjacent to slip ring 30 are a plurality of gripping slips 44 that are deposed within slots 45 of a cone 46 . Cone 46 is attached about the outer surface of the mandrel by a threaded connection to upper gage ring 47 . Cone 46 possesses a plurality of slots 45 cut through it, said slots being cut at such an angle that they break through the outer diameter of the cone. These slots 45 will extend slips 44 radially outward when downward longitudinal movement of the slips occurs. Slips 44 may continue to move radially outward until they either reach the walls of the wellbore and secure the tool in the desired position within the wellbore, or the stroke of cone 46 has been traversed. Disposed within cone 46 are a plurality of shoulder bolts 48 which have the purpose of limiting the movement of slip ring 30 and slips 44 to the predetermined stroke of cone 46 .
On the inner diameter of cone 46 is a counterbore 49 coaxially located with a groove 50 a cut in the outer diameter of the mandrel. A split ring 50 is disposed between cone 46 and the mandrel 14 residing within groove 50 a . Split ring 50 has the purpose of preventing the relative movement of cone 46 toward the bottom of the mandrel.
Adjacent and attached to cone 46 is upper gage ring 47 , and all components of the alternative embodiment from the upper gage ring down to the end of the tool are the same as for the preferred embodiment.
Operation of the alternative embodiment may be illustrated as follows. The FracShield is run into the wellbore on a work string and positioned adjacent to the interval of interest. The work string may consist of drill pipe, tubing, or coiled tubing. While the shield is being inserted, fingers 26 of control collet 24 are extended around shoulder 28 to prevent movement of the slip ring relative to the mandrel, which would prematurely actuate slips 44 . Collet fingers 26 are necessary in the event that the slip ring comes into contact with the wall of the wellbore when the tool is retracted from the hole. For example, it may be necessary to retract the tool a certain distance in order to overcome an obstacle or to reposition the tool for further deployment. If the control collet is not engaged with the shoulder, the frictional force of the slip ring against the well might be more than the force being used to pull the tool back, and slips 44 would stroke up cone 46 and set prematurely.
Once the tool has been positioned adjacent to the first interval of interest, the ball is deployed and circulated down through the work string in the same manner as described above for the preferred embodiment to jettison sheath 60 from the end of the tool. FIGS. 4B-1 to 4 B- 4 illustrates the alternative embodiment immediately after the protective sheath has been jettisoned from the tool.
Sealing cup 70 operates in the same manner in the alternative embodiment as it does in the preferred embodiment described above. However, the longitudinal force transmitted in a piston-like fashion to the packing element is further communicated in the alternative embodiment to the cone. When pressure is transmitted to cone 46 , the cone moves up relative to the mandrel 14 and forces gripping slips 44 radially outward and into engagement with the casing or rock which secures the tool in place.
Once the alternative embodiment of the tool is set in place and work string pressure continues to increase, there may be some contraction of the work string as a result of cooling, high pressure, or other phenomena. The contraction of the work string will tend to pull mandrel 14 of the tool back out of the hole, as the mandrel is rigidly connected to the work string via topsub 12 . To avoid movement of packing element 51 , sealing cup 70 , and slips 44 as the work string contracts, slip ring 30 allows movement of mandrel 14 relative to the components mounted on the outer surface of the mandrel. Control collet 24 will allow movement of the mandrel as the tubing contracts provided the contraction force exceeds the force necessary to overcome fingers 26 engaged with retaining shoulder 28 . Thus, control collet fingers 26 of the alternative embodiment are designed such that they provide enough retaining force to hold slip ring 30 in position during insertion of the tool, but release prior to pulling slips 44 off of cone 46 once the tool is set in position and the work string contracts. FIGS. 4C-1 to 4 C- 4 show the situation herein described with slips 44 fully deployed and control collet fingers 26 no longer engaged with shoulder 28 .
When the alternative embodiment has been anchored and a double seal accomplished, the isolated wellbore section can be treated and plugged in the same manner as described above for the preferred embodiment.
When the treatment is complete and the plug is in place, the pressure in the tubing string is reduced and the alternative embodiment returns to its relaxed position as shown in FIGS. 4B-1 to 4 B- 4 . Sealing cup 70 relaxes to a less substantial seal with the wellbore wall, packing element 51 which had buckled is returned to the initial position, and slips 44 release their grip as they move back down cone 46 . The tubing string is slacked off so that control collet fingers 26 return to their position engaged with shoulder 28 . Similar to the preferred embodiment, should the seals and slips remain set after the pressure has been reduced (due to friction, for example), the annular space between the tool and the wellbore can be pressurized from the surface to relax the slips and seals.
After the alternative embodiment of the tool has been returned to the relaxed position as shown in FIGS. 4B-1 to 4 B- 4 , it can be pulled back in the wellbore any desired distance to the next section of the wellbore to be treated, or it can be recovered to the surface, just as described above for the preferred embodiment.
The alternative embodiment of invention may also be used to test isolated sections of the wellbore in the same manner as described for the preferred embodiment.
While the present invention has been particularly shown and described with reference to various illustrative embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention. The above-described embodiments are illustrative and should not be considered as limiting the scope of the present invention.
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A tool for isolating segments of a wellbore. The tool includes a packing cup housed in a protective sheath during the insertion of the device into the wellbore. The packing cup is radially outward biased. The protective sheath is removable. Upon removal of protective sheath the packing cup expands and creates a seal with the wellbore. Pressurized fluid pumped through the tool increases pressure within the segment and tightens the packing cup seal. Packing cup also acts like a piston, imparting a force to a packing element predisposed to buckle in a radially outward direction. Packing element makes a second seal with the wall of the wellbore. A hydraulically actuated button slip assembly anchors the tool in place. The tool can contain significant pressure to facilitate well stimulation and completion by fracture or acidization. The tool can also be used to facilitate measuring production from an isolated segment of the well. The tool is resettable and can be maneuvered to isolate any desired length of the wellbore.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ultrasonic treatment apparatus for treating a tumor or the like in a living body using an ultrasonic wave.
2. Description of the Related Art
In recent years, an improvement of the quality of life (QOL) for patients after surgical operations has been demanded. With this trend, treatments categorized a minimally invasive treatment (MIT) has received a great deal of attention in the medical field.
An example of an MIT is a practical application of a lithotrite for irradiating a high-intensity extracorporeal ultrasonic wave on a stone to non-invasively break it, thereby greatly changing the therapy for urinary calculi. A high-intensity ultrasonic source used in such lithotrite is of a submerged discharge, electromagnetic induction, small-explosion, or piezoelectric type. In particular, although the piezoelectric ultrasonic source has a disadvantage in that the pressure of a high-intensity ultrasonic wave is low, it has the following advantages. The piezoelectric ultrasonic source can form a small focus spot, does not have any expendable components, can facilitate output control, can phase-control the driving voltages applied to a plurality of piezoelectric elements to arbitrarily control the focal position (Jpn. Pat. Appln. KOKAI Publication No. 60-145131 and U.S. Pat. No. 4,526,168).
In the therapeutic field of cancers, the MIT is one of the key words. Most cancer treatments currently depend on surgical operations. The functions and outer shapes of internal organs upon surgical operations often suffer greatly, which imposes great burdens on patients although they live on. Strong demand has therefore arisen for establishing an MIT and a treatment apparatus in consideration of the QOL.
Under these circumstances, a hyperthermia treatment has received an attention as one of malignant neoplasm, so-called cancer treatment techniques. According to this treatment method, utilizing a difference in caumesthesia between a tumor tissue and normal tissue, a morbid portion is heated to 42.5° C. or more and kept at this temperature to selectively kill only cancer cells. A method using an electromagnetic wave such as a microwave is popular as the heating method. However, this method is difficult to selectively heat a deep tumor due to the electrical characteristics of the living body. A good treatment effect cannot be expected for a tumor 5 cm or more deep from the skin surface. A method using ultrasonic energy which has excellent focusing characteristics and can reach a relatively deep portion is proposed as a method of treating a deep tumor (Jpn. Pat. Appln. KOKAI Publication No. 61-13955).
As an improvement of the above thermotherapy, there is also reported a treatment method of sharply focusing an ultrasonic wave generated by a piezoelectric element to heat a tumor portion to a temperature of 80° C. or more, thereby instantaneously thermally degenerating and necrotizing the tumor tissue (G. Vallancien et. al.: Progress in Uro. 1991, 1, 84-88 EDAP papers!, and U.S. Pat. No. 5,150,711).
According to this thermotherapy, unlike in the conventional hyperthermia, an ultrasonic wave having a very high intensity of, e.g., several hundred or thousand W/cm 2 is incident on a limited area near the focal point. For this reason, a specific phenomenon occurs in which cavitations (bubbles) are formed and the morbid portion qualitatively changes due to heat. By this specific phenomenon, the acoustic characteristics of the area change, the treatment effect may be decreased, and the treatment time may be prolonged.
Air is a highly reflective substance for an ultrasonic wave, and the ultrasonic wave cannot reach deeper than the area where bubbles are formed.
In the area where bubbles are formed, the ultrasonic wave is scattered and the apparent attenuation amount increases. For this reason, heat tends to be generated. When irradiation of a high-intensity ultrasonic wave is continued while cavitation are kept formed, an unwanted portion may be heated to cause a side effect.
As described in Jpn. Pat. Appln. KOKAI Publication No. 60-145131 and U.S. Pat. No. 4,658,828, high-intensity ultrasonic waves are intermittently irradiated at an interval corresponding to the time required for the cavitation to naturally break. This method, however, poses a problem of a long treatment time.
A morbid portion may be treated while the treatment progress and temperature are monitored by the MRI. However, the magnetic susceptibility of the portion under treatment changes in the presence of cavitation, and an error may occur.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an ultrasonic treatment apparatus capable of forcibly SUPPRESSING cavitation.
A related object of the present invention is to provide an ultrasonic treatment apparatus comprising: an ultrasonic source for generating an ultrasonic treatment wave; and driving means for driving the ultrasonic source such that a frequency of the ultrasonic treatment wave generated by the ultrasonic source changes along a time axis.
A further object of the present invention is to provide an apparatus according to claim 1, further comprising: means for scanning a slice of a target object with an ultrasonic beam to repeatedly generate ultrasonic images on the basis of resultant reception signals; difference means for obtaining a difference between two ultrasonic frame images generated at different times; and means for counting, on the basis of a difference result from the difference means, timings at which the frequency of the ultrasonic treatment wave is changed.
A still further object of the present invention is to provide an ultrasonic treatment apparatus comprising: an ultrasonic source for generating an ultrasonic treatment wave; and driving means for driving the ultrasonic source such that a phase of the ultrasonic treatment wave generated by the ultrasonic source is modulated.
Yet another object of the present invention is to provide an ultrasonic treatment apparatus comprising: a first ultrasonic source for generating an ultrasonic treatment wave; a second ultrasonic source for generating an ultrasonic cavitation destruction wave having a frequency higher than that of the ultrasonic treatment wave; and driving means for driving the first and second ultrasonic sources.
The frequency of the ultrasonic treatment wave is changed over time. By this change in frequency, some cavitation are divided, and some collapse to be destroyed. A side effect to an unwanted portion and a spread of the thermal degeneration area can be suppressed. At the same time, a desired portion can be accurately thermally degenerated, thereby realizing a reliable, safe ultrasonic thermotherapy. Since cavitation are positively destroyed, the total treatment time can be shorter than the time during which cavitation naturally break and disappear, thereby improving the throughput.
In addition, the phase of the ultrasonic treatment wave is changed. By this change in phase, growing cavitation collapses and is destroyed. A desired portion can be accurately thermally degenerated, thereby realizing a reliable, safe ultrasonic thermotherapy. Since cavitation are positively destroyed, the total treatment time can be shorter than the time during which cavitation naturally break and disappear, thereby improving the throughput.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention and, together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a block diagram showing an arrangement according to the first embodiment of the present invention;
FIG. 2A is a chart showing one waveform of a frequency-modulated driving signal along the time axis;
FIG. 2B is a chart showing a change in frequency of the driving signal in FIG. 2A along the time axis;
FIG. 3A is a chart showing another waveform of the frequency-modulated driving signal along the time axis;
FIG. 3B is a chart showing a change in frequency of the driving signal in FIG. 3A along the time axis;
FIG. 4A is a chart showing still another waveform of the frequency-modulated driving signal along the time axis;
FIG. 4B is a chart showing a change in frequency of the driving signal in FIG. 4A along the time axis;
FIG. 5A is a chart showing still another waveform of the frequency-modulated driving signal along the time axis;
FIG. 5B is a chart showing a change in frequency of the driving signal in FIG. 5A along the time axis;
FIG. 6 is a graph showing the relationship between the frequency and the impedance;
FIG. 7A is a chart showing the waveform of an amplitude-modulated driving signal along the time axis;
FIG. 7B is a chart showing a change in output energy of an ultrasonic wave generated by the driving signal in FIG. 7A along the time axis;
FIG. 8 is a chart showing the waveform of a phase-modulated driving signal along the time axis;
FIG. 9 is a block diagram showing an arrangement according to the second embodiment of the present invention;
FIG. 10A is a chart showing the waveform of a frequency-modulated driving signal along the time axis;
FIG. 10B is a chart showing a change in frequency of the driving signal in FIG. 10A along the time axis;
FIGS. 11A to 11C are timing charts showing other changes in frequencies of driving signals along the time axis;
FIG. 12 is a graph showing the relationship between the cycle time, Tc, and the residual cavitation amount;
FIG. 13 is a graph showing the relationship between the frequency modulation time, Tfm, and the residual cavitation amount;
FIG. 14 is a graph showing the relationship between the frequency modulation width and the residual cavitation amount;
FIG. 15 is a block diagram showing an arrangement according to the third embodiment of the present invention;
FIG. 16A is a chart showing the waveform of a driving signal as time-divisional treatment and cavitation destruction driving signals along the time axis;
FIG. 16B is a chart showing one waveform of a driving signal obtained by superposing the cavitation destruction driving signal and the treatment driving signal;
FIG. 16C is a chart showing another waveform of a driving signal obtained by superposing the cavitation destruction driving signal and the treatment driving signal;
FIG. 17A is a sectional view of an ultrasonic source showing an arranging relationship between two types of piezoelectric elements having different resonance frequencies;
FIG. 17B is a sectional view of an ultrasonic source showing another arranging relationship between two types of piezoelectric elements having different resonance frequencies;
FIG. 18 is a block diagram showing an arrangement according to the fourth embodiment of the present invention;
FIG. 19A is a view illustrating a mask image before ultrasonic irradiation;
FIG. 19B is a view illustrating a real-time image during ultrasonic irradiation;
FIG. 19C is a view illustrating a difference image between the mask image and the real-time image;
FIG. 20A is a chart showing a change in difference level along the time axis;
FIG. 20B is a chart showing a timing at which frequency modulation is started;
FIG. 20C is a chart showing a timing at which phase modulation is started; and
FIGS. 21A and 21B are charts showing a change in frequency of the driving signal.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will be described with reference to the accompanying drawings.
(First Embodiment)
FIG. 1 is a view showing the arrangement of an ultrasonic treatment apparatus according to the first embodiment of the present invention. The ultrasonic treatment apparatus is a thermotherapy apparatus for continuously irradiating an ultrasonic treatment wave on a morbid portion for a relatively long period of time to heat the morbid portion, thereby treating the morbid portion.
An applicator 401 has an ultrasonic source 402 for generating an ultrasonic treatment wave having a relatively high output level. The ultrasonic source 402 has a plurality of piezoelectric elements. The plurality of piezoelectric elements are arranged in a spherical pattern so as to focus ultrasonic treatment waves from the respective elements at a focal point 406.
A water bag 405 is mounted on the focal point side of the ultrasonic source 402. A coupling solution 404 is sealed in the bag 405 so that an ultrasonic treatment wave generated by the ultrasonic source 402 is guided onto a target object 403 with little loss. The central portion of the ultrasonic source 402 is notched, and an ultrasonic imaging probe 408 for confirming the position of a morbid portion 407 is inserted in the central notch of the ultrasonic source 402. An ultrasonic tomograph 409 scans the interior of the target object 403 with an ultrasonic beam through the ultrasonic imaging probe 408 to obtain an ultrasonic tomogram (B-mode image) near the focal point. The ultrasonic tomogram is visually displayed as a halftone image on a CRT 415.
A frequency/phase modulator 412 generates a driving signal which oscillates in the form of a sinusoidal wave. The frequency/phase modulator 412 can modulate the frequency of this driving signal. In addition, the frequency/phase modulator 412 can also modulate the phase of the driving signal, as needed. For this purpose, the frequency/phase modulator 412 comprises a sinusoidal wave oscillator for performing, e.g., frequency modulation, and a phase modulator arranged to be capable of being bypassed between the sinusoidal wave oscillator and an output terminal. A driver 411 serving as a voltage amplifier amplifies the driving signal output from the frequency/phase modulator 412 and is arranged to perform amplitude modulation under the control of a system controller 413. The amplified driving signal is supplied to each piezoelectric element of the ultrasonic source 402 through an impedance matching circuit 410. Each piezoelectric element generates an ultrasonic treatment wave at a frequency equal to that of the driving signal.
The system controller 413 serving as the control center of the entire apparatus is connected to a console 414. The console 414 has a switch for designating the start/stop of irradiation (treatment) of the ultrasonic treatment wave, switches for setting various treatment conditions, and other switches.
An operation of this embodiment will be described below. First, frequency modulation will be described. It is preferable that the piezoelectric elements be driven at a resonance frequency f0 unique to the thickness of the piezoelectric elements to generate ultrasonic treatment waves at the resonance frequency f0 from the viewpoint of conversion efficiency of electrical signal/mechanical vibrations. As well known, when an ultrasonic treatment wave is irradiated on a target object for a relatively long period of time while the frequency of the ultrasonic treatment wave is kept at the resonance frequency f0, a cavitation (bubble) gradually grows to a size which depends on its wavelength.
The system controller 413 controls the frequency/phase modulator 412 to change a frequency fm of the driving signal in the range of f0-Δf/2≦fm<f0+Δf/2 centered on the resonance frequency f0 along the time axis. The frequency of the driving signal is equal to that of the ultrasonic treatment wave generated by the ultrasonic source 402. In the following description, the "driving signal" equivalently represents the "ultrasonic treatment wave". FIGS. 2A, 3A, 4A, and 5A show the waveforms of various driving signals along the time axis, respectively. FIGS. 2B, 3B, 4B, and 5B show changes in frequencies of the corresponding driving signals along the time axis, respectively. An operator may select one of a plurality of types of driving signals, or one type of driving signal may be permanently selected. The driving signal in FIG. 2A is generated such that its frequency changes sinusoidally. The driving signal in FIG. 3A is generated such that its frequency changes stepwise. The driving signal in FIG. 4A is generated such that its frequency continuously changes with a predetermined gradient from a low frequency (f0-Δf/2) to a high frequency (f0+Δf/2). The driving signal in FIG. 5A is generated such that its frequency is alternately switched between a time interval in which the frequency is fixed to the resonance frequency f0 and a time interval in which the frequency changes sinusoidally.
Such a change in frequency along the time axis, i.e., a change in wavelength along the time axis suppresses growth of cavitation, divides grown cavitation, and reduces the sizes of growing cavitation. Therefore, all adverse influences caused by cavitation formed by cavitation can be eliminated.
Amplitude modulation of a driving signal will be described below. As shown in FIG. 6, the impedance on the piezoelectric element side when viewed from the driver 411 exhibits a minimum value at the resonance frequency f0 but has larger values at other frequencies. The conversion frequency of electrical signal/mechanical vibrations of the piezoelectric element exhibits a maximum value at the resonance frequency f0 and has smaller values at other frequencies. The degree of attenuation of an ultrasonic treatment wave in a living body depends on its frequency. The output energy of the ultrasonic treatment wave generated by the ultrasonic source 402 exhibits a maximum value at the resonance frequency and decreases at frequencies other than the resonance frequency f0. In this embodiment, the amplitude of the driving signal is modulated with its frequency, so that the output energy of the ultrasonic treatment wave is kept constant regardless of changes in frequency.
The system controller 413 controls the gain of the driver 411 in accordance with changes in frequency of the driving signal so as to maintain the output level of the ultrasonic treatment wave almost constant regardless of changes in frequency, thereby maintaining the input power to the ultrasonic source 402 constant. FIG. 7A shows the waveform of an amplitude-modulated driving signal, and FIG. 7B shows changes with time of the output energy of the ultrasonic treatment wave generated by the ultrasonic source 402 upon application of the amplitude-modulated driving signal. The amplitude of the amplitude-modulated driving signal exhibits a minimum value at the resonance frequency f0 and a maximum value at f0±Δf/2.
The impedance may be measured by an impedance measurement circuit and feedback control may be performed using this measurement value. Alternatively, the actual input power may be measured by a wattmeter, and feedback control may be performed using this measurement value.
In addition, as another method of correcting this output level, the variable inductance and capacitance values of the impedance matching circuit 410, which correspond to the frequency of the driving signal, may be stored in the internal memory of the system controller, and electrical matching may be controlled by the system controller 413 in accordance with the frequency.
The following method may be used in place of amplitude modulation or may be used together therewith as a method of reducing the output level variations of the ultrasonic treatment waves. According to this method, assuming that the wavelength of an ultrasonic wave at a frequency largely different from the resonance frequency f0 is defined as λ, an acoustic matching layer having a thickness λ/4 (λ=wavelength) is arranged on a piezoelectric element surface, and the output band is broadened to improve the output efficiency of the ultrasonic wave having the frequency greatly different from the resonance frequency.
Phase modulation will now be described. The phase modulation may be used together with the above frequency modulation. Alternatively, the driving signal fixed at the resonance frequency f0 is phase-modulated without performing the above frequency modulation. As shown in FIG. 8, the system controller 413 controls the frequency/phase modulator 412 to intermittently shift the phase of the driving signal 180° at a period T. Upon intermittent irradiation of ultrasonic treatment waves, cavitation gradually grow. When the phase of the ultrasonic treatment waves is inverted, the cavitation receive a pressure opposite to that upon growth. Therefore, cavitation thus grown is destroyed.
(Second Embodiment)
FIG. 9 is a block diagram showing an ultrasonic treatment apparatus according to the second embodiment. The same reference numerals as in FIG. 1 denote the same parts in the second embodiment, and a detailed description thereof will be omitted. A fundamental frequency signal generator 418 is a circuit for causing a piezoelectric element to generate a driving signal at its unique resonance frequency f0. A frequency modulation signal generator 419 is a circuit for generating a driving signal whose frequency instantaneously changes along the time axis. A switch 420 alternately connects the fundamental frequency signal generator 418 and the frequency modulation signal generator 419 to a driver 411 under the control of a system controller 417. A driving signal generated by one of the fundamental frequency signal generator 418 and the frequency modulation signal generator 419 is amplified by the driver 411 through the switch 420. The amplified driving signal is supplied to each piezoelectric element of an ultrasonic source 402 through an impedance circuit 410.
FIG. 10A shows the waveform of the driving signal output from the driver 411 along the time axis. FIG. 10B shows changes in frequency of the driving signal shown in FIG. 10A along the time axis. The fundamental frequency signal generator 418 and the frequency modulation signal generator 419 are alternately connected to the driver 411 by switching operations of the switch 420. The fundamental frequency signal generator 418 is intermittently connected to the driver 411 for a first interval Tf0, while the frequency modulation signal generator 419 is intermittently connected to the driver 411 for a second interval Tfm.
For the first interval Tf0, the ultrasonic source 402 is driven with a driving signal whose frequency is fixed to the resonance frequency f0, and an ultrasonic treatment wave is steadily generated at the resonance frequency f0. For the second interval Tfm, the ultrasonic source 402 is driven with a driving signal whose frequency instantaneously changes along the time axis, and an ultrasonic treatment wave whose frequency instantaneously changes along the time axis is generated. Any one of the changes in FIGS. 2B, 3B, and 4B may be used as a change in frequency along the time axis. In this case, the frequency fm linearly changes from a low frequency f0-Δf/2 to a high frequency f0+Δf/2, this change is repeated in a predetermined cycle time Tc; the driving signal changes in the form of a saw-tooth wave. In this case, the frequency fm may change with an opposite gradient, i.e., from the high frequency f0+Δf/2 to the low frequency f0-Δf/2. In addition, the cycle time Tc is not limited to be constant if it falls within a specific range (to be described later). As shown in FIGS. 11A, 11B, and 11C, the cycle time may be gradually shortened or prolonged, or may be irregularly changed.
FIG. 12 shows the relationship between the cycle time Tc and the cavitation amount. The cavitation amount is defined such that a cavitation amount obtained upon repeating continuous driving at the resonance frequency f0 and driving at a frequency changing along the time axis is represented by a relative value when a cavitation amount upon continuous driving at the resonance frequency f0 is given as 1. The efficiency of cavitation destruction depends on the rate of change in frequency, i.e., the length of the cycle time Tc when the frequency modulation width is assumed constant. The cycle time Tc is set within the range of 500 μs to 50 ms.
FIG. 13 shows the relationship between the second interval Tfm and the cavitation amount. The time required for destroying cavitation is longer than the time required for forming them. In this embodiment, the second interval Tfm is set three times or more the first interval Tf0 so as to sufficiently destroy the cavitation. When the second interval Tfm is excessively long, the first interval Tf0 for which the frequency is fixed to the resonance frequency f0 is shortened. For this reason, the time efficiency of the acoustic output is degraded, and the treatment time is undesirably prolonged. In this embodiment, in consideration of this point, the upper limit of the second interval Tfm is set 10 times the first interval Tf0.
FIG. 14 shows the relationship between the cavitation amount and the ratio (Δf/f0) of the frequency change width Δf to the resonance frequency f0. In this embodiment, the frequency change width Δf is set to 20% or more the resonance frequency f0. Although the upper limit of the frequency change width Δf is determined depending on the critical value for maintaining the conversion efficiency of electrical signal/mechanical vibrations of the piezoelectric element to a predetermined level, the upper limit is preferably set to 100% or less the frequency f0 in consideration of degradation of the conversion efficiency of the piezoelectric element.
The range of changes in the frequency fm is preferably set to satisfy the range f0-Δf/2≦fm≦f0+Δf/2 centered on the resonance frequency f0 in consideration of degradation in the piezoelectric element conversion efficiency when the frequency fm is separated from the resonance frequency f0. However, the range of changes in the frequency fm is not limited to this range. For example, as shown in FIG. 21A, Δf1 may be not equal to Δf2. As shown in FIG. 21B, "f0+Δf1>f0+Δf2>f0" may be made up.
According to this embodiment, an ultrasonic treatment wave having a maximum efficiency can be generated in respects of cavitation destruction and the treatment period.
(Third Embodiment)
FIG. 15 is a block diagram showing an ultrasonic treatment apparatus according to the third embodiment. The same reference numerals as in FIG. 1 denote the same parts in the third embodiment, and a detailed description thereof will be omitted. An ultrasonic treatment wave driver 431 generates a driving signal fixed at a resonance frequency f0 unique to the thickness of a piezoelectric element of an ultrasonic source (first ultrasonic source) 402 for treatment. This treatment driving signal is supplied to the ultrasonic source 402 through an impedance matching circuit 410 to generate an ultrasonic treatment wave. A cavitation destruction driver 432 generates a driving signal fixed at a frequency f' higher than the resonance frequency f0. The cavitation destruction driving signal is supplied to an ultrasonic source (second ultrasonic source) 434 for cavitation destruction separate from the ultrasonic source 402 through a second impedance matching circuit 433 to generate an ultrasonic cavitation destruction wave.
The ultrasonic source 434 for cavitation destruction comprises a plurality of piezoelectric elements arranged in a spherical pattern. To destroy the cavitation formed by the ultrasonic treatment waves, the piezoelectric elements are positioned and directed to irradiate the ultrasonic cavitation destruction wave to an area where cavitation are generated by the ultrasonic treatment wave, i.e., to the transmission path of the ultrasonic treatment wave.
The ultrasonic source 402 for treatment and the ultrasonic source 434 for cavitation destruction may be separately arranged, as described above. Alternatively, as shown in FIG. 17A, high-frequency piezoelectric elements constituting the ultrasonic source 434 for cavitation destruction may be located as central elements, and low-frequency piezoelectric elements constituting the ultrasonic source 434 for treatment may be located outside the central elements in a spherical pattern as a whole. As shown in FIG. 17B, piezoelectric elements having the resonance frequency f0 may be adhered in a two-layered structure. In this case, only one layer is driven to generate an ultrasonic treatment wave at the resonance frequency f0, while the two layers are simultaneously driven to generate an ultrasonic cavitation destruction wave at the high frequency f'.
FIGS. 16A to 16C show the waveforms of the driving signals of this embodiment. In FIG. 16A, the ultrasonic treatment wave having the relatively low frequency f0 and the ultrasonic cavitation destruction wave having the relatively high frequency f' are alternately irradiated. In FIG. 16B, the ultrasonic cavitation destruction wave is intermittently superposed on the ultrasonic treatment wave. In FIG. 16C, the ultrasonic waves having two frequencies (f0 and f') with a small difference are continuously superposed on each other to generate a "beat" signal, and the cavitation is destroyed using this beat signal.
As described above, according to the third embodiment, it is possible to forcibly destroy the cavitation generated upon irradiating the ultrasonic treatment wave. A side effect to an unwanted portion and a spread of the thermal degeneration area can be suppressed. At the same time, thermal degeneration can be accurately induced in a desired portion. A reliable, safe ultrasonic thermotherapy can be realized. Since cavitation caused by the cavitation can be suppressed, the ultrasonic energy can be continuously input to shorten the treatment period and increase the throughput.
(Fourth Embodiment)
In this embodiment, the cavitation amount is monitored. When the cavitation amount reaches a predetermined amount, an ultrasonic cavitation destruction wave is irregularly generated. FIG. 18 is a block diagram showing an ultrasonic treatment apparatus according to the fourth embodiment. The same reference numerals as in FIG. 1 denote the same parts in the fourth embodiment, and a detailed description thereof will be omitted. Ultrasonic image data generated by an ultrasonic image diagnosis unit 409 is supplied to a CRT 415 and a difference circuit 416.
An ultrasonic image generated by the ultrasonic image diagnosis unit 415 when no cavitation or a very small number of cavitation are generated, as shown in FIG. 19A, is stored as a mask image in the internal memory of the difference circuit 416. This mask image does not have cavitation images or has a very small number of cavitation images.
FIG. 19B shows an ultrasonic image (real-time image) generated by the ultrasonic image diagnosis unit 415 immediately after irradiation of the ultrasonic treatment wave. The ultrasonic treatment wave is intermittently irradiated as a burst wave, a slice near the focal point is scanned with the ultrasonic imaging beam at the irradiation interval of the ultrasonic treatment wave, and ultrasonic images of this slice are repeatedly generated. The number of cavitation images gradually increases with an increase in irradiation time of the ultrasonic treatment wave.
The differences between the real-time images and the mask images are calculated to sequentially generate difference images shown in FIG. 19C. The difference image data is supplied to a system controller 413. The system controller 413 obtains, as a difference level, the sum of the pixel values of a plurality of pixels within a specific area of the difference image. FIG. 20A shows transitions in difference level along the time axis. The difference level depends on the generated cavitation amount. Note that the specific area is set as a propagation area of the ultrasonic treatment wave up to the focal point at which cavitation are assumed to be generated.
The system controller 413 compares the resultant difference level with a threshold level. When the difference level is lower than the threshold level, the system controller 413 generates an ultrasonic treatment wave at the resonance frequency f0, as shown in FIG. 20B, and controls a frequency/phase modulator 412 so as to continue the thermotherapy.
During an interval in which the difference level exceeds the threshold level, in order to positively destroy cavitation, the system controller 413 controls the frequency/phase modulator 412 so as to change the frequency, as shown in FIG. 20B.
When the difference level exceeds the threshold level, the system controller 413 controls the frequency/phase modulator 412 to invert the phase of the ultrasonic treatment wave, as shown in FIG. 20C, while maintaining the frequency at the resonance frequency f0 in addition to this change in frequency.
In this manner, cavitation can be appropriately destroyed, and a decrease in treatment rate can be prevented.
According to the present invention, since the cavitation formed upon irradiation of the ultrasonic treatment wave can be effectively suppressed, a side effect to an unwanted portion and a spread of the thermal degeneration area can be more effectively suppressed than the conventional method. At the same time, thermal degeneration can be accurately induced in a desired portion, thereby realizing a more reliable, safer ultrasonic thermotherapy. In addition, the total treatment period can be reduced to increase the throughput.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, and representative devices shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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An ultrasonic diagnosis apparatus for raising tissue temperature for hypothermic treatments, including an ultrasonic source for generating an ultrasonic treatment wave and a driving means for driving the ultrasonic source such that a frequency of the ultrasonic treatment wave generated by the ultrasonic source changes with time. The frequency of the ultrasonic treatment wave is changed along the time axis. By this change in frequency, some bubbles formed by cavitation as a result of the ultrasonic treatment wave are divided, and some bubbles are collapsed and therefore eliminated. Side effect cavitation and spread of a thermal degeneration area is suppressed, and thermal degeneration can be accurately induced in a desired area, thereby realizing a reliable, safe ultrasonic thermotherapy. Since cavitation is positively suppressed, the total treatment period can be shortened because cavitation would otherwise interfere with and slow down the thermal degeneration process. Therefore, treatment throughput can be improved as compared with a case in which cavitation is left to naturally break and disappear.
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[0001] The present invention relates to a device for conveying sticks in an apparatus for inserting sticks into ice cream bodies, as well as to a conveying belt for use in the device.
BACKGROUND
[0002] Danish Patent Application No. 1832/86 discloses an apparatus of the kind referred to above. The apparatus according to Danish Patent Application No. 1832/86 is intended to be able to function even with deformed sticks. Experience has shown, however, that when using high rates of delivery of sticks, occurring in i.a. intermittent operation, high demands are placed on the construction of the carrier, in this case constituting a belt with pockets, into which the sticks are to be pressed singly from the stack of sticks. Thus, the sticks are to be pushed directly into the pockets under the action of a force applied through the stack. For this reason, this force will be continuously exerted against the belt, causing wear of the latter. As it is also necessary for the pockets formed in the belt to have a depth not exceeding the thickness of a stick in order to be able to destack one stick at a time, problems may arise in making the pockets hold sticks that are not quite straight.
SUMMARY OF THE INVENTION
[0003] The present invention relates to a device in which the sticks are handled without problems, even at high rates of destacking and conveying, and even if the sticks are skewed or in other manner deviate from a standard stick having dimensions and shape in common with at least the majority of the sticks in a given stack.
[0004] Furthermore, it is an object to simplify the construction of a device of the kind referred to, in which the requirements to the components are less critical, and hence that the construction is simpler and more durable and reliable.
[0005] Accordingly, in one aspect the invention relates to a device for conveying sticks in an apparatus for inserting sticks into ice cream bodies, said device comprising guide means having an exit aperture, in which guide means the sticks are supplied in the form of an elongated stack of sticks, and from which guide means the sticks are destacked singly when contacted by a pocket attached to a conveying belt, said device further comprising said conveying belt, said destacked sticks being deposited in a pocket on said conveying belt when the pocket is moving past the exit aperture of the guide means, said conveying belt comprising a plurality of pockets, wherein each pocket has a longitudinal surface for housing a part of one stick, and each pocket furthermore has at least two guide pins projecting upwards on each side of said longitudinal surface.
[0006] In another aspect the invention relates to the conveying belt as such, namely, a conveying belt for conveying sticks in an apparatus for inserting sticks into ice cream bodies and of the kind in which the sticks are supplied in the form of an elongated stack of sticks in guide means, from which the sticks are destacked singly and deposited in a pocket on the conveying belt moving past the exit aperture of the guide means, said conveying belt comprising a plurality of pockets, wherein each pocket has a longitudinal surface for housing a part of one stick, and each pocket furthermore has at least two guide pins projecting upwards on each side of said longitudinal surface.
DRAWINGS
[0007] FIG. 1 a shows in a schematic view pockets passing the exit of a guide means of the device according to the invention, wherein the sticks have a circular cross-section.
[0008] FIG. 1 b shows in a schematic view pockets passing the exit of a guide means of the device according to the invention, wherein the sticks have a rectangular cross-section.
[0009] FIG. 2 shows a pocket detached from a conveying belt according to the invention. The front guide pins of said pocket are lower than the back guide pins.
DETAILED DESCRIPTION OF THE INVENTION
[0010] The present invention provides a simple, durable and reliable solution to the problem of conveying sticks to be inserted into ice cream bodies, even if the sticks vary in form, such as skewed or bent sticks deviating from normal sticks having an even, non-bent form.
[0011] The problem of prior art, i.e. that curved and skewed sticks could not fit into their pockets, leads to empty pockets on the conveying belt. This would subsequently lead to some ice cream bodies not being provided with a stick, and thereby not being lifted out of their mould. The ultimate consequence of empty pockets on the conveying belt is that the ice cream moulds may be emptied manually which of course leads to a stop in the ice cream line and delays.
[0012] In accordance with the invention the device comprises guide means in which the sticks are supplied in the form of an elongated stack of sticks, and from which guide means the sticks are destacked singly. The guide means may be of any form and construction, such as guide means shown in WO 96/22697 wherein the guide means positions sticks transported from a feed bin to a feed chain and further into the guide means. The guide means are arranged above the conveying belt, and the sticks are transferred from the exit aperture of the guide means and into the pocket on the conveying belt.
[0013] The pockets are arranged on a conveying belt, so that destacked sticks exiting the device guide means may be deposited in the pocket passing under the exit aperture of the guide means.
[0014] Each pocket is constructed as follows: Each pocket has a longitudinal (i.e. elongated) surface for housing at least a part of a stick. The length of the longitudinal surface preferably corresponds to at least a fifth of the length of the stick to be deposited in the pocket, more preferable at least a fourth of the length of the stick to be deposited in the pocket, more preferable at least a half of the length of the stick to be deposited in the pocket. The longitudinal surface is preferably a plane supporting surface.
[0015] On each side the longitudinal surface is flanked by at least two guide pins, said guide pins being arranged to position the stick along the axis of the longitudinal surface. The guide pins are denoted front guide pins, i.e. the guide pins being in the front in the moving direction of the conveying belt, and back guide pins (the opposite guide pins). The back guide pins are designed to effect the destacking of one stick from the exit aperture of the guide means, and transferring the stick in the pocket.
[0016] The guide pins can be positioned in the four corners of a pocket, but need not be so. The only requirement is that at least some of the back guide pins allow sticks from a stack of sticks to be singly detached therefrom when the stick at the bottom of the stack is contacted by one or more back guide pins on the pocket preferably projecting along an axis perpendicularly, or essentially perpendicularly, to the elongated base surface of a pocket. By essentially perpendicularly is meant an axial direction having an angle in the range of from 70 to 110 degrees relative to the base surface of the pocket, such as from 80 to 100 degrees, for example from 85 to 95 degrees.
[0017] Accordingly, the guide pins can project upwards on each side of said longitudinal surface. By the term upwards is meant the direction from the pocket to the exit aperture of the guide means, and the guide means being arranged above the conveying belt. The guide pins can be straight or curved. Accordingly, the top part of e.g. the back guide pin(s) may extend or curve partially towards the front guide pins (i.e. in the direction of movement of the pocket), thereby creating a groove for the stick to fall into when the stick is detached from the stack of sticks.
[0018] The pocket is capable of accommodating sticks of various forms, including skewed sticks, since the pocket is not flanked by solid bars, but only flanked by a few pins allowing a curved stick to lie on the longitudinal surface, because the curve of the stick may protrude into the space between two guide pins. The guide pins are preferably located along each end of the longitudinal surface, as shown in FIG. 2 , thereby allowing for a number of various forms of sticks to lie on the longitudinal surface.
[0019] The guide pins may be of any suitable form. In one embodiment, the guide pins are formed as cylinders. In another embodiment the guide pins are formed as blocks. The upper edge of the guide pins may be cut horizontally or, in a preferred embodiment, the upper edge is inclined, and the higher part being towards the longitudinal surface.
[0020] It is important that the height of the back guide pins match the thickness and shape of the sticks so that the height allows for the stick to be singly detached from the stack of sticks positioned in the device guide means—taking into account that bent or skewed sticks must also be able to be singly detached from the stack of sticks.
[0021] In one embodiment it is preferred that the height of the back guide pins is equal to or higher than the height of the stick, when the stick is arranged in the pocket. By the term height of the stick is meant the vertical dimension of the stick when the stick is positioned in the pocket.
[0022] It is furthermore preferred that the height of the front guide pins, in the direction of the conveying belt, is lower than the height of the back guide pins. Thereby the front guide pins may be allowed to pass under the stick, allowing the stick to be positioned on the longitudinal surface and the back guide pins may then effect that the stick is transported from the exit aperture of the guide means in the direction of the conveying belt.
[0023] In particular when the height of the back guide pins is higher than the vertical height of the stick it is preferred to provide a lower guide plate for receiving and housing a stick until the stick is arranged in a pocket. Accordingly, in one embodiment at least one lower guide plate is arranged below the guide means in order to receive one stick from the guide means, and arranged to deliver said one stick to a pocket passing the exit of the guide means. The lower guide plate is in one embodiment two surfaces, one on each side of the conveying belt. The stick falls from the exit aperture onto the lower guide plate and rests thereon until the next pocket enters between the two surfaces. The stick is then carried from the lower guide plate with the pocket due to the back guide pins. Once the pocket has been conveyed from the area below the exit aperture, the next stick falls onto the lower guide plate ready for the next pocket to pass.
[0024] It is preferred that the lower guide plate(s) is arranged at a higher vertical level than the longitudinal surface of the pocket. Thereby, the stick in the bottom of the stack, i.e. the next or first stick to be captured by the back guide pins of a pocket passing the exit aperture of the guide means of the device keeping the stack of sticks in place, rests on the lower guide plate of the device guide means at a height—relative to the pockets attached to the conveying belt—which is higher than the front guide pins of the pockets (so that the front guide pins will pass underneath the stick when a pocket initially enters the device guide means) while still allowing the (higher) back guide pins to make contact with the stick, thereby detaching the stick from the stack and placing the stick in the pocket on the conveying belt when the pocket exits the device guide means through the exit aperture of the device guide means.
[0025] The sticks may be pressed into the pockets through the use of a suitable pressing force, such as a spring, or merely forced due to gravity. In a preferred embodiment the sticks are falling due to gravity.
[0026] The conveying belt according to the invention may be constructed from any suitable material, such as a chain belt or a belt made from a soft material, for example a plastic material.
[0027] As discussed above the conveying belt is provided with a plurality of pockets. The pockets may be integrated with the belt, or attached to the belt. The latter embodiment is preferred since it facilitates rearrangements of the pockets, if for example the distance between the pockets should be adjusted. The pockets may be attached to the conveying belt through any suitable attachment means. The pockets are preferably releasably attached to the conveying belt.
[0028] The pockets may be spaced apart regularly within the same group or section of pockets on the conveying belt, the distance between two pockets preferably corresponding to the distance between insertion means arranged for inserting the sticks into ice cream bodies. In a preferred embodiment the conveying belt has the form of an endless belt, whereby the circumference of the conveying belt is adjusted so that a suitable amount of pockets may be arranged on the belt.
[0029] Evenly spaced apart pockets within the same section or group of pockets on the conveying belt can be separated from one or more additional groups or sections of pockets on the same conveying belt. A group or section of evenly spaced apart pockets can contain from 6 or less to 50 or more pockets, such as from 8 to about 40 pockets, for example from 8 to about 30 pockets. Each conveying belt can contain one or more groups or sections of evenly spaced apart pockets, such as 1 group or section, for example 2 groups or sections of evenly spaced apart pockets, such as 3 groups or sections of evenly spaced apart pockets, for example 4 or 5 groups or sections of evenly spaced apart pockets, for example 6 or 7 groups or sections of evenly spaced apart pockets. The individual design of the conveying belt can be adapted according to the needs of an ice cream producer having a certain line of ice cream manufacturing equipment installed in his production facility.
[0030] The pockets may be constructed from any suitable material, it is however preferred that the pockets, or at least the part of the pocket facing the stick is made from metal or metal alloy, said metal and metal alloy being suitable for contact to foods.
[0031] It is preferred that the construction of the guide means secures that sticks leaving the exit aperture, only falls down orientated in the direction of the longitudinal surface of the pocket. Thus, in one embodiment an upper guide plate is arranged on the guide means, so that the distance between said upper guide plate and the lower guide plate is above the height of one stick, and below the height of two sticks. Thereby one stick is allowed to pass under the upper guide plate with the pocket; however, two sticks cannot be transferred by one pocket.
[0032] In yet another aspect the invention relates to a conveying belt as described above for conveying sticks in an apparatus for inserting sticks into ice cream bodies.
[0033] The sticks arranged in the pocket may then be inserted into the ice cream bodies through any suitable means. In one embodiment the conveying belt is constructed to stop at regular intervals, whereby inserting means grip the sticks from the pockets and insert the sticks into the ice cream bodies, upon which the conveying belt moves again allowing pockets to be filled with sticks, before the next stop allows the inserting means to grip the sticks.
[0034] The invention furthermore, relates to a method for conveying sticks in an apparatus for inserting sticks into ice cream bodies, said method comprising arranging sticks into a guide means in which the sticks are supplied in the form of an elongate stack of sticks, and destacking from said guide means the sticks singly, arranging a stick in a pocket on a conveying belt, said conveying belt moving past the exit aperture of the guide means, and said conveying belt comprising a plurality of pockets, wherein each pocket has a longitudinal surface for housing a part of one stick, and each pocket furthermore has at least two guide pins projecting upwards on each side of said longitudinal surface as described above.
REFERENCE SIGNS IN THE DRAWINGS
[0000]
1 pocket
2 front guide pin
3 back guide pin
4 longitudinal surface
5 stick
6 upper guide plate
7 lower guide plate
arrow—the moving direction of the conveying belt
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A device is described for conveying sticks in an apparatus for inserting sticks into ice cream bodies, said device comprising guide means in which the sticks are supplied in the form of an elongate stack of sticks, and from which guide means the sticks are destacked singly, said device further comprising a conveying belt, said destacked sticks being deposited in a pocket on said conveying belt moving past the exit aperture of the guide means, said conveying belt comprising a plurality of pockets, wherein each pocket has a longitudinal surface for housing a part of one stick, and each pocket furthermore has at least two guide pins projecting upwards on each side of said longitudinal surface. Hereby the sticks are handled without problems, even at high rates of destacking and conveying, and even if the sticks are skewed or in other manner deviate from a standard stick having dimensions and shape in common with at least the majority of the sticks in a given stack.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to improvements in fittings used to lock modular packages such as sinks into apertures and surfaces provided by counter tops or other utilization frameworks.
2. Description of the Prior Art
Prior art devices commonly use relatively rigid fasteners to secure devices such as kitchen sinks into surfaces such as counter tops. J-bolts are fitted into eyes beneath a sink flange and threaded to receive nuts which may be tightened after insertion to engage the lower surface of the counter top, either directly or by means of a cooperating pivoted bar. Such prior art devices require assembly of parts under and behind an installation and require relatively much time and effort to effect a firm connection of the sink and other package to the counter top or other surface.
SUMMARY OF THE INVENTION
In accordance with the present invention a threaded stud is received in an inverted U-shaped channel inwardly of the edge of a flange surrounding the upper or outer portion of a package to be installed through an aperture in a surface, for example, a sink-disposer module in a counter top. A spring clamp is captured by a nut received on the threaded stud. The spring clamp has first and second cam surfaces extending outwardly from the package and under the flange a distance sufficient to engage the wall of the aperture in the surface to which the package is to be joined, i.e., in interfering registry, with the edges of the opening.
A second nut may be threaded to the end of the stud beneath the free end of the spring clamp to selectively adjust the tension if necessary or desirable. A sufficient number of clamps are disposed about the periphery of the unit to be installed in the U-shaped channel as aforesaid to effect a secure and rigid installation. Each of the spring clamps is cammed inwardly of the wall of the aperture in the receiving surface during such insertion, but each clamp will spring outwardly to engage the lower edge of said aperture in the surface once the package has been inserted a sufficient distance. The spring cams will then obstruct any attempted removal of the package from the aperture by the force of the spring cam on the lower edge of the aperture. A firmer connection may be had by forcing the second threaded nut against the lower surface of the cam after installation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view partially in cross section of a kitchen sink and garbage disposer module unit mounted in a counter top showing use of the invention about the periphery of the module to engage the walls of the aperture in the counter top.
FIG. 2 is a top view of the sink in FIG. 1 with one corner cut away to show the use of the invention.
FIG. 3 is an enlarged view partially in cross section of a kitchen sink and counter top secured together by a clamp unit embodying the principals of the invention.
FIG. 4 is a view taken on line IV--IV of FIG. 3.
FIG. 5 is a view similar to FIG. 3 but showing a clamp unit of the present invention embodying a form somewhat modified from the form of FIG. 3.
FIG. 6 is a view taken on line VI--VI of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
It is frequently desirable to install modular units in the cabinetry of kitchens. For example, a typical modular package may include a sink, a food waste disposer, and all plumbing and electrical connections therefor. Such a construction is shown in partial cross section in FIG. 1, where a module 10 has a sink flange 11 which when installed rests upon an upper surface 12 of a counter top 13 outwardly adjacent a vertical aperture wall 14 through the working surface of the counter top. Such modules are readily installed by lowering the unit downwardly between the aperture walls 14 until the lower surface of the flange 11 contacts the upper surface 12 of the counter top 13 and thereby supports the unit 10 in suspension.
Water drainage and food waste disposal devices 15 may be located in the lower portion of the module 10 and hot and cold water connections can be made to the faucet and spray spigot 16.
In accordance with this invention a specific form of retainer device is shown generally at 17 in FIGS. 1 and 2 and in enlarged detail in FIGS. 3 and 4. An inverted U-shaped channel 18 is attached to the lower surface of the sink flange 11 inwardly of the outer edge thereof sufficient to allow clearance for wall 14 in the aperture of the counter top 13. The head 19 of an externally threaded stud is received within the channel 18 and a plurality of such studs 20 are disposed in spaced array at various places around the periphery of the sink 10 as shown in FIGS. 1 and 2. The edges of the head 20a overlie an inwardly reversely turned flange 18a formed on each side of the channel 18. A spring clamp 21 is formed from flat spring material as shown in FIGS. 3 and 4. In its final shape, the spring clamp is generally C shaped when viewed in the orientation of FIG. 3. The spring clamp 21 has a substantially horizontal portion 22 with a tab portion 23 cut or partially struck out from the main body of the spring 21 to form a horizontal support 24 which underlies the channel 18. A nut 25 is threadedly engaged with corresponding threads on the stud 20 and is screwed up the shaft of the stud 20 to engage the underside of support 24 thereby to capture spring clamp 21 between the nut 25 and flange 18a of the channel 18. An upwardly-extending flange 26 on the free end of tab portion 23 engages the lower outer abutment portion 18b of the channel 18. The flange 26 in cooperation with a vertical portion 27 of spring clamp 21 serves to align the spring clamp assembly in a position perpendicular to the edge of the sink flange 11, and to confine channel 18 against opening to release head 19 of stud 20.
The vertical portion 27 joins an angled leg 27a extending generally upwardly and outwardly and terminating in a generally rounded abutment surface 28 which engages the lower surface of a sink or other member of the module 10 inwardly of the flange 11 to further assist in the alignment and rigid support of the spring clamp 21 against twisting forces on the spring clamp 21.
A body portion of the spring clamp 21 lies below the horizontal portion 22 and consists of a camming leg 29 extending downwardly and laterally outwardly to a medially disposed knee or nose 30. A camming leg is then reversely turned to extend generally downwardly and laterally inwardly towards the axis of the stud 20.
The leg 31 terminates in a foot portion 32 which is reversely turned to form a surface 36 adapted to engage a nut threaded on the stud 20. An upwardly extending flange 34 completes the spring clamp as shown in FIG. 3. The lateral displacement of the nose or knee 30 of the spring clamp 21 is sufficient to dispose the camming legs in interfering registration with the edges of the opening prescribed by the aperture walls 14. Reinforcing notches 47 are embossed in the cam legs 29, 31 to improve selectively the strength and rigidity of the clamp. A pair of apertures are formed in the horizontal leg 22 as at 22a and in the foot 32 as at 32a to provide clearance for stud 20 and nut 25.
In installation, a plurality of studs 20 are inserted into the channels 18 in spaced relation about the periphery of the module 10. A spring clamp 21 is inserted over each stud and a nut 25 is employed to secure each stud 20 and clamp 21 to the channel 18. A cone nut 35 is then screwed onto the end of each stud 20 a short distance so as not to interfere with movement of the spring clamp foot 32.
As the module is lowered into the aperture 14 in the counter top 13, the cam leg 31 engages an upper edge 50 of the aperture, thereby camming the clamp 21 so that the nose or knee 30 slidingly engages the interior wall 14 of the aperture. As the nose 30 moves past a lower edge 51 of the aperture in the counter top, the camming leg 29 will underlie the lower edge 51, thereby resiliently clamping the module to the counter top.
When the module is fully inserted, the flange 11 engages the surface 12 and supports the weight of the unit while the cam leg 29 applies a resilient clamping bias resisting removal of the unit in the opposite direction. Insertion of the module is thereby permitted but removal obstructed.
The module may be more permanently attached to the surface by locking the spring clamp 21 against inward deflection by screwing the cone nut 35 into the opening 32a in the lower end 32 of the spring clamp 21 as shown in FIGS. 3 and 4.
Another form of the invention is shown in FIG. 5. Like reference numerals identify like parts. A sink 10 has a channel 18 inwardly of a supporting flange 11 as previously, and a similar stud 20 with a head 19 is received in the channel 18.
In this form of the invention, the nut 25 captures a separate thrust bracket 37 rather than the spring clamp. The thrust bracket 37 has a pair of axially spaced cut-outs 38, 38 which are offset relative to the main body of the bracket 37 and together therewith are shaped and formed to provide a bore in which is received the stud 20. The lowermost cut-out 38 provides with the bracket 37 an abutment surface 39 against which the nut 25 bottoms.
A pair of tabs 40, 40 are struck out from the bracket 37 and are disposed to underlie the edges of the channel 18. An upwardly extending arm of the bracket 37 terminates in a curved finger 41 which engages the sink 10.
The spring clamp is shown generally at 42 and comprises a first horizontal leg 43 apertured as at 44 to receive the stud 20. A semi-circular curved bight portion 45 extends from the leg 43 to a second horizontal leg 46 spaced from and parallel to the leg 43. The leg 46 is also apertured as at 47 to pass the stud 20.
A first camming leg is shown at 48 and extends upwardly and laterally outwardly relative to the axis of said stud terminating at a knee 49. The clamp is then bifurcated to form a pair of camming legs 58, 58 which extend away from the knee 49 in an upward and inward direction relative to the stud axis. The legs 58, 58 each terminate in an offset finger 59, 59. The clamp 42 may be embossed to form such additional strengthening ribs as are desired. A nut 35a is threaded onto the stud 20 and can be turned against the leg 46 to increase the resilient resistance of the clamp.
In operation, when the unit is dropped into place the leg 48 will engage the edge 50 and will cam the clamp inwardly, the bifurcated legs 58, 58 clearing the stud 20 and bracket 37 on opposite sides thereof. As the knee 49 passes the lower edge 51, the legs 58, 58 will underlie the edge 51 and the counter top 12 will be clamped resiliently and securely.
It will be understood that while I have described the invention as applied to a sink-disposer module, the principles of the present invention are applicable to other modular units and appliances as well, such as stoves.
Although various modifications might be suggested by those versed in the art, it should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art.
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Shaped springs are fitted to a flange of a modular package such as a sink-disposer unit inserted through an aperture in a surface. One camming surface moves each spring out of the way during insertion of the package into the aperture and a second camming surface sprung outwardly against the wall of the aperture to obstruct removal of the package as insertion is completed. The spring may then be selectively tensioned by a threaded nut.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an industrial robot, in particular, to a device for detecting the limits of the rotational motion of a rotating member in an industrial robot.
2. Description of the Related Art
An industrial robot has a robot arm, and a robot wrist is provided at the distal end of the robot arm. An end effector, such as a robot hand, is mounted onto the robot wrist. The robot arm has a plurality of articulated portions which include a fixed member and a rotating member which rotates relative to the fixed member. The end effector is moved along a desired path due to the relative motion between the rotational and fixed members according to a program in a robot control unit. In order to prevent the robot arm moving beyond a predetermined limit, a device for detecting the limits of rotational motion, such as a limit switch, is provided at the articulated portion.
Referring to FIG. 10, a prior art device for detecting the limits of rotational motion is illustrated. The device is provided at the articulated portion. In FIG. 10, a fixed member 46 has dogs 48a and 48b. On the other hand, a rotating member (not shown) has a limit switch 44 electrically connected to a robot control unit (not shown). The limit switch 44 may be a conventional plunger type. The rotating member can rotate relative to the fixed member 46 about an a'-axis.
At the home position, indicated by O', the limit switch 44 is drawn with solid lines. When the rotating member rotates in the counterclockwise direction from the home position, the limit switch 44 also rotates in the counterclockwise direction therewith. When the limit switch 44 rotates to the limit of the rotational motion indicated by X, the limit switch 44 contacts the dog 48a. The limit switch 44 detects that the rotating member has rotated to the limit and sends a signal to the robot control unit. Upon receiving the signal, the robot control unit stops the rotating member.
On the other hand, when the rotating member rotates in the clockwise direction from the home position O', the limit switch 44 also rotates in the clockwise direction therewith. When the limit switch 44 rotates to the limit of the rotational motion shown by Y, the limit switch 44 contacts the dog 48b. The limit switch 44 detects that the rotating member has rotated to the other limit and sends a signal to the robot control unit. Upon receiving the signal, the robot control unit stops the rotating member.
Thus, the limits of the rotational motion are detected by the contact between the limit switch 44 and the dogs 48a or 48b, and this stops the rotating member of the robot moving beyond the limit of the rotational motion. In FIG. 10, the total rotational movement possible is the rotational angle of 162 degrees in the clockwise and in the counterclockwise directions from the home position. Thus, the rotating member can rotate within the range of 324 degrees about the a'-axis.
As the motion of the rotating member is limited to within the range of 324 degrees about the a'-axis by the device shown in FIG. 10. That is, the prior art device does not allow an angular range of more than 360 degrees. Thus, the robot with the prior art device has a problem in that, sometimes, the robot cannot move along a desired path and it takes long time to teach the robot arm. For that reason, some robots are not provided with a device for limiting the motion of the robot arm. This is a problem from the view point of safety around the robot.
SUMMARY OF THE INVENTION
Therefore, the object of the invention is to provide a device for detecting the limits of the rotational range of the rotating member at more than 360 degrees.
To realize the invention, a device for detecting the limits of the rotational motion of a rotating member in an industrial robot, which the rotating member rotates relative to a fixed member in a first and a second rotational direction about an axis, the device comprising a limit switch provided on one of the members and a contact piece for activating the limit switch. The contact piece is rotatable between first and second angular position about an axis parallel to the axis of the members.
In the preferable embodiment of the invention, one of the members is a fixed base having substantially a circular section and the other is a rotating base rotatably mounted onto the fixed base about the axis. The fixed base includes substantially a cylindrical island provided on an end face of the fixed base at substantially the center thereof so that the center axis of the island is aligned with that of the fixed base and has a diameter smaller than that of the fixed base. The contact piece is attached to the fixed base. The limit switch is a plunger type having a detecting portion at an end of the limit switch, and being attached to the rotating base so as to be able to contact the contact piece with the detecting portion when the rotating base rotates the limit switch to a position near one of the first and second limits. The contact piece rotates about the axis thereof when the limit switch contacts the contact piece with the detecting portion of the limit switch.
In one aspect of the invention, the contact piece is a limit cam having first and second abutment surfaces. The limit cam is rotated, about the axis thereof by the contact between the limit cam and the detecting portion of the limit switch, to the first or second angular position when the rotating base is rotated to first and second limits of rotational motion respectively. One of the abutment surfaces of the limit cam abuts the outer surface of the island when the limit cam rotates to one of the first or second angular positions, and the rotation of the limit cam being stopped by the abutment, the detecting portion of the limit switch being depressed by the stopped limit cam, whereby the limit switch is activated.
In another embodiment of the invention, one of the members is a fixed base having substantially a circular section and the other is a rotating base rotatably mounted onto the fixed base about the axis. The rotating base includes a circumferential wall along a circle, about the axis, having a diameter larger than that of the fixed base. The contact piece is attached to the rotating base, and the limit switch is a plunger type having a detecting portion at an end of the limit switch, and is attached to the fixed base so as to be able to contact the contact piece with the detecting portion when the rotating base rotates the contact piece to a position near one of the first and second limits. The contact piece rotates about the axis thereof when the limit switch contacts the contact piece with the detecting portion of the limit switch.
Preferably, the contact piece is a limit cam having first and second abutment surfaces. The limit cam is rotated about the axis thereof by the contact between the limit cam and the detecting portion of the limit switch to the first and second angular position when the rotating base is rotated to first or second limits of rotational motion respectively. One of the abutment surfaces of the limit cam abuts an inner surface of the circumferential wall when the limit cam rotates to one of the first or second angular positions, and the rotation of the limit cam is stopped by the abutment, the detecting portion of the limit switch is depressed by the stopped limit cam, whereby the limit switch is activated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of a welding robot which includes a device for detecting the limits of the motion according to the invention.
FIG. 2 is a schematic section along line A--A in FIG. 1 and illustrates the arrangement of the limit switch assembly and the cam assembly of the device according to one embodiment of the invention.
FIG. 3 is enlarged side elevation from the line B--B in FIG. 1 with partial section.
FIG. 4A is a side view of the limit cam.
FIG. 4B is a plan view of the limit cam.
FIG. 5 is a enlarged side view of the portion V in FIG. 1 and illustrates the limit switch assembly.
FIG. 6 is a schematic illustration for explaining the operation of the device of the invention.
FIG. 7 is a schematic illustration for explaining the operation of the device of the invention.
FIG. 8 is a schematic illustration for explaining the operation of the device of the invention.
FIG. 9 is a schematic section along line A--A in FIG. 1 and illustrates the arrangement of the limit switch assembly and the cam assembly of the device according to another embodiment of the invention.
FIG. 10 is a schematic illustration of the prior art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a schematic side elevation of a suspended welding robot 10 with the device of the invention. In FIG. 1, the welding robot 10 comprises a robot arm 14 having a plurality of articulated portions 22, 24 and 26. The welding robot 10 is suspended from a base 12 provided at a high place such as a ceiling of a factory. The welding robot 10 comprises a fixed base 16 fixed to the base 12 and a rotating base 18 mounted onto the fixed base 16. The robot arm 14 is mounted onto the rotating base 18 via the articulation 22. The rotating base 18 is rotated by an electrical motor 20 about an a-axis within a predetermined angular range. Thus, the robot arm 14 is also rotated about the a-axis within the predetermined angular range. The robot arm 14 is provided with a known welding device 30 at the distal end thereof. The torch 32 of the welding device 30 is mounted onto the robot wrist 28 of the robot arm 16 by a bracket 29.
The welding robot 10 is provided with a robot control unit (not shown). The robot control unit is a known type and is preferably a programmable numerical controller. In order to weld along a predetermined welding line, the welding robot 10 moves the torch 32 according to a program in the robot control unit. FIG. 1 illustrates an example in which a fillet welding is being carried out between a rectangular plate 36 and a cylindrical pipe 10 by the welding robot 10.
The rectangular plate 36 is placed on a table or a floor 34. The cylindrical pipe 38 is placed on the upper face of the plate 36. The robot arm 14 is held above the plate so as to keep the end of the torch 32 near and at substantially the same height as that of a welding portion or a welding line 37. The robot arm 14 rotates about the a-axis with the welding device 30 activated. Thus, the cylindrical pipe 38 is welded to the rectangular plate 36 along the circular welding line 37. Although the welding robot 10 welds along the circular welding line 37, in FIG. 1, it can also weld along a straight line.
The welding robot 10 comprises a device for detecting the limits of rotational motion about the a-axis, and the device contains a limit switch assembly and a cam assembly. The device is described with reference to FIGS. 2 to 5.
FIG. 2 illustrates a schematic side elevation from the direction A--A in FIG. 1. In order to simplify the drawing, the rotating base 18 is not shown in FIG. 2. However, the rotating base 18 is mounted onto the fixed base in a known manner. The limit switch assembly 40 is attached to the rotating base 18 for rotation therewith about the a-axis. In FIG. 2, the home position of the limit switch assembly 40 is indicated by O. In FIG. 2, the rotating base and the limit switch assembly 40 is also shown as having rotated 182 degrees about the a-axis in the clockwise direction from the home position O. However, it can be seen that the rotating base and the limit switch assembly 40 can also rotate 182 degrees about the a-axis in the counterclockwise direction from the home position O. That is, the rotating base and the limit switch assembly 40 can rotate relative to the fixed base 16 within a total angular range of 364 degrees. The angular range of 182 degrees in FIG. 2 is an example and the invention is not limited to this value.
FIG. 3 illustrates a partial enlarged portion indicated by III in FIG. 1. FIG. 3 is also a schematic side elevation is the direction B--B in FIG. 2 and illustrates a partial section. Furthermore, in FIG. 3, the arrangement is inverted compared with that in FIG. 2. The fixed base 16 includes a base portion 16b, which is substantially cylindrical, and an island 17 protruding from the end face of the fixed base 16. The island 17 is also substantially cylindrical with an outer surface 17a, and is positioned so that the center line of the island 17 is aligned with that of the fixed base 16. The island 17 has a diameter smaller than that of the base portion 16b so that a ring face 16a is formed at the end of the fixed base 16. The cam assembly 42 is attached at a point diametrically opposite to the home position O on the ring face 16a.
The cam assembly 42 includes a limit cam 48 and a shaft 50. The configuration of the limit cam 48 is described hereinafter. The shaft 50 is essentially a bolt having a head portion 51 and threaded portion 52 at the opposite end thereof. A body portion 54 is provided between the head portion 51 and the threaded portion 52. The body portion 54 functions as a rotational shaft. The shaft 50 is screwed into a threaded hole in the ring face 16b after being inserted into a through hole 56 in the limit cam 48. Then, the outer surface of the body portion 54 faces the inner surface of the through hole 56, and the body portion 54 functions the rotational shaft for the limit cam 48. Thus, the limit cam 48 is attached to the ring face 16b of the fixed base 16 for rotation about the shaft 50.
The fit between the through hole 56 of the limit cam 48 and the body portion 54 of the shaft 50 is a clearance fit so that the limit cam 48 can rotate about the shaft 50 smoothly. Furthermore, in order to prevent rotation of the limit cam 48 being obstructed by contact between the head portion 51 and the limit cam 48, the dimension of the body portion 54 is such that a clearance "t" is kept therebetween. The clearance "t" is 0.1 mm-0.9 mm, preferably, about 0.5 mm. Although the head portion 51 of the shaft 50 is shown as a hexagon socket head in FIG. 3, it can also be a usual head without a hexagon socket.
FIGS. 4A and 4B illustrate the side elevation and the plan view of the limit cam 48. The limit cam 48 is symmetrical heptagonal plate as shown in FIG. 4B. The limit cam 48 includes the through hole 56 through which the shaft 50 is inserted. The limit cam 48 has contact surfaces 58 and 60 adapted to contact a detecting portion 72 of a limit switch (FIG. 6) and abutment surfaces 62 and 64 adapted to abut the outer surface 17a of the island 17 of the fixed base as a stopping means. The abutment surfaces 62 and 64 are connected each other by a surface 63. Alternatively, the abutment surfaces 62 and 64 can be connected to each other by a ridgeline (not shown) extended parallel to the shaft 50. The limit cam 48 can be made of any material, preferably a plastic material such as nylon, having enough strength.
The side elevation of the limit switch assembly 40 is shown in FIG. 5 which is also an enlarged illustration of the portion indicated by V in FIG. 1. Additionally, it should be noted that the arrangement in FIG. 5 is inverted compared with that in FIG. 1. The limit switch assembly 40 comprises a limit switch 68 and a cover 66 for the limit switch 68. The limit switch 68 is a conventional plunger type, and has a body 70 and a detecting portion 72. The limit switch 68 is secured to the inner side of the cover 66 by bolts. The cover 66 is secured to a bracket 19 portion of the rotating base 18 by bolts. The cover 66 is formed of a metal plate or of a molded plastic material.
The operation of the device in accordance with the preferred embodiment of the invention is described with reference to FIGS. 6-8 in which the rotating base 18 rotates in the clockwise direction in FIG. 2.
When the limit switch assembly 40 attached to the rotating base 18 rotates to a angular position of 176 degrees in the clockwise direction from the home position "O", the detecting portion 72 of the limit switch 68 contacts the contact surface 60 of the limit cam 48, and this forces the limit cam 48 to rotate in the clockwise direction about the shaft 50. At this time, the limit cam 48 does not contact the outer surface 17a of the island 17 as shown in FIG. 6. It should be noted that the limit cam 48 must be arranged so that the surface 63 does not contact the outer surface 17a of the island 17 at any time to allow the limit cam to rotate smoothly.
When the rotating base 18 rotates further in the clockwise direction from the position shown in FIG. 6, the limit cam also rotates in the clockwise direction. When the rotating base 18 rotates to the angular position of 181 degrees (FIG. 7), the abutment surface 62 of the limit cam 48 abuts the outer surface 17a of the island 17, and the rotation of the limit cam 48 is stopped by the abutment therebetween. The detecting portion 72 of the limit switch 68 is pressed by the limit cam 48 in a direction indicated by an arrow C.
When the rotating base 18 rotates further from the angular position shown in FIG. 7, the detecting portion 72 is depressed. Thus, the limit switch 68 detects the rotating base 18 reaching the limit of rotational motion, and sends a signal to the robot control unit. Upon receiving the detecting signal, the robot control unit stops the rotation of the rotating base 18. In the embodiment in the drawings, the rotating base 18 stops at the angular limit of 182 degrees from the home position (FIG. 2).
In addition to the above, when the abutment surface 64 of the limit cam 48 contacts the outer surface 17a of the island 17, as shown in FIG. 8, when the limit switch 68 contacts the limit cam 48, the device of the invention will attain the same condition as shown in FIG. 6 due to the smooth rotation of the limit cam 48 in the clockwise direction. The operation of the device after the above condition attained is the same as described above.
Although the operation of the preferred embodiment has been described when the rotating base rotates in the clockwise direction in the drawings, it may be understood that the operation of the device of the invention is the same as described when the rotating base rotates in the counterclockwise direction.
Furthermore, in the described embodiment, the limit switch assembly is attached to the rotating base, and the limit cam assembly is attached to the fixed base. However, the limit cam assembly can be attached to the rotating base and the limit switch assembly can be attached to the fixed base. Referring to FIG. 9, the fixed base 16 does not include island, but the rotating base 18 includes a ring face 18a and a circumferential wall 18b. The limit switch assembly 40 is attached to the fixed base 16, and the limit cam assembly 42 is attached to the ring face 18a of the rotating base 18. When the rotating base 18 and the limit cam assembly 42 rotate to the angular limit (in FIG. 9, the angular limit of 182 degrees in the clockwise direction from the home position), the rotation of the limit cam 48 about the shaft 42 (FIG. 3) is stopped by the abutment between the abutment surface 62 or 64 of the limit cam 48 and an inner surface 18c of the circumferential wall 18b.
Moreover, the abutment surfaces 62 and 64 of the limit cam 48 are substantially plane in the above embodiment. However, the abutment surfaces may be formed complementary to the outer surface 17a of the island 17 or the inner surface 18c of the circumferential wall 18b. In the above embodiment, although the limit cam 48 is heptagonal plate, the limit cam can be formed into any other suitable configuration such as a lever.
Furthermore, in the described embodiment, the device of the invention is provided on the fixed base and the rotating base which are provided between the base 12 and the robot arm 14, however, the device of the invention can be provided on the articulations 22, 24 and 26 of the robot arm 14.
From the above description, it may be understood that a total angular range of more than 360 degrees can be provided on the rotatable portion or the articulation of an industrial robot by the invention. Therefore, an industrial robot with the device of the invention can weld a full circle on the workpiece, in safety, without complex teaching.
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A device for detecting the limits of the rotational motion of a rotating member in an industrial robot is provided. The rotating member rotates in a first and a second rotational direction about an axis relative to a fixed member. The device comprises a limit switch provided on one of the members and a contact piece, provided on the fixed member, for activating the limit switch. The contact piece is rotatable between first and second angular position about an axis parallel to the axis of rotating member.
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BACKGROUND OF THE INVENTION
The present invention relates generally to household refrigerators and, more particularly, to a refrigerator operating mode appropriate for an extended period of zero usage such as would occur when a user is on vacation.
Modern automatically-defrosting refrigerators are designed to provide proper and efficient operation during normal usage conditions. During normal usage conditions, temperatures within the refrigerated compartments are maintained at levels appropriate for safe storage of food. The frequency of or, expressed alternatively, the interval between successive automatic defrosting operations is selected to avoid unnecessary defrosting operations and to prevent excessive accumulation of frost on the evaporator under reasonably expected humidity loading conditions. Further, many modern refrigerators include automatic icemakers connected to household water supply lines to conveniently provide a ready supply of ice cubes at all times. Additionally, many modern refrigerators are provided with anti-condensation heaters for heating selected portions of the exterior of the refrigerator cabinet, which portions might otherwise be cooled below the ambient dewpoint, resulting in unsightly condensation forming. Also, butter conditioner heaters are sometimes provided to maintain a butter compartment at a temperature slightly warmer than the remainder of the refrigerated space.
Many of the features and functions mentioned above have been provided with independent control for various reasons. For example, to minimize energy consumption, switches have been provided to turn off anti-condensation heaters during periods of low ambient humidity. For the same reason, various forms of variable defrost interval control have been developed. For example, adjustable defrost control timers have been provided which permit a user to optimize the defrosting interval for particular ambient and usage conditions. Furthermore, various so-called "demand defrost" systems have been proposed whereby the refrigerator control system itself varies the interval between successive defrosting operations depending on various sensed parameters such as door openings and ambient humidity. A simple form of demand defrost is achieved by connecting the motor in the defrost control timer such that it operates only when the refrigerator compressor is operating in response to a thermostatic temperature control. Thus, under high usage conditions when the compressor runs frequently, the defrost control timer accumulates time at a faster rate. During low usage conditions the compressor operates less frequently and the defrost control timer accumulates time at a slower rate. Automatic icemakers customarily are equipped with switches or other means to effectively turn them off when desired. Lastly, most household refrigerators include a user-adjustable thermostatic temperature control for setting a desired temperature to be maintained within at least one refrigerated compartment.
The operating conditions of the various elements of a refrigerator, being designed for normal usage conditions, are in some respects inappropriate for extended periods of non-usage of the refrigerator, such as might occur when a user is away for periods of a week or longer while on vacation ("Non-usage" and "zero-usage" are interchangeably employed herein and are intended to refer to a condition wherein the door of the refrigerator is not opened over an extended period of time, in contrast to a condition where the refrigerator is unplugged or otherwise turned off and placed into storage.)
By suitable adjustment of the refrigerator controls, an operating condition more appropriate to an extended period of zero usage might be achieved. Such an operating condition would be more appropriate both from the standpoint of avoiding unnecessary consumption of energy, and from the standpoint of decreasing the possibility of a failure which, under normal conditions of daily use would be merely an inconvenience, but which, during an extended unattended period of operation could have potentially greater consequences. While serious failures are relatively rare, on a statistical basis there is always some probability of occurrence despite good design practices.
It is therefore an object of the invention to provide a convenient means for a user to affect various operating conditions to place a refrigerator in an operating mode appropriate to a condition of zero usage.
It is a further object of the invention to provide an inexpensive means for effectively extending the interval between successive automatic defrosting operations when appropriate.
SUMMARY OF THE INVENTION
Briefly stated, and in accordance with one aspect of the invention, an automatically-defrosting household refrigerator includes a user-operable "vacation switch" effective to enable the operation of the refrigerator in a mode appropriate to a condition of zero usage. The mode appropriate to a condition of zero usage includes having the interval between successive automatic defrosting operations extended. An extended interval of ten times a normal interval may sometimes be desirable. When the vacation switch is thrown to the vacation position, unnecessary energy consumption is avoided and the likelihood of failure of the refrigerator while unattended diminished.
After operating the "vacation switch," the user is assured at once that he has done all that is necessary, and has avoided the trouble of adjusting various controls. Furthermore, it is unlikely that many users would make any adjustment at all before going on vacation in the absence of a vacation switch.
The term "vacation switch" is employed herein in the specification and claims as a matter of convenience to describe a switch which is operated by the user whenever the refrigerator is unattended for an extended length of time for any reason. Thus, the invention is not intended to be limited to a switch which is operated only for vacation purposes.
There are a number of operations within an automatic refrigerator which the vacation switch may affect according to various aspects of the invention. In particular, as previously mentioned, the interval between successive automatic defrosting operations is extended. During a zero-usage condition, very little ambient moisture enters the refrigerated space to become deposited on the evaporator surface because the door is never open. It would therefore be wasteful to defrost the evaporator as often as is usual. Furthermore, there is always a slight possibility of the defrosting mechanism failing, resulting in a loss of cooling and possible spoilage of food while the refrigerator is unattended. With defrosting operations occurring less frequently, the chances of such a failure occurring are decreased, thus energy saving and increased reliability result.
For refrigerators equipped with automatic icemakers, according to another aspect of the invention the vacation switch is effective to disable the icemaker when the zero usage mode is enabled. Preferably, the means for disabling the icemaker includes a means for preventing the interruption of the icemaker during an ice-ejection cycle, thereby ensuring that the various movable elements of the icemaker are not held out of their resting condition over an extended period of time.
In accordance with still another aspect of the invention, the vacation switch is effective to increase the temperature set point of the thermostatic control means which maintains the temperature within the refrigerator. An increase of approximately 5° F. is appropriate. This decreases the energy consumption because the refrigeration compressor operates less frequently. This is not as harmful to the food preservation qualities of the refrigerator as might be expected. Since the doors at all times are closed, the time-averaged temperature within the refrigerated compartment is closed to what it would otherwise be. During normal usage of the refrigerator, when the door is opened, warm air flowing into the refrigerator frequently increases the temperature therein above that which the refrigerator temperature control system would otherwise allow. In other words, there is a temporary overload on the refrigeration system. As a result, during normal usage conditions, the time-averaged temperature within the refrigerated compartment may be higher than the average temperature nominally maintained by the refrigeration temperature control system.
In accordance with still further aspects of the invention, two specific means for accomplishing the increasing of the temperature set point of the thermostatic control means when the zero usage mode is enabled are contemplated. In one particular embodiment, two separate temperature control thermostats are provided, one being a normal thermostat and the other being a vacation thermostat. The vacation thermostat is adjusted to a higher temperature setting than a normal thermostat, such as 5° F. higher than a nominal setting. A circuit means, for example a switch, alternatively enables the thermostats. The vacation thermostat is enabled in the zero usage mode, and the normal thermostat is otherwise enabled.
In another particular embodiment, there is a single thermostatically controlled means having a temperature sensing element, such as a bulb at the end of a capillary tube, located within the refrigerated space. A small biasing heater, for example one-tenth watt, is thermally connected to the temperature sensing element to bias the temperature sensing element. The biasing heater is ON for normal operation, and turned OFF when the zero usage mode is enabled. For normal operation, the biasing heater causes the temperature sensing element to effectively sense a temperature which is higher than the actual refrigerator temperature. The controls are adjusted to compensate for the biasing heat so that when the thermostatic control means maintains a higher temperature at the temperature sensing element, the temperature within the refrigerated space is the normal desired temperature. When the zero usage mode is enabled by the vacation switch, the biasing heater is disabled and the thermostatic control means responds by effectively increasing the temperature set point.
In accordance with still another aspect of the invention, the anti-condensation heaters for the exterior of the refrigerator case are disabled when the vacation switch is in the vacation position. While operation without the anti-condensation heaters might be unacceptable during certain conditions of normal usage, during extended periods of non-use it is acceptable for at least two reasons. Excessive energy consumption is consequently avoided. Non-operation of the anti-condensation heaters may be tolerated during the zero usage mode, first because condensation is an appearance, not a functional, consideration. Presumably there is no one to observe the appearance. Second, due to the higher temperature maintained within the refrigerated compartments because of the effect of the vacation switch on the temperature control system, there is less cooling of the outer case, and less need for anti-condensation heaters. Thus, there is less visible condensation in any event.
In accordance with still another aspect of the invention, a novel means is provided for extending the interval between successive defrosting operations. To initiate normal defrosting operations, the refrigerator includes a defrost control timer of some sort. In accordance with this aspect of the invention, a particular means is provided for periodically disabling the timing means when the vacation switch is operated to select the zero usage mode. Specifically, a temperature-responsive switch is mounted so as to be responsive to the temperature of a predetermined portion on the refrigeration system high side. The temperature-responsive switch is closed at ambient temperature and opens at a predetermined temperature which is reached by the portion of the system high side selected a few minutes into each operating cycle of the refrigeration compressor. The switch is arranged to disable the timing means when sensed temperature exceeds the predetermined value during each operation of the compressor. In this way, a timing interval is established which controls the timing means on a duty cycle basis, and which is quite inexpensive to implement. During normal operation of the refrigerator, the temperature-responsive switch is bypassed, and the defrost timing means operates normally.
BRIEF DESCRIPTION OF THE DRAWINGS
While the novel features of the invention are set forth with particularity in the appended claims, the invention, both as to organization and content, will be better understood and appreciated, along with other objects and features thereof, from the following detailed description taken in conjunction with the drawings, in which:
FIG. 1 is an electrical circuit diagram of a refrigerator control system according to one embodiment of the invention;
FIG. 2 is an electrical circuit diagram of a refrigerator control system according to another embodiment of the invention;
FIG. 3 is an electrical circuit diagram of a refrigerator control system including an arrangement for extending the interval between successive defrosting operations;
FIG. 4 is a schematic representation of a closed circuit refrigeration system; and
FIG. 5 is a graph depicting the operation of the embodiment of FIGS. 3 and 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings wherein identical reference numerals refer to corresponding elements throughout the various figures, FIG. 1 shows a refrigerator circuit 10 including one embodiment of the invention. A conventional power plug 12 supplies L and N supply conductors 14 and 16, and has a connection 18 to ground the frame of the refrigerator. A refrigeration system includes a compressor motor 20 and an evaporator fan motor 22 connected in parallel. The refrigeration system further includes a condenser fan motor 23 for forced-air cooling of the compressor.
For controlled operation of the refrigeration system, the compressor and evaporator fan motors 20 and 22 are connected to the L supply conductor 14 through a defrost control 24 and through a thermostatic means 26 for controlling the interior temperature of the refrigerator. The compressor, evaporator fan and condenser fan motors 20, 22 and 23 each have return electrical connections to the N supply conductor 16.
The defrost control 24 includes a cam-operated, single-pole double-throw switch 28 operated through a link 29 by a defrost control cam 30 driven by a timing motor 32. When the defrost control switch 28 and the cam 30 are in the cooling position shown, the compressor and evaporator fan motors 20 and 22 are connected through the switch terminals 34 and 36 and through the thermostatic control means 26 to the L supply conductor 14.
The particular thermostatic control means 26 illustrated includes two thermostats, a normal thermostat 38 and a vacation thermostat 40. The normal thermostat 38 is a conventional hydraulic type normally employed in refrigerators, and includes a remote temperature-sensing bulb, represented by an element 41, at the end of a small-diameter tube. The vacation thermostat 40 is a similar thermostat and preferably has a specific fixed temperature adjustment. The vacation thermostat 40 is adjusted to a higher temperature setting than the normal thermostat 38, preferably approximately 5° F. higher than a nominal setting. For example the range of adjustment for the normal fresh food compartment temperature setting is 33° F. to 43° F., with 38° F. being a nominal setting. In this situation, the setting of the vacation thermostat 40 is approximately 5° F. higher than 38° F., which is 43° F.
Alternately, since the normal thermostat 38 is adjustable, the vacation thermostat 40 may also be adjustable and arranged to automatically track the setting of the normal thermostat 38, maintaining a constant 5° F. differential in setting.
In order to alternatively enable the thermostats 38 and 40, a vacation switch 42 is provided. In the illustrated embodiment, the vacation switch 42 is a double-pole, double throw switch comprising sections 44 and 46. When the vacation switch 42 is thrown to the normal position, the switch sections 44 and 46 connect the terminal 36 of the defrost control 24 through the normal thermostat 38 to the L conductor 14. Conversely, when the vacation switch 42 is thrown to the vacation position, the switch sections 44 and 46 connect the terminal 36 of the defrost control 24 through the vacation thermostat 40 to the L supply conductor 14.
In the operation of the circuitry thus far described, either the normal thermostat 38 or the vacation thermostat 40 is enabled to cycle the compressor motor 20, the evaporator fan motor 22 and the condenser fan motor 23 as required to maintain the temperature in the refrigerated compartments. Since the temperature set point of the vacation thermostat 40 is higher than that of the normal thermostat 38, the temperature set point of the thermostatic control means 26 is effectively increased when the zero usage mode is enabled by the vacation switch 42.
Each time the enabled thermostat 38 or 40 closes, power is additionally supplied along a conductor 47 to the defrost control timing motor 32 to rotate the defrost control cam 30. In order to initiate automatic defrosting operations, the timing motor speed and cam arrangement are such that for every six hours of timing motor running time, the cam 30 switches the defrost control switch 28 to the lower position, de-energizing the compressor and evaporator fan motors 20 and 22, and energizing a defrost heater 48. The defrost control switch 28 remains in the lower position for a period of approximately twenty minutes.
The N return for the defrost heater 48 is connected through a defrost-terminating bimetallic switch 50 which is adjusted to open at approximately 50° F. Under normal frost loading conditions, the evaporator is completely defrosted and the bimetallic switch 50 opens within the twenty-minute defrost duration period determined by the defrost control cam 30 and the defrost control timing motor 32.
In order to extend the interval between successive automatic defrosting operations when the vacation switch 42 is in the vacation position to enable the zero usage mode, a defrost interval extending timer 52 is provided. The interval-extending timer 52 has a cam operated switch 54 interposed in series with the defrost control timing motor 32. A motor 56 and a cam 58 operate the switch 54 through a link 59, with a duty cycle which is 10% ON and 90% OFF. The motor and cam arrangement is such that the timer 52 resets by returning the cam 58 to the switch ON position illustrated every time the motor 56 is deenergized. To ensure reasonably accurate duty cycle control despite discontinuities caused by the timer 52 resetting every time the vacation thermostat 40 opens, the cam 58 preferably rotates several times during each cycling of the compressor motor 20. A typical compressor ON cycle lasts for forty minutes, and the cam 58 speed may be eight revolutions per hour. Thus, when the motor 56 and the cam 58 are rotating, the defrost control timing motor 32 is energized approximately only one-tenth as often as would otherwise be the case.
While the particular defrost control 24 illustrated is an electromechanical device, it will be apparent that various other timing means may be employed. For example, an electronic timer may be used, using either RC or digital counter timing elements. Depending upon the precise timer employed, a different means for interrupting the timer may be appropriate, and not necessarily a simple interruption of power.
To prevent interruption of power to the timing motor 32 by the defrost interval extending timer 52 during an automatic defrosting operation, a conductor 60 supplies power to the timing motor 32 continuously when the switch 28 is in the lower position. Otherwise, if the switch 54 happens to open during a defrosting cycle, the compressor and evaporator fan motors 20 and 22 would remain de-energized an excessive length of time.
To energize the defrost extending timer 52 when the vacation switch 42 is thrown to the vacation position, a terminal 61 of the timing motor 56 is connected through a conductor 62 to an upper terminal 64 of the switch section 46. To complete the circuit, the other terminal 66 of the motor 56 is connected through a conductor 68 to the N power source conductor 16.
The refrigerator further includes conventional mullion and case heaters 70 and 71, which serve to prevent condensation forming on the visible outer portions of the refrigerator cabinet. Additionally, there is a butter conditioner heater 72. The mullion, case and butter conditioner heaters 70, 71 and 72 are electrically connected in parallel, and are energized through the switch section 44 and a conductor 73 when the vacation switch 42 is thrown to the normal position. The heaters 70, 71 and 72 are de-energized when the vacation switch 42 is thrown to the vacation position. An N return conductor 74 for the heaters 70, 71 and 72 is connected through the defrost terminating switch 50 to the N power source conductor 16 to prevent the heaters 70, 71 and 72 from operating during those periods when the evaporator temperature exceeds 50° F. during defrosting operations.
The refrigerator further includes an automatic icemaker 76. The automatic icemaker 76 is connected across the conductor 73 and the N supply conductor 16 and functions to supply ice cubes as required so long as it is energized. The icemaker 76 includes an ejection motor 78 in parallel with a mold heater 80, the parallel combination connected in series through a control thermostat 82 and a feeler arm switch 84 to the conductor 73. The icemaker 76 further includes a cam-operated switch 86 having first and second movable contact terminals 88 and 90 and a fixed contact terminal 92. Lastly, an inlet water valve solenoid 94 is connected between the fixed contact terminal 92 and the N supply conductor 16.
Considering the operation of the icemaker 76, it will be assumed that the feeler arm switch 84 is closed, meaning that the ice storage bin (not shown) is not full, and that the icemaker mold is filled with water in the process of being frozen. When the mold temperature reaches approximately 16° F., it is assumed that the water is frozen and the control thermostat 82 closes. This energizes the ejection motor 78 and the mold heater 80. The ejection motor 78 begins rotation, but is immediately stalled by the frozen ice. Before reaching the stalled condition, the ejection motor 78 and an associated cam causes a connection between the movable contact terminals 88 and 90 of the switch 86 to be made, bypassing the feeler arm switch 84 and the control thermostat 82.
The motor 78 remains in a stalled condition for about two minutes until the mold heater has melted the ice a slight amount sufficient to free the ice from the mold. The motor then resumes rotation to eject the ice cubes. At this point, the cam causes a connection to be made between all three of the switch contact terminals 88, 90 and 92, energizing the water valve solenoid 94 for approximately ten seconds. In the meantime, the control thermostat 82 has opened since the mold temperature is raised by the mold heater 80 and incoming tap water. The motor-driven cam reaches the end of its rotation, opening all of the contacts of the switch 86 and stopping operation of the icemaker 76.
In accordance with the present invention, when the vacation switch 42 is thrown to the vacation position to enable the zero usage mode, operation of the icemaker 76 is interrupted. In the illustrated embodiment, power to the entire icemaker 76 is interrupted by the vacation switch 42, which removes power from the conductor 73.
Referring now to FIG. 2, there is shown a schematic diagram of a circuit 100 according to a second embodiment of the invention. The circuit 100 of FIG. 2 differs from the circuit 10 of FIG. 1 in two respects, discussed below. It will be appreciated that the circuit 100 of FIG. 2 remains unchanged in other respects and a complete description thereof is not repeated.
In FIG. 2, the thermostatic means 26 for controlling the interior temperature of the refrigerator comprises only a single thermostat 102, and there is a different means for increasing the temperature set point of the thermostatic control means 26 when the zero usage mode is enabled by the vacation switch 42. The thermostat 102 has a temperature sensing element 104 located within the refrigerated space. Preferably, the temperature sensing element 104 again is a hydraulic bulb at the end of a small-diameter tube connected to a hydraulic diaphragm which actually operates the contact of the thermostat 102.
To bias the temperature of the refrigerator downward when in the normal mode of operation, there is provided a small-wattage heater 106 for biasing the temperature sensing element 104. The biasing heater 106 may be approximately one-tenth watt and in thermal contact with the temperature sensing element 104. The thermostat 102 is suitably calibrated, taking into account the biasing effect of the heater 106, to maintain the desired temperature within the refrigerated compartments.
The vacation switch 42 in the embodiment of FIG. 2 comprises a double-pole, double-throw switch having sections 108 and 110. When in the normal position illustrated, the switch section 108 energizes, from the L power source conductor 14, the mullion and case heaters 70 and 72 and the biasing heater 106. When the switch section 108 is thrown to the upper or vacation position, the mullion and case heaters 70 and 72 and the biasing heater 106 are de-energized, and the motor 56 of the defrost extending timer 52 is energized.
This de-energization of the biasing heater 106 during the vacation mode has the effect of increasing the temperature set point of the thermostatic control means 26. Since the thermostat 102 is calibrated to take into account the additional heat of the biasing heater 106 to provide normal temperature settings, removal of the heat supplied by the biasing heater 106 causes the temperature set point to increase, thereby maintaining a higher temperature in the refrigerated compartments. It will be appreciated that this arrangement results in a fairly constant temperature differential between the effective temperature setting during the normal mode and the temperature setting during the vacation mode.
The lower switch section 110 of the vacation switch 42 disables the icemaker 76 when the vacation or zero usage mode is enabled, but does so in a manner which prevents interruption of the icemaker 76 during an ice ejection cycle. Interruption of the icemaker 76 during an ice ejection cycle could potentially lead to improper operation of the icemaker upon subsequent restarting. To provide such disabling of the icemaker 76, the switch section 110 is connected in series with the feeler arm switch 84 and the control thermostat 82. If the vacation switch 42 happens to be thrown to the vacation position during an ice ejection cycle, the cycle continues because the first and second movable contact terminals 88 and 90 are closed, effectively bypassing the switch section 110. Upon completion of the ice ejection cycle, the icemaker 76 then becomes entirely disabled because no further ice ejection cycles can be initiated so long as the switch section 110 is open.
Referring now to FIGS. 3 and 4, there is shown a third embodiment of the invention which includes an alternative arrangement for extending the interval between successive defrosting operations. FIG. 3 is a schematic diagram of an electrical circuit 112, and FIG. 4 is a mechanical schematic diagram of a closed circuit refrigeration system 114 which includes elements are shown in the electrical circuit 112 of FIG. 3.
In FIG. 3, the thermostatic control means 26 may be either of the arrangements disclosed in FIG. 1 or FIG. 2, or may be any suitable alternative means which includes a means for increasing the temperature set point when the zero usage mode is enabled by the vacation switch 42.
The defrost control timing motor 32 is connected in series with a thermostatic switch 116. The thermostatic switch 116 is bypassed by a switch section 118, which is a portion of the vacation switch 42. When the vacation switch 42 is thrown to the normal position shown, the defrost control timing motor 32 is energized through the switch section 118 whenever the thermostatic control means 26 supplies power from the L power source conductor 14. However, when the vacation switch is thrown to the vacation position to enable the zero-usage mode, power is supplied to the defrost timing motor 32 only when the thermostatic switch contact 116 is closed. When the thermostatic switch 116 opens, power to the defrost control timing motor 32 is interrupted, extending the interval between successive defrosts.
Referring to FIG. 4, the closed circuit refrigeration system 114 includes a refrigerant compressor 120 including the compressor motor 20, a compressor exhaust line 121, a refrigerant condenser 122, a flow restricting capillary tube 124, and a refrigerant evaporator 126 to provide cooling, all connected in series. The exhaust line 121 and condenser 122, being upstream of the capillary tube 124, carry relatively high pressure refrigerant and hence comprise what is conventionally termed the refrigeration system "high side." The thermostat switch 116 is connected in thermal contact with a portion 128 of the refrigeration system high side, preferably with a portion of the exhaust line 121. Thus, the thermostatic switch 116 is responsive to a temperature of a point on the refrigeration system high side. The thermostatic switch 116 is adjusted such that its contacts are closed under ambient temperature conditions, and open under higher temperature conditions such as are reached by the portion 128 during normal operation.
The operation of the embodiments of FIGS. 3 and 4 will now be described with reference to the graph of FIG. 5. In FIG. 5, an upper line 130 represents the temperature of the portion 128 on the refrigeration system high side as a function of time as the compressor 120 cycles ON and OFF in response to the thermostatic control means 26. A lower line 132 represents whether the compressor 120 in ON or OFF any particular moment in time.
From FIG. 5, it can be seen that when the compressor 120 is OFF, the temperature of the portion 128 approaches ambient temperature. During each operation of the compressor 120, the temperature of the portion 128 increases as the operation cycle proceeds. From the graph, it can be seen that the temperature rise near the beginning of each cycle is fairly steep. When the compressor 120 cycles OFF, the temperature falls toward ambient temperature.
The temperature at which the thermostatic switch 116 opens is shown by the horizontal dash line 134, and the temperature at which it again closes is shown by the horizontal dash line 136. As these two temperatures are unequal, the thermostatic switch 116 has a hysteresis characteristic.
Assuming the vacation mode is selected and the vacation switch section contacts 118 are therefore open, at the beginning of each compressor operating cycle, the thermostatic switch 116 is closed and power is supplied to the defrost timing motor 32. This beginning point is represented by the first vertical dash lines 138. Shortly into the operating cycle, the temperature represented by the dash line 134 is reached and the thermostatic switch 136 opens. Power to the defrost control timing motor 32 is interrupted. This terminating point is represented by the second vertical dash lines 140. Power is not again supplied to the defrost timing motor 32 until the beginning of the next compressor operating cycle. Thus, power is supplied to the timing motor 32 during only a portion of each compressor operating cycle, effectively extending the time interval between defrosts. The cycle portion during which the timing motor 32 is energized is shown in FIG. 5 between a pair of arrows 142 bearing the legend "vacation mode."
When the normal mode is selected and the switch section contacts 118 are closed, the thermostatic switch 116 is bypassed and the defrost control timing motor 32 is energized during the entirety of each compressor operation cycle. In this case, the cycle portion during which the timing motor 32 is energized is shown between a pair of arrows 144 bearing the legend "normal mode."
In the embodiment of FIGS. 3 and 4, it will be apparent that the temperature at which the thermostatic switch 116 opens and the location of the thermostatic switch 116 on the refrigeration system high side may be experimentally varied to achieve various time delay intervals.
While the defrost interval extending arrangement of FIGS. 3 and 4 is illustrated and described as controlled by a switching means comprising the vacation switch 42 for selecting either normal or extended intervals between successive defrosting operations, it will be appreciated that this aspect of the invention is not so limited. The switching means for selecting either normal or extended intervals between successive defrosting operations may comprise any switching means responsive to a need to extend defrosting intervals.
While specific embodiments of the invention have been illustrated and described herein, it is realized that numerous modifications and changes will occur to those skilled in the art. It is therefore to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit and scope of the invention.
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An automatically-defrosting household refrigerator including a user-operable "vacation switch" effective to enable the operation of the refrigerator in a mode appropriate to a condition of zero usage. When the vacation switch is thrown to the vacation position, the user is assured at once that unnecessary energy consumption will be avoided and the likelihood of failure of the refrigerator while unattended will be diminished. The mode appropriate to a condition of zero usage includes having the interval between successive automatic defrosting operations extended. Additionally, the vacation switch may be effective to simultaneously disable an automatic icemaker, to increase the temperature set point of the thermostatic control means which maintains the temperature within the refrigerator to disable anti-condensation heaters, and to disable butter conditioner heaters.
There is further disclosed a particular means for extending the interval between successive automatic defrosting operations. A temperature-responsive switch is mounted so as to be responsive to the temperature of a predetermined portion of the refrigeration system high side. The switch is closed at ambient temperature and opens at a predetermined temperature which is reached by the predetermined portion of the refrigeration system high side a few minutes into each operating cycle of the refrigerator compressor. The temperature-responsive switch is arranged to disable the defrost control timer when the sensed temperature exceeds the predetermined value during each operation of the refrigeration system. During normal operation of the refrigerator, the temperature-responsive switch is bypassed, and the defrost control timer operates normally.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to improvements in tripod supports, and more particularly, to an improved tripod support for a stenographic machine typically used by a court reporter for transcribing testimony, the tripod permitting variations in the spatial orientations of the stenographic machine relative to the user to reduce muscular fatigue without reducing the stability of the tripod.
2. Description of the Prior Art
The use of tripods to support a shorthand machine is well known in the art. Because of the arduously long hours a user (such as a court reporter) must spend sitting in a fixed position relative to a stenographic (shorthand) machine, it is desirable to have a support structure for the stenographic machine which enables the user to adjust the machine to a variety of spatial positions relative to the user or the floor, thereby enabling changes from time to time of the physical position of the court reporter to provide more comfortable and variable shorthand machine operating positions which result in reduced fatigue and increased productivity.
Commensurate with this goal, a tripod support having an attachment for varying the angle of the supported shorthand machine has been developed, such as the invention disclosed in U.S. Pat. No. 4,889,301, issued to Yerkes. The Yerkes patent teaches the use of a conventional tripod base assembly having a central shaft end attached to a cantilevered support surface which may be vertically and angularly adjusted to suit the comfort zone of the user. However, by virtue of the cantilevered design, this type of support is incapable of providing a stable vibration free working surface due to the large bending moment developed by supporting the mass of the shorthand machine eccentrically relative to the central shaft axis.
Other types of tripod supports having angularly adjustable cantilevered support arms are disclosed in U.S. Pat. No. 2,593,075, issued to Dale, et al., U.S. Pat. No. 2,765,796, issued to Guenther and U.S. Pat. No. 4,671,478, issued to Schoenig, et al. It is significant that none of the aforementioned references suggest an angularly variable tripod support for a device without supporting the device in some kind of cantilevered arrangement.
Therefore, there exists a need for a tripod support apparatus having an adjustable feature to change the angular orientation of a central support shaft relative to a floor, whereby the supported object such as a stenographic machine may be conveniently positioned at different spatial locations without reducing stability and structural integrity of the tripod, especially for the benefit of a court reporter to allow for different body positions at desired intervals.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided an improved support apparatus for sturdily but adjustably supporting a shorthand or stenographic machine at varying angles of incidence relative to the floor and especially the user.
The apparatus comprises a substantially vertical support for retaining a shorthand machine above a floor, which includes a main cylindrical rigid shaft defined by a first end and a second end, the shaft having a hollow bore extending therethrough for slidably mounting a secondary rigid cylindrical shaft therein. The secondary shaft has a coupling device at one end for secure attachment to a shorthand or stenographic machine of a known type, the coupling being used conventionally, and a flange at the other end of the secondary shaft for retention thereof within the main shaft. A locking mechanism comprising a first collar having a threadably contained friction locking screw is attached to the main shaft at its first end for engaging the secondary shaft by applying a normal friction load thereto which enables the secondary shaft to be slidably adjusted coaxially longitudinally relative to the main shaft, thereby enabling the user to obtain a comfortable working height for the stenographic machine.
The invention is achieved by the moveable positioning of at least one support leg to vary the spatial position of the shorthand machine without unfavorably affecting the stability of the tripod. In one embodiment, three rigid support legs for stable supporting and adjusting the upward orientation of the support shaft are each pivotally connected above and to the main shaft at its second end by a second collar having a plurality of integral flanges extending radially outward therefrom. The support legs may be fabricated having a "U-shaped" cross-sectional channel to facilitate attachment to the second collar and for reasons to be discussed hereinbelow. Attached to each rigid metal leg is a brace for sturdily securing each leg at a predetermined angular orientation relative to the main shaft. The brace comprises a thin planar elongated bar which is pivotally connected to a slidable third collar on the main shaft at one end, and the support leg at the other end. The slidable third collar has a spring-loaded locking pin normally biased against the main shaft so that it may be axially longitudinally aligned with a plurality of longitudinally disposed holes in the wall thickness of the main shaft such that the pin provides a bearing connection between the third collar and main shaft respectively. By pulling the pin radially outward, the third collar may be slid longitudinally relative to the shaft axis thereby collapsing the legs entirely for storage, or locking them in position at varying positions relative to the main shaft to adjust the overall length of the main upward support shaft to vary the height of the shorthand machine above the floor.
In accordance with one embodiment of the invention, at least one support leg has both a pivotal and slidable connection between its brace and the leg such that the leg brace pivot point therebetween may be varied with respect to the longitudinal axis of the adjustable leg. This action permits the adjustable leg to engage the main support shaft at an angle of incidence thereto which is variable from the other two legs depending on the location of the brace pivot joint along the adjustable leg. In this embodiment, the upward orientation of the entire assembly while supporting a stenographic machine may be altered with respect to the ground while maintaining a sturdy machine platform by distributing the supported mass through direct load path without the eccentric induced instability inherent in the "cantilevered type" prior art support devices as discussed.
The pivotal and slidable point connection between the brace and the adjustable leg is accomplished by pivotally attaching the brace to a block member which is slidably disposed within the "U-shaped" leg channel. The block member has a clevis at one end for receiving the brace in a pivot joint, and a tab at the other end separated by a recessed body portion having a plurality of transverse slots defined therein. The tab end has a spring-loaded bias element situated between the block and the lower portion of the leg channel, which normally urges the slots in the intermediate body portion against a pin having a nominal width less than the slot width, which is rigidly attached to the side walls of the channel. In this manner, the braces are linearly fixed with respect to the leg by the bearing contact between the slotted block surface and the pin. To adjust the angular orientation of that particular leg relative to the other legs, human finger or foot pressure is applied to the block tab which permits the block to be slid within the leg "U-shaped" channel until an adjacent slot becomes axially aligned with the pin. Subsequently releasing pressure on the block tab allows the block to "snap" into place under load from the spring biasing means.
The invention may include other embodiments to accomplish support of the shorthand machine at various predetermined locations. For example, using a tripod and frame members as heretofore shown in general, alternate embodiments of the invention could include alteration of a single brace length for a single leg, alteration of the leg length itself and alteration of the leg and foot position with respect to the leg. Each of these embodiments would in effect change the upward angle of inclination and therefore the spatial position of a shorthand machine supported atop of the tripod with respect to a floor supporting the entire assembly. Other embodiments might include having multiple position attachments between the brace and main support shaft that can be readily moved at one end of the brace. Still another embodiment could include variable elements and components for securing the leg to the main cylindrical shaft at varying angles. Of primary concern however is to insure that there is no sacrifice of stability or sturdiness in the final support structure selected.
It is an object of the instant invention to provide an improved support apparatus for sturdily supporting a shorthand machine at a plurality of different spatial positions relative to a floor to improve the comfort of a court reporter.
It is another object of the invention to provide an improved tripod apparatus rigidly supporting a shorthand or stenographic machine at adjustably variable elevations relative to a support surface.
It is a further object of the invention to provide an improved tripod which is lightweight and easy to manufacture for adjustably supporting a court reporter's stenographic machine at different spatial orientations to permit different body positions, without reducing stability.
In accordance with these and other objects which will become apparent hereinafter, the instant invention will now be described with particular reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the tripod assembly in accordance with invention.
FIG. 2 is an elevational view of the tripod assembly supporting a machine in perpendicular orientation relative to a support surface.
FIG. 3 is an elevational view of the tripod assembly supporting a shorthand machine at an acute angle relative to the support surface.
FIG. 4 is a section view through the shaft and brace collar.
FIG. 5 is a section view through the shaft and extension adjustment collar.
FIG. 6 is a perspective view of the sliding block member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the several views of the drawing, there is depicted an improved tripod support generally by reference numeral 10, comprising shaft housing 12, rigid legs 14, and leg braces 16.
In the preferred embodiment, shaft housing 12 comprises cylindrical main shaft 18 defined by a first end 20, a second end 22, and has a hollow bore extending therethrough. Slidably disposed coaxially within main shaft 18, is a secondary shaft 24 having a flange 26 at one end, a conventional shorthand machine, and retaining fitting 28, for rigidly securing a shorthand machine 30 thereto. Fitting 28 is a generally planar cylindrical member having opposing flange portions 30 which interconnect with a fastener affixed to shorthand machine 30 in a manner well known in the art. Secondary shaft 24 has a flange 32 at its opposite end for retaining itself within main shaft 18 by coming into contact with collar locking ring 34 which is slip-fit into first end 20 of main shaft 18, which will be described in greater detail hereinbelow.
At the first end 20 of main shaft 18, there is additionally provided a means for locking secondary shaft 24 relative to main shaft 18 such as first collar assembly 35, such that the axial longitudinal distance of the support shafts and therefore the height of shorthand machine 30 may be easily adjusted to suit the particular user. First collar assembly 35 comprises collar 36 which is defined by a cylindrical outer surface 38 terminating in a raised shoulder portion 40 for mounting a threaded insert 42 therein as shown in FIG. 5. A friction locking screw 44 is threaded into insert 42 and may be urged against secondary shaft 24 through hole 46 defined in main shaft 18. Collar assembly 35, which is slip fit on main shaft 18, and friction locking screw 44, in addition to providing a locking force to retain secondary shaft 24, prevents collar 36 from sliding out of position. Collar locking ring 34 is slip fit within the hollow bore of main shaft 18 and over collar 36, to engage flange 32 of secondary shaft 24 to retain it within main shaft 18.
A second collar assembly 46 is slip fit over the second end 22 of main shaft 18. Second collar assembly 46 has a plurality of flange portions 48 extending radially outward therefrom for pivotally joining rigid legs 14 thereto as will be described hereinafter. Second collar assembly 46 is rigidly secured to main shaft 18 by fastener 50 as shown in FIG. 1.
A third collar assembly 52 is slip fit on main shaft 18 for pivotally and slidably attaching brace means 16 to main shaft 18. The third collar assembly 52 has a cylindrical outer surface 54 which has a raised shoulder portion 56 for mounting a spring loaded pin 58 therein. Shoulder portion 56 defines a hollow chamber 60 for mounting compression spring 52 between the shoulder and flange 64 on pin 58 as shown in FIG. 4. Pin 58 is biased by spring 62 against main shaft 18, so that it may be slip fit within one of a plurality of holes generally denoted by reference numeral 64 defined through the wall thickness of main shaft 18 to lock collar assembly 52 relative to main shaft 18, thereby adjusting the angular orientation of legs 14 relative to main shaft 18 as will be described below. Extending radially outward from the cylindrical outer surface 54 of collar assembly 52 are a plurality of clevis attachments 56 for receiving brace means 16 therein and pivotally attaching brace means 16 by pin 58.
The leg braces 16 are a plurality of elongated rigid metal planar bars which support legs 14 relative to main shaft 18. Each brace 16 is pivotally attached to third collar assembly 52 as described above, and is pivotally attached to the legs 14 as described hereinafter.
The tripod support legs 14 are constructed in the form of a "U-shaped" channel 61 in the preferred embodiment which is defined by a planar bottom wall 60 joined by two planar and parallel side walls 62a and 62b at substantially right angles thereto. Each leg 14 is pivotally connected to collar 46 by pin 64 through flanges 48 at one end as described above and has an elastomeric tab 65 to prevent floor damage at its other end. Braces 16 are pivotally connected to legs 14 by pin 66 and spacer 68, and pivotally and slidably connected to leg 14a by block member 70.
At least one leg 14a, and brace 16a, are joined in a pivotal and slidable connection by block member 70 located within channel 61, such that the pivot point may be linearly translated relative to the leg 14a to vary the angle of that particular leg 14a relative to the other legs 14 to incline the entire tripod assembly 10 at an acute angle relative to the ground or a floor support surface as shown in FIG. 3. FIGS. 1 and 6 depict block member 70 having a clevis 72 at one end for receiving brace 16 in a pivot joint secured by pin 73, and a tab 74 at the other end separated by a recessed body portion 76 having a plurality of transverse slots 78 defined therein. Tab end 74 has a spring loaded biasing means 80 disposed between block 70 and the leg planar bottom 60 in channel 61 which normally urges slotted recessed body portion 76 against pin 82. Pin 82 has a nominal width less than the width of slot 78 and is situated a distance greater than the thickness of recessed body portion 76 above planar bottom wall 60 and between walls 62a and 62b, thereby facilitating bearing contact between pin 82 and block 70 to rigidly and adjustably secure brace 16 to leg 14a. To change the location of the pivot point relative to leg 14a, finger or foot pressure on tab 74 against spring loaded biasing means 80 permits block member 70 to be slid relative to pin 82 so that block 70 may engage pin 82 via a different slot 78. By axially aligning adjacent slots 78 with pin 82, the angle of the tripod assembly 10 may be varied while still providing a vibration free and stable support surface for a shorthand machine 30. Tab 74 is constructed so that the tab 74 extends above the U channel of leg 14a so that the tab can be actuated by the user's foot to change positions of the shorthand machine.
The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to a person skilled in the art.
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A tripod especially suited for use by a court reporter for supporting a court reporter's stenographic machine, the tripod providing an adjustable support leg that allows the stenographic machine to be firmly and stably supported in space at different locations relative to the court reporter for increased comfort and change of position by the court reporter throughout the day. In one embodiment, the leg includes an adjustable block and pin which provides several different positions relative to the supporting brace of that leg aligned for change in inclination of the overall support device.
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BACKGROUND OF THE INVENTION
1. Field of the Invention:
The invention relates to heddle frames with an improved structure for fixing the aluminum bar to the side tray.
2. Description of the Prior Art:
FIG. 1 is a partially abbreviated side elevation view of a heddle frame of a loom which has been conventionally used, wherein 1' indicates an aluminum bar, the end of which is fixed with side stay 2' to form a frame. In the drawing, 3' is a heddle rod which is horizontally suspended to side stay 2' and expandingly supports many heddles 4'. The heddle rod is supported by middle hooks 5' at a given interval in the length of the rod; the middle hook 5' is fixed by hook hanger 6' which is engaged in the supporting line groove 7' on aluminum bar 1'.
In the drawing, 8' is a guide plate which guides the function of aluminum bar 1'.
In the conventional heddle frame constituted by the above described structure, a fixing structure A and A', portions of which joint aluminum bar 1' and side stay 2', requires greater fixing strength as the speed of the loom becomes higher. An increase of the joint strength of aluminum bar 1' and side stay 2', however, leads not only to a complicated joint structure requiring very difficult assembly and disassembly, but also results in increased inertia force for the opening operation of the heddle frame because of increased weight, or in the failure of the joint of aluminum bar 1' or in deficiencies such as greater wear or higher noise. Therefore, a variety of devices have been considered for the fixing structure of A and A'. However, none with a satisfactory joint structure has been developed yet.
SUMMARY OF THE INVENTION
The present invention has as its object to supply a practical and convenient heddle frame characterized in joining an aluminum bar and a side stay by the use of a special joint-block. The present invention also includes pressing and pressure receiving pieces resulting in a simple structure which allows easy assembly and disassembly of the side stay against the aluminum bar with a relatively light-weight, highly rigid structure, thereby complying with the higher speed operation of the loom.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features and attendant advantages of the present invention will be more fully appreciated as the same becomes better understood from the detailed description of the drawings wherein like reference characters designate like or corresponding parts throughout the several views, and wherein:
FIG. 1 is a side view of a conventional heddle frame of a loom, partially abbreviated;
FIG. 2 is the side view of a part of the heddle frame of this invention corresponding to the A portion of FIG. 1;
FIG. 3 is the plan of FIG. 2;
FIG. 4 is the sectional view of a cut along IV--IV line of FIG. 3;
FIG. 5 through FIG. 8 are sectional views, respectively along the line V--V, line VI--VI, line VII--VII and line VIII--VIII of FIG. 4;
FIG. 9 is a sectional view indicating another embodiment corresponding to FIG. 6; and
FIG. 10 is the side view of FIG. 9.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the Figures, 1 is an aluminum bar, in which a hollow portion 2 is formed. A guide groove line 3 is provided on the under side of the bar to engage in a hook hanger. Portion 4, like hollow 2, is a hollow space formed to further reduce the weight of the aluminum bar.
Joint block 5 is inserted into the hollow portion 2 at the end of aluminum bar 1, and firmly fixed to it by rivets 6. The end of the block 5 projects horizontally from the end of aluminum bar 1 by an amount which is determined as necessary.
Stay 7 is a hollow side-stay constructed of a hollow square pipe which is to be connected to the end of aluminum bar 1. It is provided with an opening 9 at the side of the stay facing the end of the aluminum bar 1, to which projecting end 8 of the joint block 5 is to be inserted. Piece 10 is a pressure receiving piece fitted in the hollow part 11 of the side-stay 7, and is inserted in a position so that its end touches an opposing surface of the projected end part 8 of the joint block 5, which is horizontally inserted into the opening 9 on the side face of the side-stay 7. The piece 10 is fixed to side-stay 7 by spot welding 12 or by rivets.
Piece 13 is a pressing piece, loosely fitted in the hollow part 11 of the side-stay 7, and able to move up and down in the hollow portion 11. The sole of piece 13 is constructed so as to touch the opposing side of the projected part 8 of the joint block 5. Vertical through bolt holes 14 and 15 are respectively provided in the pressing piece 13 and the projected end 8 of joint block 5. A threaded hole 16 is provided in pressure receiving piece 10 so as to be aligned with bolt holes 14 and 15.
Bolt 17 is a clamping bolt, which may be set through bolt holes 14 and 15 and screwed into the threaded hole 16 of pressure receiving piece 10 and fastened to securely hold the projected part 8 of the joint block 5 against the sole of pressing piece 13 and the end of pressure receiving piece 10.
A V-shape projected line 18 is provided on the sole of the pressing piece 13 and is parallel with the edge of aluminum bar 1. On the other hand, as shown in FIG. 7, V-shape groove line 19 is constructed to join with V-shaped projected line 18 on the opposing face of the projected part 8 of the joint block 5. Vertically elongated guide hole 20 is provided on the side wall of pressing piece 13 as shown in FIG. 4 and FIG. 6, and pin 21, which is horizontally fixed to the side wall of side-stay 7, is loosely fitted in the guide hole 20.
The head of the clamping bolt 17 is provided with hexagonal hole 22 as shown in FIG. 3, to allow access to the head immersed in the counter bored hole 23 provided on the end face of pressing piece 13.
To assemble the heddle frame of this invention, one may insert projected end 8 of the joint block 5 into the opening 9 of the side-stay 7, until the side of opening 9 of the side-stay 7 contacts with the end face of the aluminum bar 1. When pressing piece 13 receives an upward component force at the V-shape projected line at its base due to the opposing surface of projected end 8 as a result of the insertion of projected portion 8 of the joint block 5, the pressing piece 13, which is loosely fitted in the hollow part 11 of the end of side stay 7, can move in the X direction as shown in FIG. 4 because of the freedom of pin 21 to move up and down along the longitudinal length of guide hole 20. When the projected end part 8 is inserted fully into the opening 9 to make the side face of the side-stay contact with the end of aluminum bar 1, the V-shape projected line 18 of the pressing piece 13 meets with the V-shape groove line 19 of the projected part 8 of joint block 5 and the pressing piece 13 moves in the X' direction to make the V-shape projection 18 fit with V-shape groove line 19. And when the V-shape projected line 18 engages with the V-shape groove line 19 as shown in FIG. 4, the relative position of the parts is so determined that bolt hole 14 in pressing piece 13, bolt hole 15 in the projected portion 8 of the joint block 5 and the threaded hole 16 in the pressure receiving piece 10 will be aligned in the vertical direction. Therefore, clamping bolt 17 can be smoothly inserted through bolt holes 14 and 15, and by screwing the pointed end of the bolt in the threaded hole 16 to fasten tightly, the projected portion 8 of the joint block 5 is held between pressing piece 13 and pressure receiving piece 10, to strongly fix side-stay 7 to the end of aluminum bar 1 as shown in FIG. 4. In this case, the head of the bolt 17 is immersed in the counter sunk hole 23 to the surface of pressing piece 13. However, because of the hexagonal drive hole 22 of the head of the bolt 17, the screwing operation will not be obstructed even when the head of the clamping bolt is completely immersed in the counter sunk hole to the extent that the top face of the clamping bolt 17 comes even with the end face of the pressing piece 13.
To remove side-stay 7 from the end of the aluminum bar 1 for repair, maintenance and inspection purposes, it is required only to horizontally pull out side-stay 7 after loosening and removing clamping bolt 17. The aluminum bar 1 and the side-stay 7 will then be separated from the boundary line a-b-c-d-e-f shown in FIG. 4. It is clear that the horizontal pulling out of side-stay 7 causes the V-shape projection line 18, which is engaging in V-shape groove line 19, to be subjected to an upward component force which pushes the pressing piece 13 in the X direction to disengage the connection of V-shape projection line 18 and V-shape groove line 19, and that the projecting part 8 of joint block 5 will be smoothly pulled out of the opening 9 of the side-stay 7.
The structure shown in FIG. 2 through FIG. 8 is the portion corresponding to the portion A of FIG. 1. The portion A' is identically structured.
When side-stay 7 is removed from the end of the aluminum bar 1, the pressing piece 13, which is loosely fitted in the hollow portion 11 of the end of the side-stay 7, is loosely engaged to the guide hole 20 by pin 21. Therefore, it will not fall out of the hollow part 11 of the side-stay 7.
Because joint block 5 is firmly fixed to aluminum bar 1 with rivets 6, and the pressure receiving piece 10 is fixed firmly to the side-stay 7 by spot welding 12 or a rivet or rivets, their rigidity is quite high and they will not be loosened by repetetive attaching and removing.
Although, in the described example, pressing piece 13 was loosely fitted to side-stay 7 and allowed to move up and down, the device is intended to allow smooth attachment and removal of joint block 5 to or from side-stay 7, and the pressing piece 13 may be fixed if such consideration is unnecessary. It is evident that V-shape groove line 19, guide hole 20 and pin 21 can be eliminated, if such fixed attachment is applied.
FIG. 9 and FIG. 10 are another embodiment of a device to fix a pressing piece to a side-stay, of which FIG. 9 is a sectional view corresponding to FIG. 6, and FIG. 10 is its side view. As may be clearly seen from the drawing, the apparatus of the present invention may be modified to provide an elongated guide hole 20 on the side wall of the side-stay 7 instead of the side wall of the pressing piece 13, and to allow pin 21, which is horizontally fixed to the pressing piece 13, to fit loosely in the guide hole 20' provided in the side-stay 7. This arrangement permits up and down movement of pressing piece 13, which is loosely fit in the hollow portion 11 of the end of the side-stay 7, and prevents the pressing piece 13 from falling out from the hollow portion 11.
Because this invention has the above structure and function, and because the joint block and pressure receiving piece are respectively inserted into aluminum bar and side-stay and are strongly fixed, this structure does not result in loosening by repetetive attachment and removal of the side-stay and is sufficiently durable for long service. The attachment or removal of the side-stay is made only by pushing or pulling the side-stay to or from the aluminum bar, with only the screwing in or loosening out of the clamping bolt, thereby resulting in very simple operation which may be completed in a short time.
Because the projected part of the joint block is inserted not only into the opening portion of the side-stay but is also held between the passing piece and pressure receiving piece and clamped to form one body with those pieces by way of clamping bolt, the joining strength between the aluminum bar and the side-stay is quite strong and its rigidity is high. The heddle frame can be made light in weight and low in cost because the aluminum bar and side-stay have a hollow portion, and the joint block, pressure receiving piece and pressing piece can be made of smaller pieces which can be inserted or loosely inserted into the hollow portions. Further, the aluminum bar and side-stay can be made to relatively higher moduli of elasticity due to their hollow sectional configuration, resulting in strong bending resistance, which is sufficient to bear high speed operation and heavy loads. Aside from those many advantageous points, the structure provides a very convenient heddle frame for practical applications, allowing one to locate their relative position automatically, so that they may be assembled only by engaging extruded portions of the pressing piece and joint block at the V-shaped projected line and the V-shaped groove line; the joint of the longitudinally elongated guide hole and a pin between the pressing piece and side-stay can prevent the falling of pressing piece which has vertical movement allowance. Further facilitating the clamping operation is the adoption of a hexagonal hollow head bolt for clamping.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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A joint between a cross bar and a side-stay of a heddle frame is disclosed. The cross bar is hollow and has a joint block inserted in the end thereof. The joint block extends into the hollow side-stay and contacts a pressing piece and a pressure receiving piece on opposite sides thereof. The pressing piece has a V-shaped projection which mates with a V-shaped groove on one face of the joint block for mating contact therebetween. The pressing piece and joint block have aligned bolt holes which are in turn aligned with a threaded hole in the pressure receiving piece. A clamping bolt is insertable through the bolt holes and screwable into the threaded hole to secure the pressing piece, joint block and pressure receiving piece together for securing the joint of the heddle frame.
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FIELD OF THE INVENTION
[0001] This invention is generally directed to high-speed data communication, and more specifically, to the area of high-speed modem design. It relates to achieving high spectral efficiency in signaling systems.
BACKGROUND OF THE INVENTION
[0002] Modern telecommunication applications have resulted in substantial increases in the need for additional bandwidth. For example, in the area of wired communications, there is a need to simultaneously support voice, video, and data applications at low BER (Bit Error Rates) using new high-speed modem designs for twisted pairs. At signaling rates better than 10 Mbits/s performance bounds generally exceed a BER of 10 −6 . When the conventional Pulse Amplitude Modulation (PAM) technique is used, the baseband communication signal is represented by a series of modulated pulses whose amplitude levels are determined by the symbol to be transmitted. For example, with 16-QAM (Quadrature Amplitude Modulation), typical symbol amplitudes of ±1 and ±3 are utilized in each quadrature channel. For digital communication systems, efficient used of bandwidth is crucial when dealing with time-dispersive channel, as is common with wireless systems. In these types of systems, whenever there is distortion of the signals due to preceding or following pulses, normally referred to as pre-cursors and post-cursors, respectively, the amplitude of the desired pulse is affected due to superimposition of the overlapping pulses. This phenomenon is known as intersymbol interference, and is an impediment to high-speed data transmission, especially in systems that are constrained by limited bandwidth.
[0003] One way to minimize the effects of intersymbol interference is to use an equalizer. Fixed equalizers are designed to be effectively operated between an upper and lower bound between which the channel is expected to deviate. Whenever these limits are exceeded, the equalizer ceases to operate effectively. Hence, there has to be a certain degree of precision when channel equalization is employed, and fixed equalizers are implemented. There are adaptive equalizers (i.e., continuous) that track dynamic channel dispersion and make continuous adjustments to compensate for such intersymbol interference. This provides some improvement in performance over the fixed equalizer.
[0004] Incorporation of the equalizer into some communication systems does not come without penalty. In wireless systems, for instance, insertion loss becomes a critical factor if the equalizer is present and the associated impairment does not occur. The main purpose of the equalizer implementation is to enhance the information bearing capability of the communication system with the design objective of asymptotically approaching the capacity bounds of the transmission channel. Consequently, the use of the equalizer can be regarded as one instance of an array of possibilities that may be implemented to enhance the bit rate of the communication system design.
SUMMARY OF THE INVENTION
[0005] In accord with the invention, a method and apparatus is provided that makes more efficient use of the available signaling bandwidth in the sense of asymptotically approaching possible transmission limits. This is done by significantly reducing the effects of intersymbol and interchannel interference by a judicious choice of the signaling pulse shapes. In particular, prolate pulses are used to extend channel capacity and reduce interference. By use of orthogonal axes that span the signal space, combined with water filling techniques for efficient allocation of transmission energy based on the noise distribution, the information content can be increased without increase in bandwidth.
[0006] The signaling space is spectrally decomposed to support the simultaneous transmission of multiple signals each with differing information bearing content. These signals being orthogonal, are non-interfering. Signals are constructed as complex sets and are generally represented with axial coordinates, all orthogonal to one another within the complex plane. The real axis is termed the in-phase (I) component and the imaginary axis is termed the quadrature (Q) component. Each component defines a spanning vector in the signal space.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is a graph depicting the concentration of energy in a prolate pulse interval;
[0008] [0008]FIG. 2 is a block schematic illustrating an optimized modem using the invention;
[0009] [0009]FIG. 3 is a block schematic of a Single Segment Discrete Prolate Transmitter;
[0010] [0010]FIG. 4 is a graph illustrating the application of water filling to the present invention.
[0011] [0011]FIG. 5 is a graph depicting channel segmentation and use of the frequency response; and
[0012] [0012]FIG. 6 is a block schematic of the Discrete Prolate demodulator corresponding to FIG. 3.
DETAILED DESCRIPTION
[0013] Spectral efficiency in digital systems is largely a function of the wave shapes of the signals that are used to carry the digital information. There are tradeoffs between time limitations and frequency limitations. These two requirements generally have a flexible relationship. The characteristics of prolate pulses may be chosen to limit spectral energy dispersion thereby permitting more signaling channels for a given bandwidth. These advantages become readily apparent with an analysis of the prolate pulse spectral performance. In particular, the Fourier transform of the waveform is very band limited. Proper selection of signal space such as axes or spectral vectors representing signal coordinates are very important. If signals are orthogonal to one another, transmission techniques utilizing methods of water filling may be implemented with significant increase in efficiency. The technique of water filling is discussed in “Multicarrier Modulation for Data Transmission: An Idea Whose Time Has Come”, J. A. C. Bingham, “ IEEE Communications, ” May 1990, pp. 5-14 incorporated by reference. An illustration of water filling may be ascertained from the graph of FIG. 4. A bandwidth of a channel is defined by the marks 401 and 402 on the horizontal axis. The curve 403 defines the noise level produced as seen by a receiver. The energy level, which the channel can transmit, is defined by the horizontal level 404 . The area 405 bounded by the curve 403 and energy level 404 may be “water filled” by data signals. The data acceptance area 405 of the band is divided into sections 408 by vertical dividers 409 . The signal data is inserted into a section until the added data and noise in that section reaches the energy level limit. This filling combined with the orthogonal nature of the data signals inserted in the sections permit the increase in the data capacity of the channel.
[0014] Consider a trigonometric polynomial p t (t) defined as follows:
p i ( t ) = ∑ n = - N N a in j n π t ( 1 )
[0015] In equation (1) the period may be chosen to be 2 by suitable scaling of t. The coefficients a in can be obtained by an optimization process, the objective of which is to obtain a spectrally efficient pulse. The process may be regarded as a scheme in which the energy of the pulse is concentrated in the interval [−ε,ε]. This is shown in FIG. 1 where a more or less generic pulse 101 is shown and the constraining interval 102 is indicated. The optimization process is a transmission pulse design problem, and a particular mathematical approach for achieving this objective is now described. In general, optimal communication system design requirements often necessitate the transmission of spectrally efficient pulses in order to minimize both intersymbol interference and interchannel interference where application requires segmented spectrum utilization.
[0016] Based on the specified format in equation (1), it can be shown that the coefficients a in of p 1 (t) satisfy the following system of equations:
∑ m = - N N sin ( n - m ) π ɛ ( n - m ) ɛ a im = λ a m , n = - N , - N + 1 , … N . ( 2 )
[0017] Equation (2) may be rewritten in the form,
S{overscore (a)} 1 =λ 1{overscore (a)} i (3)
[0018] Where the coefficients S nm of the matrix S defined by equation (3), and eigenvectors {overscore (a)} i are given by,
S n m = sin ( n - m ) π ɛ ( n - m ) ɛ ( 4 )
[0019] and
{overscore (a)} 1 =[a −Nt′ a (−N+1)1′ . . . a 0t′ . . . ′ a (N−1)t′ a N1 ] t (5)
[0020] Where t denotes transpose. The matrix S is a real, symmetric, and positive definite with other mathematical properties of interest to the development, as now discussed. There are thus 2N+1 real eigenvalues λ, which satisfy (3) and which may be ordered such that:
λ 1 >λ 2 >. . . >λ 2N+1 (6)
[0021] For each eigenvalue λ 1 , there is an associated eigenvector {overscore (a)} i , whose coefficients can be used to form the trigonometric function defined in equation (1). The eigenvectors of the matrix S may be normalized to have unit energy. Because of the orthogonality of the eigenvectors of symmetric matrices, their dot products {overscore (a)} 1 {overscore (a)} j satisfy the following relationship,
a → i · a → j = ∑ n = - N N a in a jn = δ ij , ( 7 )
[0022] Where δ ij the Kronecker delta function. Because of equation (3) and equation (7), it can be shown that functions of the form of equation (1) whose coefficients are those of the eigenvectors of the matrix S as defined in equation (4), the following relationships holds:
1 2 ∫ - 1 1 p i ( t ) p j ( t ) t = δ ij ,
and , ( 8 ) 1 2 ∫ - ɛ ɛ p i ( t ) p j ( t ) t = λ i δ ij ( 9 )
[0023] Functions so formed are described as discrete prolate.
[0024] With the background material discussed above, a particular method of communicating digital information using the functions p i (t) defined earlier is now presented. Again, in view of equation (6), there are 2N+1 eigenvectors that satisfy equation (3). The vectors together form a spanning set for the vector space defined by the matrix S. Define D to be the dimension of the associated vector space. Then D is given by:
D= 2 N+ 1 (10)
[0025] Note that D is a design parameter, and is a function of N. By analogy, {p i (t)} form a spanning set for the signal space associated with the matrix S, and this signal space is also D dimensional. Consider the construct:
x i ( t ) = ∑ k = - ∞ ∞ I k p i ( t - kT ) ( 11 )
[0026] Generalizing and using equation (8), it can be shown that the following holds:
1 2 T ∫ - T + kT T + kT x i ( t ) p j ( t ) t = δ ij I k ( 12 )
[0027] Equation (12) is of critical importance to the invention. The implications are that if a function of the form of equation (11), for a specific value of i, is transmitted over a communication channel, then the transmitted alphabet I k will only be uniquely determined in an interval defined by k if the corresponding p i (t) is used as the receiving filter. If a function of the form of equation (11), for a specific value of i, is transmitted over a communication channel, and p J (t) for j#i, is used as the receiving filter, then the function p I (t) will be virtually non-existent. Thus in order to extract the information content of a signal whose format is given by equation (11), the signaling pulse must be matched at the receiver. In anticipation of making reference to Cartesian space, the format of equation (11) is used in the construction of y I (t) defined as follows:
y i ( t ) = ∑ k = - ∞ ∞ Q k p i ( t - kT ) ( 13 )
[0028] where again Q k is the alphabet to be transmitted. It is clear that equation (13) also satisfies a relationship similar to equation (12). Equations (11) and (13) can now be used to quadrature modulate a carrier in the final part of the transmission signal synthesis. Define s i (t) by:
s I ( t )= x I ( t )cos(2π f c t )− y I ( t )sin(2π f c t ) (14)
[0029] Thus, the signals are constructed as complex sets and are generally represented as vectors within the complex plane. The real axis is termed the in-phase (I) component and the imaginary axis is termed the quadrature (Q) component.
[0030] As indicated by equation (10), there are D such constructs possible. Because of the Orthogonality of the building blocks {p I (t)} discussed earlier, {s I (t)}, being linear combinations of a single p i (t) for each i, are themselves orthogonal, forming a spanning set for the signal space defined over the channel band limited by W=½T. That is to say, each such signal s i (t) may be regarded as an orthogonal “finger” over which the symbols {I k , Q k } may be independently transmitted. Thus, equation (14) can be used to increase the bit rate of the communication channel without bandwidth expansion. Of course coding and equalization may be added to improve fidelity.
[0031] The parameters ε and N determine the spectral shape of the transmission pulses p I (t). In general ε will be used to determine the compactness of the fit within the signaling period, while N determines the peaking and roll-off. It is important for N to be fairly large (N≧10) as there are at least two benefits to be gained in this regard. Firstly, large values of N contribute to better roll-off characteristics, which directly minimize intersymbol interference. Secondly, as can be seen by equation (10), large values of N contribute directly to an increase in the dimension of the signaling space, providing more discrete prolate functions that can be used to increase the capacity of the transmission system design. However, these benefits must be balanced by the fact that tighter peaks that are made possible by larger values of N are likely to place greater implementation constraints on the receiver, to the extent that more accurate symbol timing shall be required to retrieve the encoded digital information.
[0032] In general, the range of values that can be taken on by the discrete symbols {I k , Q k } determines the number of levels M that may be reasonably distinguished at the receiver, with noise, crosstalk, and interference playing a critical role in the process. Conventional modulation techniques, such as QAM for instance, may be referenced, and the value of M shall be determined in an optimization process in which the power is held constant, and the bit rate is maximized for a given BER constraint. Given M, the information bearing capacity C of the transmitter is computed in a straightforward manner. Thus,
C = log 2 M T ( 15 )
[0033] Where C is given in units of bits/s. Equation (15) holds for the one-demensional case. That is, only when one signal of duration T having M reasonably distinguishable levels is transmitted in a channel bandlimited by W. However, when multiple orthogonal signaling is used for data transmission, the parameter M in equation (15) will be a function of the number of signals chosen, along with the associated levels that may be represented by each independent choice. A limiting reformulation of equation (15) is now given by:
C lim = log 2 ∏ i M i T ( 16 )
[0034] Equation (16) hints of the possibility of channel optimization with more efficient encoding of the signaling data. A concrete use of equation (16) is demonstrated in the sequel, specifically, with the aid of FIGS. 3 and 6.
[0035] The area of optimal communication system design is generally one in which various signal-processing techniques are comprised to asymptotically approach theoretically established channel capacity limits. Transmission rates may further be optimized if a process known as water filling is implemented. With the implementation of water filling, the available signaling power is allocated to the communication channel, and the bits are loaded in a manner related to the noise spectral density, with the objective of maximizing resource utility. It may be regarded as a process in which the sqander of the available signal energy is avoided. Let the noise be Gaussian, with the power spectral density given by N(f), with H(f) being the associated complex transfer function of the channel. Then, in order to make efficient use of the available signaling power S, the optimal channel input power is given by:
S = ∫ f ∈ Ω B - N ( f ) H ( f ) 2 f ( 17 )
[0036] where the region of integration Ω is defined by:
Ω = { f : N ( f ) H ( f ) 2 ≤ B } ( 18 )
[0037] Equations (17) and (18) describe the elastic relationship that exists between the power spectral densities of the input signal and the noise during the process of optimizing the available channel bandwidth. In equations (17) and (18) B is an average input power constraint.
[0038] From a practical standpoint, the optimal allocation of signaling power is best achieved by channel segmentation. Then, the allocation of bits to the various sub channels is achieved through the process of maximizing the channel capacity while minimizing the baud error rate. There exist in the literature a variety of optimal loading algorithms through which the required energy distribution may be accomplished. A good example may be found in patents: “Ensemble Modem Structure For Imperfect Transmission Media” U.S. Pat. No. 4,679,227, 4,732,826 and 4,833,706.
[0039] With the aid of FIG. 5, an exemplary approach to optimized loading is now discussed. Let the available channel bandwidth be divided into N equal segments of length W. Assume that the frequency response within the i th segment is flat and given by H i (f). Let the noise be additive white Gaussian with double-sided spectral density N O /2 watts/Hz. Let the available signal power P be equally divided among all sub channels available, and normalize the system to the first sub channel. The received power in the i th sub channel is thus P i =l i P/N where l I =|H i (f)| 2 /|H 1 (f)| 2 . It can then be shown that a possible optimal choice of bit loading n I is given by:
n i = log 2 = { ( l i / N ) ( 3 / 2 ) ( P / N o W ) - ln Pr ( ɛ ) } ( 19 )
[0040] Where n i is the number of bits allocated to the i th sub channel, and Pr (ε) is the probability of symbol error for all sub channels. In equation (19), since l I P/N O W is the signal to noise ratio in the i th sub channel, a preferred embodiment of the invention will use a measured value of the noise in the i th sub channel for the computation of n 1 . This combined approach to the allocation of signaling energy and of bits to each sub channel comprises a specific optimal approach to water filling.
[0041] A block diagram of the complete transmitter/receiver pair is shown in FIG. 2. In FIG. 2 the transmitter comprises N sub-transmitters 201 - 1 to 201 -N and the summer 202 . Input data for transmission through the channel are modulated at each sub-transmitter 201 - 1 to 201 -N, and the outputs are summed at the summer 202 for transmission through the channel characterized by the function block 203 . Addition of noise into the system is depicted by function block 204 in FIG. 2. The i th sub-transmitter 201 -i is optimized in accord with water filling as described above for the i th segment of the channel. Similarly, the receiver is comprised of N subcomponents 205 - 1 to 205 -N, the i th subcomponent 205 -i corresponding the component 201 -i of the transmitter.
[0042] The invention is now further described with greater specificity with the use of FIG. 3, which illustrates how the discrete prolate functions are used for capacity optimization. With reference to function block 201 - 1 , assume that, with the use of equation (19), a computed value of 6 was obtained for n 1 . It is clear from the foregoing discussion that this loading bound can be assured through the resolution of the transmitted signal with the use of two discrete prolate functions. Let n 1 =n 11 +n 12 with n 11 =2 and n 12 =4. It can further be shown that, given the specific choices for n 11 and n 12 , if it is assumed that the symbol error is equal in both signaling dimensions, the power must be divided such that P 1 =P 11 +P 12 , where P 11 =P 1 /3 and P 12 =2P 11 . Given the foregoing choices of parameters, an exemplary embodiment of the invention in function block 201 - 1 is illustrated in FIG. 3. As can be seen from the figure, the six bits to be transmitted are segmented at function block 301 into 2- and 4-bits packets that are sent to function blocks 302 - 1 and 302 - 2 . At function block 303 - 1 , a 4-level I/Q mapper is used, while a 16-level mapper is used at function block 303 - 2 . Within function block 304 - 1 the I and Q components from function block 303 - 1 and the power P 11 are used to generate the in-phase and quadrature components of the prolate pulses corresponding to p 1 (t). Further, these components are modulated at function block 306 - 1 and 308 - 1 , then summed at function block 309 for output to the channel. As can be seen from FIG. 3, similar activities occur for the dimension corresponding to p 2 (t)).
[0043] The structure of the optimized sub-receiver 205 - 1 , associated with sub-transmitter 201 - 1 , is shown in FIG. 6. As discussed earlier, the key to retrieving the bits that were sent in a particular dimension is the use of a low pass eigenfilter for that dimension. The discrete prolate pulses are thus used to form a low pass orthogonal filter bank for extracting the bit information from each dimension. The demodulated I k and Q k values finally go through a reverse mapping process, after which the original block of bits is reconstructed.
[0044] In the receiver of FIG. 6 the channel output is received as indicated by the block 601 . This channel output is connected to a plurality of mixers 603 - 1 , 603 - 2 , 605 - 1 and 605 - 2 and are mixed with cosine and sine signals, respectively. These mixed signals are demodulated in the orthogonal filter bank containing filters 606 - 1 , 606 - 2 , 606 - 3 and 606 - 4 . I/Q reverse mappings are performed in reverse mappers 607 and 608 to recover the segmented bits and the originally transmitted bit pattern is reconstructed in block 609 . While discrete blocks are illustrated, the processes are stored program processes that are performed independently of block identification.
[0045] Synchronousness being of critical significance to the design of telecommunication systems, reference is now made to the fact that in the construction of FIG. 2, FIG. 3, and FIG. 6, this requirement is stipulated. Thus, in a complete embodiment of the present invention, methods of carrier tracking and symbol recovery shall be implemented. There are various procedures well documented in the literature to accomplish these operations. One reference describing synchronism with respect to carrier tracking and symbol recovery is the text “Digital Communications, Fundamentals and Applications” by Bernard Sklar. Information specifically related to synchronization may be found in chapter 8, Pages 429-474.
[0046] Recall that in equation (2) ε was used to determine the pulse efficiency. Thus, in a preferred embodiment equation (9) may be used to shorten the length of the filtering process, in an effort to seek implementation efficiency. Filtering must then be normalized by a factor of 1/λ i for each finger. In this case, keeping jitter to a minimum will be a critical issue.
[0047] In present-day communication systems, because of the inefficiencies that occur with the application of a single signal for information bearing, the implementation of complex equalization structures is imperative to achieve the most efficient use of the channel. With the implementation of the design discussed herein, the equalizer shall effectively be reduced to a simple scaling function.
[0048] The invention presented herein was described in light of a preferred embodiment. It should be understood that such preferred embodiment does not limit the application of the present invention. Persons skilled in the art will undoubtedly be able to anticipate alternatives that are deemed to fall within the scope and spirit of the present application.
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A method and apparatus of high speed multi-dimensional signaling via a modem has a processing method of utilizing prolate pulses to optimize the transmission capacity of the channel. The modem includes a process that segments the channel bandwidth and allocates the power and bit loading in relation to a measure of the noise in each spectral bin. Data are carried over a plurality of frequencies across the channel, and within each spectral bin, a plurality of orthogonal signaling dimensions.
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TECHNICAL FIELD
This invention relates to rotary dampers used to control rotary vibrations in a clutch disposed within a torque converter used with a transmission. The exemplary embodiment described in this disclosure establishes a tuned damper which is attached to the pressure plate of the clutch. The tuned damper is designed to damp out rotary vibrations at the natural frequency of the pressure plate relative to the other rotating components.
BACKGROUND OF THE INVENTION
Automatic transmission torque converters are often equipped with a clutch to rotatively link a torque converter turbine with a torque converter input shell, i.e. a clutch drive element. Engagement of a clutch pressure plate, i.e. a clutch driven element with the clutch drive element rotatively restricts the rotary displacement of the engine relative to a torque converter output element, eliminating the slip within an automatic transmission torque converter.
The clutch driven element is rotatively connected through intermediate elements to the turbine of the torque converter and to the output element of the torque converter, both of which are rotatively fixed to one another. One of the intermediate elements connecting the clutch driven element with the output element is a set of springs which compress to allow the clutch driven element to be rotatively displaced relative to the turbine and the torque converter output element. Spring compression occurs upon engagement of the clutch driven element with the clutch drive element when they are rotating at different speeds or when the clutch is engaged and subjected to transient torsional impulses, such as impulses produced by the engine firing frequency. When displacement between the elements occurs because of either clutch engagement or the transmission of transient impulses, the driveline system, comprising the elements rotatively connected to the clutch driven element, may respond by rotatively vibrating at a natural frequency associated with the system.
Driveline systems have a number of modes of vibration, each mode with its own natural frequency. It is desirable to minimize the amplitude of the vibrations produced by these vibration modes. A common method of minimizing and reducing the magnitude of the vibrations is to apply a rotary frictional load between the clutch driven element and the torque converter output element, in parallel with the spring force. Another method is to provide a viscous load between the clutch driven element and the torque converter output element. The result with either method is to damp out the vibrations between the clutch driven element and the torque converter output element.
Those damping methods may not be adequate when the frequency of the exciting force is at a natural frequency of the system. When the initial amplitude of the exciting force is sufficient to overcome the frictional or viscous resistance, and the exciting force is at a natural frequency, then the sympathetic elements of the driveline system will oscillate at an amplitude sufficiently large to become objectionable to the vehicle operator in the form of noise and vibrations transmitted through the structure of the vehicle.
The use of tuned propeller shaft dampers, the dampers comprising a ring shaped inertia element with a layer of rubber between the ring shaped inertia element and the propeller shaft, would not be effective in quieting these vibrations in the driveline system of a rear drive vehicle. Such a damper is beneficial only to the extent that reducing propeller shaft vibration reduces overall system vibration. In systems where the sympathetic element is being excited by the engine firing frequency and is on the input side of the transmission, a propeller shaft vibration damper would only be effective in damping the vibrations of those elements in a single gear ratio.
SUMMARY OF THE INVENTION
Analysis of the driveline system shows there are three modes of vibration, each with an associated natural frequency in a free/free system model of a three degree of freedom system. The first mode of vibration is the system rigid body mode in which all of the rotary inertias of the driveline system oscillate in phase with one another, resulting in a natural frequency of 0 hertz. The second mode of vibration occurs when the transmission rotary inertia and the engine rotary inertia (or the clutch driven element rotary inertia if the clutch is not engaged) oscillate out of phase with the equivalent vehicle rotary inertia. Here, the axle spring serves as the sole system node. The third mode of vibration occurs when the engine rotary inertia (or the clutch driven element rotary inertia if the clutch is not engaged) and the equivalent vehicle rotary inertia oscillate out of phase with the transmission rotary inertia, with the torque converter clutch spring and equivalent axle spring being the system nodes.
Mathematically, the natural frequencies can be expressed as follows: letting
W 1 =the first natural frequency,
W 2 =the second natural frequency,
W 3 =the third natural frequency,
J 1 (when the clutch is not engaged)=the rotary inertia of the clutch driven element,
J 2 =the rotary inertia of the rotating transmission parts,
J 3 =the rotary inertia of the vehicle as reflected through a final drive ratio of the vehicle,
K 1 =the torsional spring rate between the transmission and the clutch driven element, and
K 2 =the torsional spring rate of the axles, then
W 1 =0 radians/second,
W 2 =(((-J 1 J 3 -J 1 J 2 )K 2 +(-J 2 J 3 -J 1 J 3 )K 1 )-((J 1 2 J 3 2 +2J 1 2 J 2
*J 3 +J 1 2 J 2 2 )K 2 2 +(2J 1 2 -2J 1 J 2 )J 3 2 +(-2J 1 J 2 2 -2J 1 2 J 2 )J 3 K 1 K 2 +
(J 2 2 +2*J 1 J 2 +J 1 2 )J 3 2 K 1 2 ) 0 .5 /(2*J 1 J 2 J 3 )) 0 .5 rad/sec., and
W 3 =(((-J 1 J 3 -J 1 J 2 )K 2 +(-J 2 J 3 -J 1 J 3 )K 1 +((J 1 2 J 3 2 +2J 1 2 J 2 *
J 3 +J 1 2 J 2 2 )K 2 2 +(2J 1 2 -2J 1 J 2 )J 3 2 +(-2J 1 J 2 2 -2J 1 2 J 2 )J 3 K 1 K 2 +
(J 2 2 +2*J 1 J 2 +J 1 2 )J 3 2 K 1 2 ) 0 .5 /(2*J 1 J 2 J 3 )) 0 .5 rad/sec.
Engine cylinder firing frequencies which excite the driveline system at any of these natural frequencies will result in large amplitudes of vibration for the system rotary inertias as well as high levels of load in the springs which are nodes for the corresponding system mode.
The specific discovery here was that an engine firing frequency equal to the third natural frequency produced the noise and vibrations of which elimination was desired. Changing the clutch driven plate springs so as to provide a torsional spring rate for a natural frequency outside of the operating range of the engine firing frequency is a potential solution in some cases. For those cases where this is not possible though, the addition to the clutch driven element of a damper tuned to the third natural frequency would provide an effective solution. When excited at the natural frequency to which the damper has been designed, the tuned damper will oscillate at that natural frequency, but out of phase with the element to which it is coupled, reducing the amplitude of vibration.
It has also been discovered that the optimal clutch position for generating oscillations of the greatest magnitude is at the point of incipient contact, i.e. incipient engagement, between the clutch driven element and the clutch drive element. Given the rotary inertias and the spring rates of the elements common in many systems, the third natural frequency is often within the operating range of the engine firing frequency of the engine, inducing the clutch driven element to generate a vibration in the driveline system that can be sensed by the operator of the vehicle as audible transmissions if the natural frequency is above approximately 20 hertz, and as vibrations transmitted through the structure of the vehicle, such as the seat of the vehicle, the throttle, and the steering wheel.
Knowing both that the clutch is positioned at the point of incipient clutch contact and that the engine firing frequency equals the third natural frequency simultaneous to the vibrations reaching their greatest magnitude, it is possible to eliminate the vibrations by providing a damper tuned to the third natural frequency. The rotary inertia of the ring shaped inertia element and the torsional spring and the torsional damping characteristics of the visco-elastic material are to be chosen so that the tuned damper will have a natural frequency equal to the third natural frequency. With a tuned damper, vibration amplitude of the rotary inertias of the driveline system, as well as the torque levels in the torque converter clutch and axle springs, will be reduced during excitation of the driveline system at the third natural frequency. Because the third natural frequency is vehicle dependent, the rotary inertia of the ring shaped inertia element and the damping and spring characteristics of the visco-elastic material element must be selected for each vehicle application.
The following benefits will be derived from this invention:
1. rotary vibrational amplitudes will be reduced, reducing both the magnitude of audible driveline system noise and vibration perceived by the vehicle operator;
2. peak clutch spring torque at third mode natural frequency will be reduced, enhancing the durability characteristics of the clutch; and
3. a single spring package providing the same rate and travel could be used for multiple vehicle applications with the inertia of the ring shaped inertia element being selected to accommodate the different natural frequencies.
It is an object of this invention to provide an improved damper within an automatic transmission torque converter, comprising a ring shaped inertia element joined to a clutch driven element through a visco-elastic material element.
It is also an object of this invention to provide an improved damper within an automatic transmission torque converter, comprising a ring shaped inertia element joined to a clutch driven element through a visco-elastic material element which together damp out a vibration at a natural frequency dependent on the clutch driven element inertia, clutch spring rate, transmission inertia, suspension spring rate, and vehicle inertia system.
It is a further object of this invention to provide an improved damper within an automatic transmission torque converter, comprising a ring shaped inertia element joined to a clutch driven element through a visco-elastic material element which together damp out a vibration at a natural frequency, that natural frequency of rotary vibration W 3 dependent on the rotary inertia J 1 of the clutch driven element, on a torsional spring rate K 1 between the transmission and the clutch driven element, primarily controlled by the spring rate of the clutch springs, on a rotary inertia J 2 of the rotating transmission components, on a rotary inertia J 3 of the vehicle as reflected through a final drive ratio of the vehicle, and on a torsional spring rate K 2 of the vehicle primarily controlled by the rate, that dependence defined by the equation
W 3 =(((-J 1 J 3 -J 1 J 2 )K 2 +(-J 2 J 3 -J 1 J 3 )K 1 +((J 1 2 J 3 2 +2J 1 2 J 2
*J 3+ J 1 2 J 2 2 )K 2 2 +(2J 1 2 -2J 1 J 2 )J 3 2 +(-2J 1 J 2 2 -2J 1 2 J 2 )J 3 K 1 K 2 +
(J 2 2 +2*J 1 J 2 +J 1 2 )J 3 2 K 1 2 ) 0 .5 /(2*J 1 J 2 J 3 )) 0 .5 rad/sec.
These and other objects and advantages will be more apparent from the following description and drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of the relevant parts of the torque converter and the engine to torque converter attachment.
FIG. 2 is a schematic representation of the driveline system as a series of rotary inertias and torsional springs.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a torque converter 10, for a transmission (not shown) in a vehicle (not shown), having an internally disposed clutch 12, and adapted to be driven by an internal combustion engine 14. The torque converter 10, is a conventional fluid drive mechanism and includes a turbine 16 and a stator 18 disposed in toroidal flow relation with an impeller (not shown), all disposed within an input shell 20. The impeller is secured for rotation with the input shell 20. The input shell 20 has a rigid rotary connection 22 to the engine 14 provided by bolts 24 passing from a torque converter side 26 of a flexplate 28 through to a flange 30 on the end of an engine crankshaft 32 and by bolts 34 passing through the same flexplate 28 from the engine side 36 and threading into threaded bosses 38 provided on the input shell 20.
Disposed between the turbine 16 and the input shell 20 in the direction of the engine 14 is the clutch 12. The clutch 12 includes a clutch pressure plate 40, i.e. a clutch driven element 40, with a friction pad 42, i.e. a clutch engagement surface 42, adapted to frictionally engage a complementary clutch engagement surface 44 of the input shell 20, i.e. the clutch drive element 20. The clutch driven element 40 has both an apply side 46 and a release side 48. The friction pad 42 is on the release side 48 of the clutch driven element 40 which faces the clutch engagement surface 44 of the input shell 20. The apply side 46 of the clutch driven element 40 faces the turbine 16.
The clutch driven element 40 is rotatively supported on a turbine hub 50. The clutch driven element 40 has an engagement portion 52 with a plurality of openings 54 to accommodate clutch springs 56. The openings 54 are of approximately the same shape and size as the springs 54 in their free state. The engagement portion 52 is concentric with and rotatively locked to the clutch driven element 40. A clutch hub 58 links the clutch driven element 40 to the turbine hub 50. The clutch hub 58 is splined to the turbine hub 50, allowing relative axial movement, but no rotary movement between the hubs 50 and 58. The turbine hub 50 in turn is splined to an output element 60 which drives a gear system (not shown) within the transmission. An axis of rotation 61 of the output element 60 is the axis of rotation 61 for all elements of the torque converter 10, including the clutch drive element 20 and the clutch driven element 40.
The clutch driven element 40 and clutch hub 58 interface so as to prevent axial movement of the clutch driven element 40 relative to the clutch hub 58. The clutch hub 58 has openings 62 for clutch springs 56 corresponding to the openings 54 in the engagement portion 52 of the clutch driven element 40. The clutch springs 56 are interposed between the clutch hub 58 and the engagement portion 52 to minimize the harshness of the torsional vibrations transmitted from the clutch driven element 40 to the clutch hub 58. The clutch springs 56 are disposed in the openings 54 and 62 so as to be axially compressed whenever there is rotary displacement of the clutch driven element 40 relative to the clutch hub 58.
The clutch driven element 40 has a lip 64 at its outer periphery which projects away from the clutch engagement surface 44. The lip 64 is concentric with the axis of rotation 61 of the clutch driven element 40.
A ring shaped inertia element 66 is centered relative to the clutch driven element 40. The ring shaped inertia element 66 is linked to an inside diameter 68 of the lip 64 by a visco-elastic material element 70. The visco-elastic material element 70 holds the ring shaped inertia element 66 concentric with the lip 64 of the clutch driven element 40. The visco-elastic material element 70 possesses both torsional spring and torsional damping characteristics. The ring shaped inertia element 66 is linked to the clutch driven element 40 in parallel with the clutch driven element's 40 link to the output shaft 60 through the clutch spring 56, the clutch hub 58, and the turbine hub.
The advantages of this invention become more apparent when observing the system in operation.
The clutch 12 typically remains disengaged during vehicle acceleration because the torque multiplying effect of the torque converter 10 is desired to aid in vehicle acceleration. Clutch 12 engagement usually occurs after the acceleration rate decreases. Engagement is initiated per a schedule (not shown) which is a function of throttle position and vehicle speed. When a combination of vehicle speed and throttle position corresponding to an engagement point in the schedule is reached, the clutch 12 is applied by supplying transmission fluid under pressure to the apply side 46 of the clutch driven element 40. This forces the clutch driven element 40 and the clutch hub 58 to translate axially toward the clutch drive element 20 until the friction pad 42 on the clutch driven element 40 comes into contact with the complementary clutch engagement surface 44 on the clutch drive element 20. There will, for most clutch engagements, be a speed differential between the two elements 20 and 40. The speed differential results in torque being developed upon engagement of the clutch drive element 20 with the clutch driven element 40. The magnitude of torque is dependent on both the relative speed of the engaging elements 20 and 40 and the rotary inertias of elements rotatively linked to the engaging elements 20 and 40. The torque is transmitted through the clutch driven element 40 into the clutch springs 56 and through the clutch springs 56 to the clutch hub 58, to the turbine hub 50 and into the torque converter output element 60. The clutch springs 56 between the clutch driven element 40 and the clutch hub 58 are compressed when transmitting torque. The deflection of the clutch springs 56 minimizes the harshness of the torque transmitted between the clutch driven disc 40 and the clutch hub 58, such as that produced by the engagement of the clutch drive element 20 and the clutch driven element 40, or the impact of the cylinder firings of the engine 14 on the output element 60. The deflections of the clutch springs 56 will produce undesired vibrations and oscillations at natural frequencies which are dependent on the spring rate of the clutch springs 56 as well as the rotary inertias and the spring rates of the other elements rotationally linked to the driven element 40. The elements rotatively linked to the driven element 40, including the output element 60, the transmission, and a vehicle suspension, comprise the driveline system. The natural frequencies will also vary with engagement and disengagement of the clutch 12 because that effectively changes the rotary inertia on the driven clutch element 40 side of the clutch springs 56.
This invention is designed to deal with a very specific mode of vibration, that mode occurring when there is incipient engagement between the clutch driven element 40 and the clutch drive element 20. The contact between the two elements 20 and 40 must be such that the effective rotary inertia of the clutch driven element 40 is not significantly altered by the rotary inertia of the clutch drive element 20 and of the engine 14, yet the engine firing frequency is transmitted to the clutch driven element 40. In many cases, the driveline system has a natural frequency near that of the engine firing frequency such that the clutch driven element is excited relative to the torque converter output element.
FIG. 2 shows a schematic diagram of the torsional elements of the driveline system from the rotary inertia J 1 of the clutch driven element 40 through the equivalent vehicle rotary inertia J 3 .
The natural frequency of rotary vibration W 3 is dependent on the rotary inertia J 1 of the clutch driven element 40, on a torsional spring rate K 1 between the transmission and the clutch driven element, primarily controlled by the spring rate of the clutch springs 56, on a rotary inertia J 2 of the rotating transmission components (not shown), on a rotary inertia J 3 of the vehicle (not shown) as reflected through a final drive ratio of the vehicle, and on a torsional spring rate K 2 of the vehicle primarily controlled by the spring rate of the axles (not shown). The natural frequency W 3 is defined by the equation
W 3 =(((-J 1 J 3 -J 1 J 2 )K 2 +(-J 2 J 3 -J 1 J 3 )K 1 +((J 1 2 J 3 2 +2J 1 2 J 2
*J 3+ J 1 2 J 2 2 )K 2 2 +(2J 1 2 -2J 1 J 2 )J 3 2 +(-2J 1 J 2 2 -2J 1 2 J 2 )J 3 K 1 K 2 +
(J 2 2 +2*J 1 J 2 +J 1 2 )J 3 2 K 1 2 ) 0 .5 /(2*J 1 J 2 J 3 )) 0 .5 rad/sec.
When the engine firing frequency equals W 3 and there is incipient contact between the clutch driven element 40 and the clutch drive element 20, the clutch driven element 40 oscillates with such magnitude that that it can produce noise and vibrations both detectable by and objectionable to the operator of the vehicle. When this occurs, the ring shaped inertia element 66 is designed to oscillate at the natural frequency W 3 , but out of phase with the system vibrations of natural frequency W 3 such that the amplitude of the oscillations is reduced to a minimum.
Obviously, many modifications and variations of the present invention are possible in view of the above teaching. It is therefore to be understood, that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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A rotary damper is mounted to a clutch pressure plate within a torque converter clutch of an automatic transmission. The rotary damper is tuned to minimize the magnitude of a natural frequency of rotary vibration in a driveline system induced by the engine firing frequency.
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FIELD OF THE INVENTION
[0001] The field of the invention is a ball release device and more particularly a device that is mounted near the hole bottom with the stored ball or balls protected until release after circulation.
BACKGROUND OF THE INVENTION
[0002] Most prior ball release devices store the ball in the fluid stream and use circulation to transport it to the seat. Several problems can occur with this design. The ball may not release because the carrier gets clogged with debris from the mud. The carrier can become worn resulting in premature release of the ball. The ball is released during high circulation. It can slam against a seat and create high pressure spikes that can damage other equipment. The high circulation rates around the ball can erode parts of it causing it to not hold pressure even if it lands on the ball seat. Some examples of prior designs that have the ball in the circulating path are U.S. Pat. Nos. 6,390,200; 6,220,360; and 5,960,881. U.S. Pat. No. 4,171,019 shows a cement float shoe with a ball in a side pocket such that it can be displaced against a ball seat if the flow direction reverses. Balls have been used to fix a range of motion of a sleeve valve member, as shown in U.S. Pat. No. 4,406,335.
[0003] What the prior devices lacked is addressed by the present invention. The ball is retained near its intended seat near the bottom of the hole. It is retained out of the flowing stream. The ball discharge procedure is such that ball release occurs after circulation is stopped and not during circulation. Once the ball is released it is prevented from reentering its original storage location. These and other benefits of the present invention will be more apparent to those skilled in the art from a review of the description of the preferred embodiment and the claims, which appear below.
SUMMARY OF THE INVENTION
[0004] A ball release mechanism is mounted near the intended seat. The ball or balls are kept out of the circulating stream. High circulation rates followed by curtailment of circulation places an outlet port in position to allow the ball or balls to be pushed out by a spring. The spring or one of the balls prevents the return of an ejected ball back into the protected pocket. The ball is delivered to the seat without circulation.
DETAILED DESCRIPTION OF THE DRAWINGS
[0005] [0005]FIG. 1 is a part section view of the tool during the run in;
[0006] [0006]FIG. 2 is the view of FIG. 1 in the circulation position;
[0007] [0007]FIG. 3 is the view of FIG. 2 with the ball released after circulation has ceased.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0008] Referring to FIG. 1, a housing 10 is connected at thread 12 to a string and downhole equipment (not shown). Housing 10 comprises a primary ball seat 14 preferably mounted on ball carrier 16 or in another housing in fluid communication with housing 10 . As illustrated, ball seat 14 provides resistance to circulation to move the ball carrier 16 . However, that resistance can be from another constriction on ball carrier 16 with the ball seat in another housing in fluid communication with housing 10 . In the preferred embodiment, the balls 22 and 24 drop less than a meter to get to ball seat 14 . A shear pin 18 initially holds the ball carrier 16 to the housing 10 . In the run in position, an outlet port 20 is so positioned that balls 22 and 24 cannot escape. Balls 22 and 24 are biased toward tapered surface 26 on ball carrier 16 by spring 28 . Housing 10 further comprises a sleeve 30 biased by spring 32 toward ball carrier 16 . A seal 34 seals between ball carrier 16 and housing 10 . For run in, sleeve 30 holds in detent pin 36 against the bias of spring 38 .
[0009] The operation of the tool will now be reviewed. Circulation is started through housing 10 . As a result a net force is applied to ball carrier 16 shifting it down against sleeve 30 and compressing spring 32 . While the restriction from ball seat 14 that causes ball carrier 16 to be displaced by circulation is shown at the lower end of the ball carrier 16 , the actual restriction that causes the ball carrier 16 to shift can be located elsewhere on ball carrier 16 , while the ball seat 14 can be in any other location below balls 22 and 24 . The shear pin 18 is broken by movement of ball carrier 16 . Balls 22 and 24 are held retained by tapered surface 26 . Circulation is then stopped. Spring 32 displaces sleeve 30 to position outlet port 20 in alignment to let balls 22 and 24 escape with a push from spring 28 . Ball 22 lands on primary ball seat 14 , which is less than a meter away, while ball 24 is optional. Ball 24 keeps ball 22 near seat 14 because the upper end 40 of ball carrier 16 as well as spring 28 in its extended position help to maintain ball 24 in the position shown in FIG. 3. Spring 38 has pushed out detent pin 36 to prevent needless cycling of ball carrier 16 at a later time when circulation is resumed for other purposes.
[0010] A secondary ball seat 42 is provided to accept a ball dropped from the surface in a known manner, in the event ball 22 fails to seal or hold enough pressure against primary ball seat 14 .
[0011] Those skilled in the art will appreciate that the present invention has many unique features. The ball or balls are stored out of the flowing path of mud and are less likely to be eroded or deformed by circulation. The balls are not released during circulation. Pressure spikes are eliminated as the balls are released from a location very close to the seat after circulation has stopped. There is no need to wait a long time for the ball to seat from the time of release, because the release point is so close to the ultimate seat location. This tool can be run below tools that would not be able to pass a ball. The tool is of particular advantage on a horizontal run. In the past, a ball dropped from the surface could land in many places short of the desired seat. This is particularly the case when running long lengths of screen to be expanded in a horizontal run. In the present invention, seating occurs almost immediately after release due to the close proximity between the release point and the seat. In the unlikely event of a failure of the tool, a secondary seat is provided to allow a backup ball to be dropped in the known manner. Alternatively, a plurality of balls of different sizes can be stored in the tool. Bigger balls can reuse Ball seat 14 after an initial ball expands the seat a given amount in a known manner. Alternatively, smaller balls can be subsequently released that will pass through seat 14 after the first ball is blown through it and land on another seat further down. While the preferred embodiment has been shown with two balls, one ball or more balls can be used. They can be released all at once or one at a time such as by using a ratchet device actuated by cycling the circulation on and off. To do this the detent pin 36 could be eliminated. No rotation is required to operate the tool making it useful in deviated wells.
[0012] 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.
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A ball release mechanism is mounted near the intended seat. The ball or balls are kept out of the circulating stream. High circulation rates followed by curtailment of circulation places an outlet port in position to allow the ball or balls to be pushed out by a spring. The spring or one of the balls prevents the return of an ejected ball back into the protected pocket. The ball is delivered to the seat without circulation.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This patent application is a continuation-in-part of my co-pending application No 10072416, filed on Feb. 7, 2002.
BACKGROUND—FIELD OF THE INVENTION
[0002] This invention relates to slow release formulations of anti-estrogens and hormonal compositions for hormonal implants to the breast as an efficient but low cost treatment of the breast cancer with minimal systemic toxicity.
BACKGROUND—DESCRIPTION OF PRIOR ART
[0003] Heretofore, hormone treatment of breast cancer is given by per oral, subcutaneous, intramuscular or intravenous injections. Because of the systemic distribution of such administrated hormones, only a very small amount of hormone will reach the target cancer cells in the breast. A great percentage of the systemically administered hormone is rapidly metabolized and eliminated from the body and hence it is wasted. Therefore patients have to take larger quantities of these hormones daily. It increases the undesirable side effects of hormone treatment making it unsafe for some patients. Daily systemic administration of the hormones also adds to the cost of these medications and hence unaffordable to some patients. Because of the very low concentration of the systemically administrated hormone reaching the cancer cells, it may not even be adequately effective in some patients.
[0004] Estrogen and or both estrogen and progesterone receptor positive tumor cells of the breast are sensitive to estrogen deprivation. Interference with estrogen signaling pathways will generate proliferative arrest of both the normal and tumor cells. Treatment with anti-estrogen tamoxifen, or raloxifene reduces the development of breast cancers (1, 2, 3, 4,5; Winer P. W. et.al, Malignant Tumors of the Breast, In Cancer, Principles and Practice of Oncology, 6 th edition, Vol. 1; DeVita, Jr. et al (Ed), 2001 page 1656-; (Ref. #110, 111, 112, 118,119)). Tamoxifen is also known to be a very effective drug against advanced breast cancer. The benefits of adjuvant treatment of both pre and postmenopausal estrogen receptor positive breast cancer patients with tamoxifen are proven to be substantial. Adjuvant tamoxifen treatment of patients with estrogen receptor positive tumors can reduce the annual odds of recurrence to 50-60 percent and annual odds of death to 23 to 36 per cent (6, 1; Winer P. W. et.al, Malignant Tumors of the Breast, In Cancer, Principles and Practice of Oncology, 6 th edition, Vol. 1; DeVita, Jr. et al (Ed), 2001 page 1690, Table 37.2-20 and Ref. #110). Similar to tamoxifen, toremifene is also an anti-estrogen used for breast cancer treatment. Like tamoxifen, toremifene also has very high tissue binding affinity (7, Erlichman C, and Loprinzi C L, Hormonal Therapies, In Cancer, Principles and Practice of Oncology, 6 th edition, Vol. 1; DeVita, Jr. et al (Ed), 2001 page 479-80, Ref#61). Raloxifene is another effective anti-estrogen used to treat the breast cancer (8, Erlichman C, and Loprinzi C L, Hormonal Therapies, In Cancer, Principles and Practice of Oncology, 6 th edition, Vol. 1; DeVita, Jr. et al (Ed), 2001 page 480). Like tamoxifen, raloxifene also prevents the breast cancer development (4,5; Winer P. W. et.al, Malignant Tumors of the Breast, In Cancer, Principles and Practice of Oncology, 6 th edition, Vol. 1; DeVita, Jr. et al (Ed), 2001 page 1656-; (Ref. #118,119)).
[0005] The group of patients treated concurrently with the anti-estrogen tamoxifen and external radiation had much lesser rate of breast cancer recurrence as compared with patients treated with radiation alone in the NSABP B-14 study. The rate of recurrent ipsilateral breast cancer after concurrent treatment with tamoxifen and radiation was lowered by 61 percent as compared to radiation alone (9; Winer P. W. et.al, Malignant Tumors of the Breast, In Cancer, Principles and Practice of Oncology, 6 th edition, Vol. 1; DeVita, Jr. et al (Ed), 2001 page 1691, Ref, #113). Concomitant anti-estrogen and lower dose conventional external beam radiation treatment is much lesser toxic and it is well tolerated. Anti-estrogen implants to the breast before and after the radiation therapy would nearly sterilize all of the focus of tumor. High efficiency anti-estrogen implant treatment with its high concentration in the breast would further improve the tumor control than those reported by Fisher et al in the NSABP B-14 study (9; Winer P. W. et.al, Malignant Tumors of the Breast, InCancer, Principles and Practice of Oncology, 6 th edition, Vol. 1; DeVita, Jr. et al (Ed), 2001 page 1691, Ref, #113).
[0006] The present standard dose of tamoxifen for the treatment of breast cancer or its prevention is 20 mg daily by mouth for several years. It is associated with potential risks of serious toxicities and adverse effects in terms of quality of life. It increase in the development of endometrial cancer and thromboembolism, especially among the older women (10,11; Winer P. W. et.al, Malignant Tumors of the Breast, In Cancer, Principles and Practice of Oncology, 6 th edition, Vol. 1; DeVita, Jr. et al (Ed), 2001 page 1657-; (Ref. #113, 114)). Like tamoxifen, treatment with raloxifene also increases the risk of thromboembolism. The risk associated with its use in developing endometrial cancer seems to have not increased by raloxifene treatment (4,5; Winer P. W. et.al, Malignant Tumors of the Breast, In Cancer, Principles and Practice of Oncology, 6 th edition, Vol. 1; DeVita, Jr. et al (Ed), 2001 page 1656-; (Ref. #118,119)). Among the other side effects of treatment with tamoxifen and raloxifene includes hot flashes, vaginal discharge sexual dysfunction depression and weight gain. The other commonly used hormonal therapies for breast cancer includes progestins, androgens, aminoglutethimide, LHRH analogues, glucocorticoids and oophorectomy (12, Haller D G, Fox K R, Schuchter L M, Metastatic Breast Cancer; In Breast Cancer Treatment A Comprehensive Guide to Management; Fowble B, Goodman R L, Glick J H and Rosato E F (Ed), Mosby Year Book, 1991, page 413).
[0007] The 20 mg once daily or 10 mg twice daily per oral dose of tamoxifen for three months delivers an average steady state plasma concentration of 122 ng per ml tamoxifen and 353 ng per ml of its metabolite N-desmethyl tamoxifen (13, Nolvadex, tamoxifen citrate, Zeneca Pharmaceuticals, Physicians Desk Reference, PDR 51, p 2957, 1997) The tissue bound tamoxifen distribution is much higher than that of its plasma concentration; a 10 to 60 fold higher concentration of tissue bound tamoxifen and its metabolites than its plasma concentration is observed (14, Erlichman C, and Loprinzi C L, Hormonal Therapies, In Cancer, Principles and Practice of Oncology, 6 th edition, Vol. 1; DeVita, Jr. et al (Ed), 2001 page 479, Ref#52). The bioavailability of orally administered tamoxifen is assumed to be about 30 percent (15, Erlichman C L, and Loprinzi C L, Hormonal Therapies, In Cancer, Principles and Practice of Oncology, 6 th edition, Vol. 1; DeVita, Jr. et al (Ed), 2001 page 479). Because of these very high tissue bindings of tamoxifen, by implanting relatively lower dose of tamoxifen directly to the breast, a very high steady state tamoxifen concentration is achieved from diffusion and biodegradation of the implants. Therefore the implant dose of tamoxifen need not to be as high as like its daily oral dose. Because of this 10 to 60 fold higher tissue binding of tamoxifen than its average plasma concentration and the only about 30 per cent bioavailability of the orally administered tamoxifen the tamoxifen implant dose needs only to be a smaller fraction of the oral dose. In this instance, the maintenance of a relatively high plasma concentration of tamoxifen is unnecessary. It reduces the toxicity associated with tamoxifen treatment. Furthermore, it reduces the cost for the anti-estrogen treatment of breast cancer. Because of these direct anti-estrogen implants to the breast can deliver a constant rate of anti-estrogens directly to the breast for months or years by diffusion and biodegradation, it is not dependent upon patient's compliance for its daily oral intake. The implant dose of anti-estrogen like tamoxifen is adjusted to give the same level of tissue bound anti-estrogen when it is administrated at higher dose by mouth daily. The tamoxifen implant dose for a patient is determined by comparative tamoxifen assays of needle biopsy specimens from the breast. After the oral administration of tamoxifen 10-mg by mouth twice daily for four weeks, the initial tissue bound tamoxifen is determined from needle biopsy specimens of the breast. Four weeks after interruption of the tamoxifen treatment the tamoxifen implant to the breast is made. A second comparative tissue bound tamoxifen is determined from breast needle biopsy specimens as before. If the implant dose needs to be adjusted an additional tamoxifen implants is made. Alternatively, a generally acceptable low implant dose that gives equivalent tissue bound tamoxifen as by its higher dose daily oral administration could be taken as a satisfactory implant dose. It can eliminate the routine breast needle biopsies to determine the tissue bound tamoxifen concentration.
[0008] In U.S. Pat. No. 4,321,208 (16; Sahadevan V: Preparation of directly iodinated steroid hormones and related compounds, U.S. Pat. No. 4,321,208; 1982) this inventor has described the methods for preparation of iodinated steroid hormones including the estradiol as early as in 1976. The I-125 labeled estradiol was shown to bind to estrogen antiserum and to the estrogen receptor sites. Because of the heaviness and the electronegative characteristic of iodine in the estradiol molecule, it would render cytotoxic actions to the breast cancer. Implantation iodoestradiol adsorbed sponges to rat breast tumor showed excellent tumor regression (unpublished data).
[0009] A controlled slow release implant of a depot preparation of anti-estrogen directly to the breast could achieve high concentrations of anti-estrogens to the breast and its very low concentration in the rest of the body. The ant-estrogen systemic toxicity is reduced and or eliminated by the very low levels of systemic ant-estrogen. The high levels of anti-estrogen from the implants to the breast would saturate the estrogen receptors of the breast. It would enhance the effectiveness of the anti-estrogen treatment of breast cancer.
[0010] Because of the systemic distribution of the orally administered or injected estrogens and anti-androgen compounds, only a portion of these compounds will reach the intended target site, the estrogen receptor rich breast. In addition, the methods of oral and or injectable forms of anti-estrogen administration need more disciplined compliance by the patients to take these medications daily. Furthermore, a greater percentage of such systemically distributed compounds are metabolized. Therefore, much larger doses of these compounds are needed to insure the delivery of the required dose at the target site, the breast. The commonly available pharmaceutical preparation of Depo-Provera containing medroxyprogesterone is used for contraceptive treatment. A subcutaneous implant of an oily preparation of 150 mg of medroxyprogesterone will provide 1 to 7 ng of medroxyprogesterone per ml plasma for three months (17; Pharmacia and Upjohn Company, Depo-Provera, Physicians Desk Reference, PDR, 51,1997,p2079). Implantation of steroid pellets under the skin is a well-known method of treatment with hormones.
[0011] Injections of pellets of hormones for hormone replacement treatment after oophorectomy result in large variations in serum hormone levels with high levels immediately after such injections. Hence the generally known methods of preparation of injectable slow-release depot formulations of hormones encapsulated in biodegradable polymers is made to deliver a constant dose of hormone. Similar preparations of microcapsules were described in U.S. Pat. No. 4,389,330 (18; Tice T R, and Lewis D H: Microencapsulation process, U.S. Pat. No. 4,389,330; 1983). Similar preparations are referenced and described in U.S. Pat. No. 5,340,586 (19; Pike M and Spicer D V: Methods and formulations for use in treating oophorectomized women, U.S. Pat. No. 5,340,586; 1994). Injectable encapsulated hormone preparations are made to facilitate a steady state of hormone release for periods ranging from a few days to several years and are used as subcutaneous injections for the hormone replacement treatment after oophorectomy U.S. Pat. No. 5,340,586 (19; Pike M and Spicer D V: Methods and formulations for use in treating oophorectomized women, U.S. Pat. No. 5,340,586;1994).
[0012] Several methods of preparation of pellets of compounds of steroids and other compositions are known in the art, which dates back as early as 1936 and onwards. Several of these methods are cited in the U.S. Pat. No. 4,244,949 (20; Gupta G N: Manufacture of long term contraceptive implant, U.S. Pat. No. 4,244,949; 1981) of 22 years ago, the entire disclosure of which is hereby incorporated by reference. In a preferred art for such implants preparation, the steroid is mixed with a lipoid carrier consisting of cholesterol and its organic carboxylic esters and loading and compacting this mixture into a Teflon tubing and heating the tubing at a temperature above the melting point of the steroid and lipoid under an inert gas like nitrogen, cooling the tubing and removing the pellets of fused steroid-lipoid composition. Cholesterol serves as the lipoid carrier. This formulation facilitates the constant slow release of desired dose of steroid hormone from the implanted bioabsorbable fused steroid-lipoid composition. Examples of such constant release implants of steroid hormones to provide 50 to 80 μg steroid per day in rhesus monkey is given in U.S. Pat. No. 4,244,949 (20; Gupta G N: Manufacture of long term contraceptive implant, U.S. Pat. No. 4,244,949; 1981) and which is sufficient to achieve the contraceptive effects of such formulation for one year and more in rhesus monkeys.
[0013] The U.S. Pat. No. 4,244,949 (20; Gupta G N: Manufacture of long term contraceptive implant, U.S. Pat. No. 4,244,949; 1981) uses the bioabsorbable fusion products of anti-ovulation steroid hormone and a lipoid carrier selected from the group of cholesterol for making the slow-release long acting contraceptives. Preparations of fusion products of steroid and lipoid were well known in the prior art, 23 years ago when this patent application was made. As claimed in this patent, the fused implant was made for fertility control and not as either by subcutaneous or intramuscular injections or by direct implant to the prostate for the hormonal treatment of prostate cancer.
[0014] The methods of preparations of encapsulated hormone implants described in U.S. Pat. No. 5,430,585 (21; Pike M and Spicer D V: Methods and formulations for use in treating benign gynecological disorders; U.S. Pat. Nos. 5,340,585; 1994) and 5,430,586 (19; Pike M and Spicer D V: Methods and formulations for use in treating oophorectomized women, U.S. Pat. No. 5,340,586; 1994) were also known in the prior art. Those prior art methods are discussed and referenced in these patents. U.S. Pat. No. 5,430,585 (21; Pike M and Spicer D V: Methods and formulations for use in treating benign gynecological disorders; U.S. Pat. No. 5,340,585; 1994) teaches methods and formulations of treatment of benign gynecological disorders and the U.S Pat. No. 5,340,586 (19; Pike M and Spicer D V: Methods and formulations for use in treating oophorectomized women, U.S. Pat. No. 5,340,586; 1994) teaches the methods and formulations for treatment of oophorectomized women. They do not teach the treatment of breast cancer either by subcutaneous or intramuscular injections or by direct breast implants of those encapsulated and or microspheres preparations of hormones. Furthermore, the hormonal compositions of the implant preparations of U.S. Pat. No. 5,430,585 (21; Pike M and Spicer D V: Methods and formulations for use in treating benign gynecological disorders; U.S. Pat. Nos. 5,340,585; 1994) and 5,430856 (19; Pike M and Spicer D V: Methods and formulations for use in treating oophorectomized women, U.S. Pat. No. 5,340,586; 1994) containing androgen are not suitable for the treatment of breast cancer. The steroid hormonal compositions of androgen and estrogen encapsulated in Silastic silicone tube implants were used for male contraception in U.S. Pat. No. 4,210,644 (22; Ewing L L, Desjardins C: Male contraception; U.S. Pat. No. 4,210,644; 1980). This composition is also not suitable for the treatment of prostate cancer. In the present invention described in this application, similar encapsulation methods are used to make implantable suitable hormonal compositions for the treatment of breast cancer.
[0015] Like in U.S. Pat. No. 4,210,644 (22; Ewing L L, Desjardins C: Male contraception; U.S. Pat. No. 4,210,644; 1980), the long acting synthetic progestin, the levonorgestrel encapsulated in Silastic silicone rubber tubing is used to prepare the Norplant System of Wyeth-Ayerst Laboratory's long-acting contraceptive (23;Norplant System, Wyeth Ayerst Laboratories, Physicians Desk Reference, PDR, 51, 1997, p2868). Implantation of this long acting encapsulated contraceptive levonorgestrel protects from fertility up to 5 years. These implants are usually implanted subcutaneousely to the upper arm. After 5 years, the inert and empty Silastic capsule is removed from the implant site. This formulation is also not for the treatment of breast cancer.
OBJECTS AND ADVANTAGES
[0016] It is therefore, an object of this invention to provide a less or no toxic improved method of hormonal treatment of breast cancer and said hormonal treatment comprising of implanting anti-estrogens in one or more slow release formulations and permitting said drugs to be continuously released at near constant rate directly to the breast for longer periods and maintaining said formulation's serum level low as to minimize or to eliminate systemic toxicity.
[0017] It is another object of the invention to provide slow-release biodegradable seeds or microcapsules or Silastic capsules containing anti-estrogenic compositions for breast implant for the hormonal treatment of breast cancer.
[0018] Another object of the invention is to provide slow-release anti-estrogen implant products for treating breast cancer with less toxicity and cost as an alternative to daily oral administration of high dose anti-estrogens and said implants consisting of implanting biodegradable seeds or microcapsules or Silastic capsules containing said anti-estrogen formulations to deliver high concentrations of said hormonal formulations to the breast for longer periods.
[0019] Still another object of this invention is to provide high concentrations of anti-estrogen formulations in the breast by said formulation's direct implant in the breast to obviates the necessity of daily systemic administration of said compositions in higher doses for the treatment of breast cancer.
[0020] It is a further object of this invention to maintain high concentrations of anti-estrogen formulations in the breast by implanting slow-release biodegradable seeds or microcapsules or Silastic capsules containing anti-estrogen compositions for breast implant to maintain such composition's systemic concentration low by dilution of said released formulations through circulation and thereby eliminate or minimize the systemic toxicity associated with such formulations.
[0021] It is a further object of this invention to make implants of iodo-estradiol as slow-release biodegradable seeds or microcapsules or Silastic capsules containing said compositions for breast implants to deliver high concentrations of said formulations to the breast.
[0022] It is still another object of this invention to make implants of natural corticosteroids and their synthetic derivatives alone or in combination with anti-estrogens as slow-release biodegradable seeds or microcapsules or Silastic capsules containing said compositions for breast implants to deliver high concentrations of said formulations to the breast for the treatment of hormone refractory breast cancer with lesser toxicity than by said formulation's higher dose systemic administration by oral, subcutaneous or intramuscular routes.
[0023] Still it is another object of this invention to make steroid hormonal implants alone or in combination with anti-estrogen compositions containing in slow-release biodegradable seeds or microcapsules or in Silastic capsules for breast implants to deliver high concentrations of said formulations to the breast and to suppress the hypothalamic-pituitary LHRH, LH and FSH secretion by their lower systemic concentrations for the treatment of hormone dependent and hormone refractory breast cancer with lesser toxicity than by said formulation's higher dose systemic administration by oral, subcutaneous or intramuscular routes.
[0024] It is still a further object of this invention to make implants of natural progesterone and its synthetic derivatives alone or in combination with anti-estrogen as slow-release biodegradable seeds or microcapsules or Silastic capsules containing said compositions for breast implants to deliver high concentrations of said formulations to the breast with lesser toxicity than by said formulation's higher dose systemic administration by oral, subcutaneous or intramuscular routes.
[0025] It is a further object of this invention to make prostate implants of anti-estrogen compounds as fused with a lipoid carrier, or as injectable microcapsules or encapsulated in Silastic capsules to achieve slow release of said compounds by diffusion and biodegradation of the carrier or by diffusion alone and the slowly released anti-estrogen to bind and to saturate the estrogen receptor sites in the breast competitively with estrogens to block the growth and proliferation of the breast cancer with lesser systemic toxicity than by said compound's daily high dose systemic administration.
[0026] It is still another object of this invention to make implants of anti-estrogen compositions as slow-release biodegradable seeds or microcapsules or Silastic capsules containing said compositions for implants to gross metastatic breast cancer to deliver high concentrations of said formulations to said metastasis as an efficient method of treatment of hormone dependent metastasis of the breast cancer with lesser toxicity than by said formulation's higher dose systemic administration by oral, subcutaneous or intramuscular routes.
[0027] It is a further object of this invention to reduce the cost of present hormonal treatment of breast cancer substantially by direct breast implants of long acting anti-estrogen compounds and to increase the efficiency of such treatments but with lesser toxicity than by said compounds daily systemic administration.
[0028] A further object of this invention is to minimize or to eliminate side effects such as thromboembolic events associated with treatments of breast cancer with anti-estrogens by minimizing its systemic concentration and maximizing its breast contents by implanting said implants directly to the breast and allowing slow release of such compositions from the implants to the prostate by diffusion and biodegradation.
[0029] A further object of this invention is to minimize or to eliminate the side effects of anti-estrogen treatments of breast cancer such as hot flashes, weight gain, vaginal bleeding and discharge, endometrial cancer by maintaining its low systemic dose while maintaining its high breast contents by release of the contents of said implants directly to the breast by diffusion and biodegradation.
[0030] It is another object of this invention to make implants of cytotoxic drugs alone or in combination with anti-estrogen compositions as slow-release longer lasting biodegradable seeds or microcapsules or Silastic capsules containing said compositions for breast implants to deliver high concentrations of said formulations to the breast for an extended period as part of concomitant radiation and hormonal treatment with lesser toxicity than by said formulation's higher dose systemic administration by oral, subcutaneous or intramuscular routes.
[0031] It is still another object of this invention to make implants of anti-estrogen compositions as slow-release longer lasting biodegradable seeds or microcapsules or Silastic capsules containing said compositions for breast implants and maintaining of said drug compositions for extended periods by diffusion and biodegradation from said breast implants at an amount effective to suppress focal tumor development as prophylaxis with minimum or no systemic toxicity.
[0032] Still further objects and advantages will become apparent from a consideration of the ensuing descriptions.
SUMMARY
[0033] Estrogen and or both estrogen and progesterone receptor positive tumor cells of the breast are sensitive to estrogen deprivation. Anti-estrogen compounds like tamoxifen or raloxifene competitively binds to estrogen receptor protein with estrogen. Interference with estrogen signaling pathways by anti-estrogens will generate proliferative arrest of both the normal and tumor cells. Treatment with anti-estrogen tamoxifen or raloxifene reduces the development of breast cancers. Adjuvant treatment of patients with estrogen receptor positive tumors with tamoxifen reduces the annual odds of recurrent breast cancer to 50-60 percent and annual odds of death from breast cancer to 23 to 36 per cent. Tamoxifen is also a very effective anti-estrogen drug against advanced breast cancer.
[0034] The present standard dose of anti-estrogen like the tamoxifen for the treatment of breast cancer or its prevention is 20 mg daily by mouth. Duration of such anti-estrogen treatment is for several years. It is associated with potential risks of serious toxicities and adverse effects in terms of quality of life. It increase in the development of endometrial cancer and thromboembolism, especially among the older women
[0035] Because of the systemic distribution of the orally administered or injected anti-estrogen compounds, only a portion of these compounds will reach the intended target site, the breast. A greater percentage of such systemically distributed compounds are metabolized. Therefore, much larger doses of these compounds are taken daily or very frequently to insure the delivery of the required dose to the breast, which increases its systemic toxicity and the cost. This invention is aimed to improve the effectiveness of anti-estrogen treatment of breast cancer and to reduce such treatment associated toxicity and cost by anti-estrogen implants to breast.
[0036] Breast implants of androgen suppressive drugs formulated as fused with a lipoid carrier or encapsulated in microcapsules or in Silastic capsules render a constant slow-release of their contents to the breast for extended periods by biodegradation and diffusion. They facilitate higher breast and lower systemic concentrations of anti-estrogen compositions. Because of their high concentrations in the breast, tumor control is much more improved. Because of the anti-estrogen's lower systemic concentrations, their toxicity is minimized or eliminated.
[0037] Interference with estrogen signaling pathways by anti-estrogens will generate proliferative arrest of tumor cells and would enhance the effectiveness radiation therapy after the removal of localized breast cancer. Like the improved effective tumor control by concomitant radiation and hormonal treatment of prostate cancer, after surgical removal of localized breast cancer, the concomitant anti-estrogen and conventional radiation therapy will improve the recurrence of breast cancer. It would also facilitate a lower dose radiation to the breast after lumpectomy. Lower dose conventional radiation combined with anti-estrogen treatment is a much less toxic treatment than the higher dose radiation alone.
DETAILED DESCRIPTION OF THE INVENTION
[0038] Pursuant to the present invention, the method of breast cancer treatment with anti-estrogen is improved by direct breast implants of such composition's depot formulations. The therapeutic effectiveness of such depot formulation is significantly improved by maintaining such formulation's higher concentration in the breast. Because of its systemic dilution, its serum concentration is much low. This low-level of systemic concentration of the anti-estrogen compounds diminishes and or eliminates many of the side effects associated with their daily oral administration. The direct breast implants of anti-estrogen compositions facilitate complete saturation of its binding sites in the breast.
[0039] A number of methods for preparing formulations of slow-release long-acting compositions of hormones are described in many of the prior arts. Such methods of preparations of slow-release long-acting hormonal compositions include the bioabsorbable fusion products of steroid and a lipoid carrier as described in U.S. Pat. No. 4,244,949 (20; Gupta G N: Manufacture of long term contraceptive implant, U.S. Pat. No. 4,244,949; 1981). Preparations of microcapsules laden with an active ingredient are described in U.S. Pat. No. 4,389,330 (18; Tice T R, and Lewis D H: Microencapsulation process, U.S. Pat. No. 4,389,330; 1983) in 1983. Similar biodegradable injectable microcapsules made of hormones and polymers such as polyortho-ester or polyacetal were used in U.S. Pat. No. 5,430,585 (21; Pike M and Spicer D V: Methods and formulations for use in treating oophorectomized women, and in 19; U.S. Pat. No. 5,340,586; 1994). Hormonal compositions as slow-release capsules made of Silastic, Dow Corning's No 602-305 medical grade polydimethylsiloxane, an inert non-reactive tube forming polymer was used to encapsulate the hormone compositions in U.S. Pat. No. 4,210,644 (22; Ewing L L, Desjardins C: Male contraception; U.S. Pat. No. 4,210,644; 1980). As in U.S. Pat. No. 4,210,644, Silastic silicone rubber tubing is used for the preparation of levonorgestrel implant, Norplant System of Wyeth -Ayerst Laboratories as a long-acting contraceptive (23; Norplant System, Wyeth Ayerst Laboratories, Physicians Desk Reference, PDR, 51, 1997, p2868). In this invention, similar prior arts methods are adapted to prepare suitable implants of anti-estrogen formulations for the implant treatment of breast cancer.
PREFERRED EMBODIMENT—DESCRIPTION
Preparation of Biodegradable Hormonal Compositions Fused With a Lipoid Carrier for Breast Implants
[0040] As a preferred method of fused implant preparation for breast implants for hormonal treatment of breast cancer, the methods described in U.S. Pat. No. 4,244,949 (20; Gupta G N: Manufacture of long term contraceptive implant, U.S. Pat. No. 4,244,949; 1981) more than 21 years ago is adapted. The entire disclosure of which is hereby incorporated by reference.
[0041] 1. Preparation of Biodegradable Fused Breast Implants of Tamoxifen and Cholesterol Formulation
[0042] In accordance with one preferred embodiment for one fused implant preparation of tamoxifen and cholesterol for prostatic implant, tamoxifen is purified by dissolving it in methanol, filtering through analytical grade filter paper and crystallizing it by slow addition of small amount of distilled water and allowing it to continue to crystallize slowly in a refrigerator for about 12 hours. Filtering it again through analytical grade filter paper and vacuum drying at 60° C. to a constant weight for two or more hours and storing the crystallized form of under nitrogen at 25° C. until it is used for fused single breast implant preparation. Thirty mg of purified tamoxifen and 7.5 mg of cholesterol is made to a powder form by thorough mixing under nitrogen. This mixture is then transferred into a 10 cm long, 2.4 to 2.8 mm diameter Teflon tubing and compacted with stainless steel probes from both open ends of the Teflon tubing under nitrogen. The portion of the Teflon tubing containing the tamoxifen and cholesterol mixture is heated over their melting points for 45 seconds over an aluminum block. The molten mixture is consolidated as one fused mass by pressing it with the stainless steel probes. After cooling, the probes are removed. The fused tamoxifen and cholesterol breast implant preparation is removed from the Teflon tubing by splitting the tube walls with a blade. As described earlier, the implant dose of tamoxifen is adjusted to give the same amount of breast tissue bound tamoxifen as 4 weeks after high dose tamoxifen treatment by mouth.
[0043] 2. Preparation of Biodegradable Fused Breast Implants of Raloxifene and Cholesterol Formulation
[0044] In accordance with one preferred embodiment for one fused implant preparation of raloxifene and cholesterol for the breast implants, the methods similar to that described for the preparation of tamoxifen fused with cholesterol is used but substituting the tamoxifen with raloxifene and adjusting the amount of raloxifene and cholesterol used for such preparation.
[0045] 3. Preparation of Iodinated Estradiol (Iodo-Estradiol)
[0046] Iodinated estradiol is prepared as per the methods described by this inventor in his U.S. Pat. No. 4,321,208 in 1982 with minor modifications (16; Sahadevan V: Preparation of directly iodinated steroid hormones and related compounds, U.S. Pat. No. 4,321,208; 1982). In brief, non-radioactive iodoestradiol is prepared by dissolving estradiol in methanol and allowing it to react with iodine. In a preferred embodiment, sodium or potassium iodide is dissolved in water. Hydrogen peroxide or chloramine-T dissolved in small amount of water is added to free the elemental iodine from its sodium or potassium salts. Iodine reactions with estrogen molecules take place spontaneously and form the iodoestradiol. The iodinated estradiol is precipitated with water and it is separated from the reaction mixture by centrifugation.
[0047] In a preferred embodiment 8 gr. Estradiol 17-β is dissolved in 100-ml methanol and filtered through analytical filter paper. Separately, 1-gr. sodium iodide and 100 μg chloramine-T is dissolved in 5-ml water and this is added to the estradiol dissolved in methanol. The iodine labeling to estradiol takes place spontaneously. After this reaction mixture is allowed to stand for about an hour, at room temperature, about 100 ml distilled water is added slowly to precipitate the iodoestradiol. The reaction mixture is centrifuged and the sediment iodoestradiol is washed repeatedly with water to remove any residual of iodine and chloramine-T. The sediment of iodoestradiol is vacuum dried at 60° C. for two or more hours to a constant weight and it is stored under nitrogen at 25° C. until it is used.
[0048] As shown by this inventor (16; Sahadevan V: Preparation of directly iodinated steroid hormones and related compounds, U.S. Pat. No. 4,321,208; 1982), such iodinated estradiol binds to both the estrogen receptor sites and to estrogen antiserum indicating its similarity with the naturally occurring estradiol 17β.
[0049] 4. Preparation of Biodegradable Fused Breast Implants of Iodoestradiol and Cholesterol Formulation.
[0050] In accordance with one preferred embodiment for one fused implant preparation of iodoestradiol and cholesterol for breast implant, the methods similar to that described for the preparation of tamoxifen fused with cholesterol is used but substituting the tamoxifen with iodo-estradiol and adjusting the amount of iodo-estradiol and cholesterol used for such preparation.
[0051] 5. Preparation of Biodegradable Fused Breast Implants of Toremifene and Cholesterol Formulation
[0052] In accordance with one preferred embodiment for one fused implant preparation of toremifene and cholesterol for breast implant, the methods similar to that described for the preparation of tamoxifen fused with cholesterol is used but substituting the tamoxifen with toremifene and adjusting the amount of toremifene and cholesterol used for such preparation.
[0053] 6. Preparation of Biodegradable Fused Breast Implants of Progesterone and Cholesterol Formulation
[0054] In accordance with one preferred embodiment for one fused implant preparation of progesterone and cholesterol for breast implant, the methods similar to that described for the preparation of tamoxifen fused with cholesterol is used but substituting the tamoxifen with progesterone and adjusting the amount of progesterone and cholesterol used for such preparation.
[0055] 7. Preparation of Biodegradable Fused Breast Implants of Androgen Fluoxymesterone and Cholesterol Formulation
[0056] In accordance with one preferred embodiment for one fused implant preparation of fluoxymesterone and cholesterol for breast implant, the methods similar to that described for the preparation of tamoxifen fused with cholesterol is used but substituting the tamoxifen with fluoxymesterone and adjusting the amount of fluoxymesterone and cholesterol used for such preparation.
[0057] 8. Preparation of Biodegradable Fused Breast Implants of Prednisolone and Cholesterol Formulation
[0058] In accordance with one preferred embodiment for one fused implant preparation of prednisolone and cholesterol for breast implant, the methods similar to that described for the preparation of tamoxifen fused with cholesterol is used but substituting the tamoxifen with prednisolone and adjusting the amount of prednisolone and cholesterol used for such preparation.
[0059] 9. Preparation of Biodegradable Fused Breast Implants of Anti-Estrogens combined with Progestins and Cholesterol Formulation
[0060] In accordance with one preferred embodiment for one fused implant preparation of ant-estrogens combined with progestins and cholesterol for breast implant, the methods similar to that described for the preparation of tamoxifen fused with cholesterol is adapted. An anti-estrogen is selected from the group of tamoxifen, raloxifene or toremifene. A progestin is selected from the group of megestrol acetate, medroxyprogesterone, norethindrone acetate or norgestrel. The amount of the selected anti-estrogen, progestin and cholesterol is adjusted for the preparation of the said fused combination hormonal breast implant of anti-estrogen combined with a progestin and cholesterol.
[0061] 10. Preparation of Biodegradable Fused Breast Implants of Anti-Estrogens Combined With Prednisolone and Cholesterol Formulation
[0062] In accordance with one preferred embodiment for one fused implant preparation of anti-estrogens combined with progestins and cholesterol for breast implant, the methods similar to that described for the preparation of tamoxifen fused with cholesterol is adapted. An anti-estrogen is selected from the group of tamoxifen, raloxifene or toremifene. The amount of the selected anti-estrogen, prednisolone and cholesterol is adjusted for the preparation of the said fused combination hormonal breast implant of anti-estrogen combined with prednisolone and cholesterol.
[0063] 11. Preparation of Biodegradable Fused Breast Implants of Anti-Estrogens combined with an Androgen and Cholesterol Formulation
[0064] In accordance with one preferred embodiment for one fused implant preparation of anti-estrogens combined with progestins and cholesterol for breast implant, the methods similar to that described for the preparation of tamoxifen fused with cholesterol is adapted. An anti-estrogen is selected from the group of tamoxifen, raloxifene or toremifene. The amount of the selected anti-estrogen, and the androgen like the fluoxymesterone and cholesterol is adjusted for the preparation of the said fused combination hormonal breast implant of anti-estrogen combined with an androgen and cholesterol.
[0065] 12. Preparation of Biodegradable Fused Breast Implants of Anti-Estrogens, Progestins, Prednisolone and Cholesterol Formulation
[0066] In accordance with one preferred embodiment for one fused implant preparation of anti-estrogens combined with progestins, prednisolone and cholesterol for breast implant, the methods similar to that described for the preparation of tamoxifen fused with cholesterol is adapted. An anti-estrogen is selected from the group of tamoxifen, raloxifene or toremifene. A progestin is selected from the group of megestrol acetate, medroxyprogesterone, norethindrone acetate or norgestrel. The amount of the selected anti-estrogen, progestin, prednisolone and cholesterol is adjusted for the preparation of the said fused combination hormonal breast implant of anti-estrogen combined with a progestin, prednisolone and cholesterol.
Preparation of Slow-Release Hormonal Compositions in Silastic Capsules for Breast Implants
[0067] As a preferred method of slow-release Hormonal Compositions in Silastic Capsules for prostatic implants for hormonal treatment of breast cancer, the methods described in U.S. Pat. No. 4,210,644 (22; Ewing L L, Desjardins C: Male contraception; U.S. Pat. No. 4,210,644; 1980) more than 21 years ago is adapted. The entire disclosure of which is hereby incorporated by reference. Similar encapsulated levonorgestrel implant, Norplant System of Wyeth-Ayerst Laboratories is used as a long-acting contraceptive (23; Norplant System, Wyeth Ayerst Laboratories, Physicians Desk Reference, PDR, 51, 1997, p2868).
[0068] 1. Preparation of Silastic Slow-Release Capsules Containing Tamoxifen for Breast Implant
[0069] In accordance with one preferred embodiment for preparation of Silastic slow release capsules containing Tamoxifen for prostatic implant, the following method is adapted. The Dow Corning Silastic, dimethylsyloxane/methylvinyalsiloxane copolymer, tubing of 0.2-mm wall thickness and 2.4 to 3.18 mm-outer diameters and of 3.5 cm in length is cut. One end is closed with Silastic adhesive (polydimethylsiloxane). Tamoxifen is filled into the cut tube through the open end at a dose of 30 mg. After the filling with DES, the open end of the tube is also closed with Silastic adhesive.
[0070] 2. Preparation of Silastic Slow-Release Capsules Containing Raloxifene for Breast Implant
[0071] In accordance with one preferred embodiment for preparation of Silastic slow release capsules containing raloxifene for the breast implants, the methods similar to that described for the preparation of Silastic slow release capsules containing tamoxifen is used but substituting the tamoxifen with raloxifene and adjusting the amount of raloxifene used for such preparation.
[0072] 3. Preparation of Silastic Slow-Release Capsules Containing Iodo-Estradiol for Breast Implant
[0073] In accordance with one preferred embodiment for preparation of Silastic slow release capsules containing raloxifene for the breast implants, the methods similar to that described for the preparation of Silastic slow release capsules containing tamoxifen is used but substituting the tamoxifen with iodo-estradiol and adjusting the amount of iodo-estradiol used for such preparation.
[0074] 4. Preparation of Silastic Slow-Release Capsules Containing Toremifene for Breast Implant
[0075] In accordance with one preferred embodiment for preparation of Silastic slow release capsules containing toremifene for the breast implants, the methods similar to that described for the preparation of Silastic slow release capsules containing tamoxifen is used but substituting the tamoxifen with toremifene and adjusting the amount of toremifene used for such preparation.
[0076] 5. Preparation of Silastic Slow-Release Capsules Containing Progesterone for Breast Implant
[0077] In accordance with one preferred embodiment for preparation of Silastic slow release capsules containing progesterone for the breast implants, the methods similar to that described for the preparation of Silastic slow release capsules containing tamoxifen is used but substituting the tamoxifen with progesterone and adjusting the amount of progesterone used for such preparation.
[0078] 6. Preparation of Silastic Slow-Release Capsules Containing Androgen Fluoxymesterone for Breast Implant
[0079] In accordance with one preferred embodiment for preparation of Silastic slow release capsules containing fluoxymesterone for the breast implants, the methods similar to that described for the preparation of Silastic slow release capsules containing tamoxifen is used but substituting the tamoxifen with fluoxymesterone and adjusting the amount of fluoxymesterone used for such preparation.
[0080] 7. Preparation of Silastic Slow-Release Capsules Containing Prednisolone for Breast Implant
[0081] In accordance with one preferred embodiment for preparation of Silastic slow release capsules containing prednisolone for the breast implants, the methods similar to that described for the preparation of Silastic slow release capsules containing tamoxifen is used but substituting the tamoxifen with prednisolone and adjusting the amount of prednisolone used for such preparation.
[0082] 8. Preparation of Silastic Slow-Release Capsules Containing Anti-Estrogens and Progestins for Breast Implant
[0083] In accordance with one preferred embodiment for preparation of Silastic slow release capsules containing anti-estrogens combined with progestins for breast implant, the methods similar to that described for the preparation of Silastic slow release capsules containing tamoxifen is adapted An anti-estrogen is selected from the group of tamoxifen, raloxifene or toremifene. A progestin is selected from the group of megestrol acetate, medroxyprogesterone, norethindrone acetate or norgestrel. The amount of the selected anti-estrogen and the progestin is adjusted for the preparation of the said Silastic slow release capsules containing the combination hormonal breast implant of anti-estrogen and a progestin.
[0084] 9. Preparation of Silastic Slow-Release Capsules Containing Anti-Estrogens and Prednisolone for Breast Implant
[0085] In accordance with one preferred embodiment for preparation of Silastic slow release capsules containing anti-estrogens combined with prednisolone for breast implant, the methods similar to that described for the preparation of Silastic slow release capsules containing tamoxifen is adapted. An anti-estrogen is selected from the group of tamoxifen, raloxifene or toremifene. The amount of the selected anti-estrogen and the prednisolone is adjusted for the preparation of the said Silastic slow release capsules containing the combination hormonal breast implant of an anti-estrogen and prednisolone.
[0086] 10. Preparation of Silastic Slow-Release Capsules Containing Anti-Estrogens and Fluoxymesterone for Breast Implant
[0087] In accordance with one preferred embodiment for preparation of Silastic slow release capsules containing anti-estrogens combined with fluoxymesterone for breast implant, the methods similar to that described for the preparation of Silastic slow release capsules containing tamoxifen is adapted. An anti-estrogen is selected from the group of tamoxifen, raloxifene or toremifene. The amount of the selected anti-estrogen and the fluoxymesterone is adjusted for the preparation of the said Silastic slow release capsules containing the combination hormonal breast implant of an anti-estrogen and fluoxymesterone.
[0088] 11. Preparation of Silastic Slow-Release Capsules Containing Anti-Estrogens, Progestins and Prednisolone for Breast Implant
[0089] In accordance with one preferred embodiment for preparation of anti-estrogens combined with progestins and prednisolone for breast implant, the methods similar to that described for the preparation of Silastic slow-release capsules containing tamoxifen is adapted. An anti-estrogen is selected from the group of tamoxifen, raloxifene or toremifene. A progestin is selected from the group of megestrol acetate, medroxyprogesterone, norethindrone acetate or norgestrel. The amount of the selected anti-estrogen, progestin, and prednisolone is adjusted for the preparation of the said combination hormonal breast implant of anti-estrogen combined with a progestin and prednisolone.
Preparation of Slow-Release Hormonal Compositions in Microcapsules for Breast Implants
[0090] As a preferred method of slow-release hormonal compositions in microcapsules for the treatment of breast cancer as breast implants, the methods described in U.S. Pat. No. 4,389,33018 (18; Tice T R, and Lewis D H: Microencapsulation process, U.S. Pat. No. 4,389,330; 1983) more than 18 years ago is adapted. The entire disclosure of which is hereby incorporated by reference. Similar methods of preparations of biodegradable microencapsulated steroid hormones are used in U.S. Pat. No. 5,340,585 (21; Pike M and Spicer D V: Methods and formulations for use in treating benign gynecological disorders; U.S. Pat. No. 5,340,585; 1994) for the treatment of benign gynecological disorders and in U.S. Pat. No. 5,340,586 (19; Pike M and Spicer D V: Methods and formulations for use in treating oophorectomized women, U.S. Pat. No. 5,340,586; 1994) for use of treating oophorectomized women. They are also hereby incorporated by reference. Similarly, any of the many previously known prior art methods for the preparation of microencapsulated compositions could also be used for the preparation of microencapsulated steroid hormones and their synthetic derivatives as breast implants for the treatment and prevention of breast cancer of this invention.
[0091] 1. Preparation of Slow-Release Biodegradable Microcapsules Containing Tamoxifen for Breast Implant
[0092] In accordance with one preferred embodiment for preparation of slow-release biodegradable microcapsules containing tamoxifen for breast implant, the following method is adapted. 3 g of tamoxifen and 3 g of poly(dl-lactide-coglycolide) are dissolved in 18 g of methylene chloride and dispersed as stable emulsions of microdroplets in 58 g of wt % of aqueous poly(vinyl alcohol). Afterwards, 60% of the solvent methylene chloride was removed by evaporation. The tamoxifen containing microcapsules are removed by centrifugation. The sediment of microencapsulated tamoxifen is then resuspended in deionized water and filtered through a fine fritted-glass funnel by slow suction while continuously adding more deionized water to remove the residual methylene chloride. This filtered microencapsulated tamoxifen is then sieved through a stainless-steel screen. The microcapsules comprising 50 wt % is then suspended in sterile normal saline. For making locally chelating implants when it comes in contact with tissue, the microcapsules are suspended in a mixture of sterile normal saline, a local anesthetic and ethanol. The microcapsule preparations are sterilized by any of the known convenient method of sterilization. It is then dispensed into sterile syringes under sterile conditions for injections.
[0093] 2. Preparation of Slow-Release Biodegradable Microcapsules Containing Raloxifene for Breast Implant
[0094] In accordance with one preferred embodiment for preparation of slow release biodegradable microcapsules containing raloxifene for the breast implants, the methods similar to that described for the preparation of slow release biodegradable microcapsules containing tamoxifen is used but substituting the tamoxifen with raloxifene and adjusting the amount of raloxifene used for such preparation.
[0095] 3. Preparation of Slow-Release Biodegradable Microcapsules Containing Iodo-Estradiol for Breast Implant
[0096] In accordance with one preferred embodiment for preparation of slow release biodegradable microcapsules containing raloxifene for the breast implants, the methods similar to that described for the preparation of slow release biodegradable microcapsules containing tamoxifen is used but substituting the tamoxifen with iodo-estradiol and adjusting the amount of iodo-estradiol used for such preparation.
[0097] 4. Preparation of Slow-Release Biodegradable Microcapsules Containing Toremifene for Breast Implant
[0098] In accordance with one preferred embodiment for preparation of slow release biodegradable microcapsules containing toremifene for the breast implants, the methods similar to that described for the preparation of slow release biodegradable microcapsules containing tamoxifen is used but substituting the tamoxifen with toremifene and adjusting the amount of toremifene used for such preparation.
[0099] 5. Preparation of Slow-Release Microcapsules Containing Progesterone for Breast Implant
[0100] In accordance with one preferred embodiment for preparation of slow release biodegradable microcapsules containing progesterone for the breast implants, the methods similar to that described for the preparation of slow release biodegradable microcapsules containing tamoxifen is used but substituting the tamoxifen with progesterone and adjusting the amount of progesterone used for such preparation.
[0101] 6. Preparation of Slow-Release Biodegradable Microcapsules Containing Androgen Fluoxymesterone for Breast Implant
[0102] In accordance with one preferred embodiment for preparation of Silastic slow release biodegradable microcapsules containing fluoxymesterone for the breast implants, the methods similar to that described for the preparation of slow release biodegradable microcapsules containing tamoxifen is used but substituting the tamoxifen with fluoxymesterone and adjusting the amount of fluoxymesterone used for such preparation.
[0103] 7. Preparation of Silastic Slow-Release Biodegradable Microcapsules Containing Prednisolone for Breast Implant
[0104] In accordance with one preferred embodiment for preparation of slow release biodegradable microcapsules containing prednisolone for the breast implants, the methods similar to that described for the preparation of slow release biodegradable microcapsules containing tamoxifen is used but substituting the tamoxifen with prednisolone and adjusting the amount of prednisolone used for such preparation.
[0105] 8. Preparation of Silastic Slow-Release Capsules Containing Anti-Estrogens and Progestins for Breast Implant
[0106] In accordance with one preferred embodiment for preparation of Silastic slow release biodegradable microcapsules containing anti-estrogens combined with progestins for breast implant, the methods similar to that described for the preparation of slow release biodegradable microcapsules containing tamoxifen is adapted. An anti-estrogen is selected from the group of tamoxifen, raloxifene or toremifene. A progestin is selected from the group of megestrol acetate, medroxyprogesterone, norethindrone acetate or norgestrel. The amount of the selected anti-estrogen and the progestin is adjusted for the preparation of the said biodegradable slow release microcapsules containing the combination hormonal breast implant of anti-estrogen and a progestin.
[0107] 9. Preparation of Slow-Release Biodegradable Microcapsules Containing Anti-Estrogens and Prednisolone for Breast Implant
[0108] In accordance with one preferred embodiment for preparation of slow release biodegradable microcapsules containing anti-estrogens combined with prednisolone for breast implant, the methods similar to that described for the preparation of slow release biodegradable microcapsules containing tamoxifen is adapted. An anti-estrogen is selected from the group of tamoxifen, raloxifene or toremifene. The amount of the selected anti-estrogen and the prednisolone is adjusted for the preparation of the said slow release biodegradable microcapsules containing the combination hormonal breast implant of an anti-estrogen and prednisolone.
[0109] 10. Preparation of Slow-Release Biodegradable Microcapsules Containing Anti-Estrogens and Fluoxymesterone for Breast Implant
[0110] In accordance with one preferred embodiment for preparation of Silastic slow release biodegradable microcapsules containing anti-estrogens combined with fluoxymesterone for breast implant, the methods similar to that described for the preparation of slow release biodegradable microcapsules containing tamoxifen is adapted. An anti-estrogen is selected from the group of tamoxifen, raloxifene or toremifene. The amount of the selected anti-estrogen and the fluoxymesterone is adjusted for the preparation of the said slow release biodegradable microcapsules containing the combination hormonal breast implant of an anti-estrogen and fluoxymesterone.
[0111] 11. Preparation of Slow-Release Biodegradable Microcapsules Containing Anti-Estrogens, Progestins and Prednisolone for Breast Implant
[0112] In accordance with one preferred embodiment for preparation of anti-estrogens combined with progestins and prednisolone for breast implant, the methods similar to that described for the preparation of slow-release biodegradable microcapsules containing tamoxifen is adapted. An anti-estrogen is selected from the group of tamoxifen, raloxifene or toremifene. A progestin is selected from the group of megestrol acetate, medroxyprogesterone, norethindrone acetate or norgestrel. The amount of the selected anti-estrogen, progestin, and prednisolone is adjusted for the preparation of the said combination hormonal breast implant of anti-estrogen combined with a progestin and prednisolone.
PREFERRED EMBODIMENT—OPERATION
Oral Pre-Implant Treatment With Tamoxifen
[0113] To determine the level of tissue bound tamoxifen after the standard dose of 10 mg twice daily by mouth for four weeks, the initial treatment with tamoxifen will be started at this standard dose for four weeks. If an anti-estrogen other than tamoxifen or an anti-estrogen in combination with other hormonal implant is planned, then the pre-implant treatment will consist of such oral preparations in its standard dose. Afterwards, a needle biopsy from the breast is taken and the concentration of the tissue bound anti-estrogen and other hormone is determined. It is followed by no treatment with anti-estrogen and other hormones for four weeks to allow the clearance of the tissue bound anti-estrogen and other hormones.
Breast Implants of the Anti-Estrogen Formulations
[0114] A formulation of slow-release anti-estrogen from any one of the preparations described before is implanted to the breast subcutaneousely. Four weeks afterwards, repeat needle biopsy specimen from the breast is taken for the determination of the tissue bound anti-estrogen. If implants of anti-estrogen in combination with other hormones are used, its tissue levels are also determined. It is compared with the tissue bound anti-estrogen or that of in combination with other hormones four weeks earlier. If the pre-treatment oral standard dose treatment shows a higher level of tissue bound anti-estrogen, additional implants are made for dose adjustments. Similar needle biopsies from the breast tissue are taken periodically to determine the satisfactory levels of tissue bound anti-estrogen and other hormones that were included in the implant.
Concomitant Hormonal Implant Treatment of the Breast With Radiation Therapy
[0115] The concomitant hormonal treatment with radiation is known to improve the treatment outcome of prostate cancer. Treatment with tamoxifen while on external beam radiation is shown to have improved tumor control. The slow constant rate hormonal release from the hormonal implants to the breast combined with radiation is an effective means to control the breast cancer and its cure. Furthermore, it would facilitate cure and control of breast cancer with lesser and better tolerated dose of radiation.
[0116] The hormonal implants to the breast is done either before or concomitantly with the interstitial radioactive seed implants to the breast. An added advantage of such combined hormonal implant and external radiation therapy is that it also effectively controls regional lymph node metastasis since these hormonal compositions from the biodegrading implants will be carried to the regional lymph nodes by the macrophages.
Hormonal Breast Implants for Prophylaxis Against Breast Cancer
[0117] Treatment with tamoxifen is a very effective prophylaxis against breast cancer. Adjuvant tamoxifen treatment of patients with estrogen receptor positive tumors can reduce the annual odds of recurrence to 50-60 percent and annual odds of death to 23 to 36 per cent. The slow-release anti-estrogen hormonal implants to the breast that will maintain the breast tissue saturated with the anti-estrogen for longer periods. The breast tissue has high affinity binding for anti-estrogens. The breast tissue bound tamoxifen is about 10 to 60 times higher than its plasma concentration. Therefore, the slow-release anti-estrogen hormonal implant to the breast is an effective hormonal prophylactic treatment without much systemic toxicity.
CONCLUSIONS, RAMIFICATIONS, AND SCOPE
[0118] Although the description above contains much specificity, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Various other embodiments and ramifications are possible within it's scope. For example, instead of the direct breast implants of anti-estrogen and related hormonal formulations that are beneficial for the treatment of breast cancer, they may be also be implanted as subcutaneous or intramuscular implants for the treatment of breast cancer. They may also be implanted directly to a metastatic site.
[0119] Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.
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An improved method and products for the hormonal treatment of breast cancer by breast implants of anti-estrogens and steroid hormones in formulations as fused with a lipoid carrier or encapsulated in microcapsules or in Silastic capsules is provided. Such breast implants renders a constant slow-release of their contents to the breast tissue for extended periods by biodegradation and diffusion. It facilitates higher breast tissue concentrations of anti-estrogen and hormonal compositions. Because of their high concentration in the breast and lower systemic distribution, tumor control is much improved and the their systemic toxicity is minimized. An added beneficial effect of these breast implants on breast cancer is mediated by the inhibition of hypothalamic-pituitary LHRH, FSH and LH secretion by these composition's systemic contents. It is also an effective prophylaxis against breast cancer. Furthermore, it reduces the cost of hormonal treatment of breast cancer. Anti-estrogen hormonal implants to the breast as concomitant hormonal treatment with conventional radiation therapy also facilitates improved tumor control and cure rates of breast cancer.
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FIELD OF THE INVENTION
[0001] The present invention is in the field of transporter proteins that are related to the phosphate translocator subfamily, recombinant DNA molecules, and protein production. The present invention specifically provides novel peptides and proteins that effect ligand transport and nucleic acid molecules encoding such peptide and protein molecules, all of which are useful in the development of human therapeutics and diagnostic compositions and methods.
BACKGROUND OF THE INVENTION
[0002] Transporters
[0003] Transporter proteins regulate many different functions of a cell, including cell proliferation, differentiation, and signaling processes, by regulating the flow of molecules such as ions and macromolecules, into and out of cells. Transporters are found in the plasma membranes of virtually every cell in eukaryotic organisms. Transporters mediate a variety of cellular functions including regulation of membrane potentials and absorption and secretion of molecules and ion across cell membranes. When present in intracellular membranes of the Golgi apparatus and endocytic vesicles, transporters, such as chloride channels, also regulate organelle pH. For a review, see Greger, R. (1988) Annu. Rev. Physiol. 50:111-122.
[0004] Transporters are generally classified by structure and the type of mode of action. In addition, transporters are sometimes classified by the molecule type that is transported, for example, sugar transporters, chlorine channels, potassium channels, etc. There may be many classes of channels for transporting a single type of molecule (a detailed review of channel types can be found at Alexander, S. P. H. and J. A. Peters: Receptor and transporter nomenclature supplement. Trends Pharmacol. Sci., Elsevier, pp. 65-68 (1997) and http://www-biology.ucsd.edu/˜msaier/transport/titlepape2.html.
[0005] The following general classification scheme is known in the art and is followed in the present discoveries.
[0006] Channel-type transporters. Transmembrane channel proteins of this class are ubiquitously found in the membranes of all types of organisms from bacteria to higher eukaryotes. Transport systems of this type catalyze facilitated diffusion (by an energy-independent process) by passage through a transmembrane aqueous pore or channel without evidence for a carrier-mediated mechanism. These channel proteins usually consist largely of a-helical spanners, although b-strands may also be present and may even comprise the channel. However, outer membrane porin-type channel proteins are excluded from this class and are instead included in class 9.
[0007] Carrier-type transporters. Transport systems are included in this class if they utilize a carrier-mediated process to catalyze uniport (a single species is transported by facilitated diffusion), antiport (two or more species are transported in opposite directions in a tightly coupled process, not coupled to a direct form of energy other than chemiosmotic energy) and/or symport (two or more species are transported together in the same direction in a tightly coupled process, not coupled to a direct form of energy other than chemiosmotic energy).
[0008] Pyrophosphate bond hydrolysis-driven active transporters. Transport systems are included in this class if they hydrolyze pyrophosphate or the terminal pyrophosphate bond in ATP or another nucleoside triphosphate to drive the active uptake and/or extrusion of a solute or solutes. The transport protein may or may not be transiently phosphorylated, but the substrate is not phosphorylated.
[0009] PEP-dependent, phosphoryl transfer-driven group translocators. Transport systems of the bacterial phosphoenolpyruvate:sugar phosphotransferase system are included in this class. The product of the reaction, derived from extracellular sugar, is a cytoplasmic sugar-phosphate.
[0010] Decarboxylation-driven active transporters. Transport systems that drive solute (e.g., ion) uptake or extrusion by decarboxylation of a cytoplasmic substrate are included in this class.
[0011] Oxidoreduction-driven active transporters. Transport systems that drive transport of a solute (e.g., an ion) energized by the flow of electrons from a reduced substrate to an oxidized substrate are included in this class.
[0012] Light-driven active transporters. Transport systems that utilize light energy to drive transport of a solute (e.g., an ion) are included in this class.
[0013] Mechanically-driven active transporters. Transport systems are included in this class if they drive movement of a cell or organelle by allowing the flow of ions (or other solutes) through the membrane down their electrochemical gradients.
[0014] Outer-membrane porins (of b-structure). These proteins form transmembrane pores or channels that usually allow the energy independent passage of solutes across a membrane. The transmembrane portions of these proteins consist exclusively of b-strands that form a b-barrel. These porin-type proteins are found in the outer membranes of Gram-negative bacteria, mitochondria and eukaryotic plastids.
[0015] Methyltransferase-driven active transporters. A single characterized protein currently falls into this category, the Na+-transporting methyltetrahydromethanopterin:coenzyme M methyltransferase.
[0016] Non-ribosome-synthesized channel-forming peptides or peptide-like molecules. These molecules, usually chains of L- and D-amino acids as well as other small molecular building blocks such as lactate, form oligomeric transmembrane ion channels. Voltage may induce channel formation by promoting assembly of the transmembrane channel. These peptides are often made by bacteria and fungi as agents of biological warfare.
[0017] Non-Proteinaceous Transport Complexes. Ion conducting substances in biological membranes that do not consist of or are not derived from proteins or peptides fall into this category.
[0018] Functionally characterized transporters for which sequence data are lacking. Transporters of particular physiological significance will be included in this category even though a family assignment cannot be made.
[0019] Putative transporters in which no family member is an established transporter. Putative transport protein families are grouped under this number and will either be classified elsewhere when the transport function of a member becomes established, or will be eliminated from the TC classification system if the proposed transport function is disproven. These families include a member or members for which a transport function has been suggested, but evidence for such a function is not yet compelling.
[0020] Auxiliary transport proteins. Proteins that in some way facilitate transport across one or more biological membranes but do not themselves participate directly in transport are included in this class. These proteins always function in conjunction with one or more transport proteins. They may provide a function connected with energy coupling to transport, play a structural role in complex formation or serve a regulatory function.
[0021] Transporters of unknown classification. Transport protein families of unknown classification are grouped under this number and will be classified elsewhere when the transport process and energy coupling mechanism are characterized. These families include at least one member for which a transport function has been established, but either the mode of transport or the energy coupling mechanism is not known.
[0022] Ion Channels
[0023] An important type of transporter is the ion channel. Ion channels regulate many different cell proliferation, differentiation, and signaling processes by regulating the flow of ions into and out of cells. Ion channels are found in the plasma membranes of virtually every cell in eukaryotic organisms. Ion channels mediate a variety of cellular functions including regulation of membrane potentials and absorption and secretion of ion across epithelial membranes. When present in intracellular membranes of the Golgi apparatus and endocytic vesicles, ion channels, such as chloride channels, also regulate organelle pH. For a review, see Greger, R. (1988) Annu. Rev. Physiol. 50:111-122.
[0024] Ion channels are generally classified by structure and the type of mode of action. For example, extracellular ligand gated channels (ELGs) are comprised of five polypeptide subunits, with each subunit having 4 membrane spanning domains, and are activated by the binding of an extracellular ligand to the channel. In addition, channels are sometimes classified by the ion type that is transported, for example, chlorine channels, potassium channels, etc. There may be many classes of channels for transporting a single type of ion (a detailed review of channel types can be found at Alexander, S. P. H. and J. A. Peters (1997). Receptor and ion channel nomenclature supplement. Trends Pharmacol. Sci., Elsevier, pp. 65-68 and http:H/www-biology.ucsd.edu/˜msaier/transport/toc.html.
[0025] There are many types of ion channels based on structure. For example, many ion channels fall within one of the following groups: extracellular ligand-gated channels (ELG), intracellular ligand-gated channels (ILG), inward rectifying channels (INR), intercellular (gap junction) channels, and voltage gated channels (VIC). There are additionally recognized other channel families based on ion-type transported, cellular location and drug sensitivity. Detailed information on each of these, their activity, ligand type, ion type, disease association, drugability, and other information pertinent to the present invention, is well known in the art.
[0026] Extracellular ligand-gated channels, ELGs, are generally comprised of five polypeptide subunits, Unwin, N. (1993), Cell 72: 31-41; Unwin, N. (1995), Nature 373: 37-43; Hucho, F., et al., (1996) J. Neurochem. 66: 1781-1792; Hucho, F., et al., (1996) Eur. J. Biochem. 239: 539-557; Alexander, S. P. H. and J. A. Peters (1997), Trends Pharmacol. Sci., Elsevier, pp. 4-6; 36-40; 42-44; and Xue, H. (1998) J. Mol. Evol. 47: 323-333. Each subunit has 4 membrane spanning regions: this serves as a means of identifying other members of the ELG family of proteins. ELG bind a ligand and in response modulate the flow of ions.
[0027] Examples of ELG include most members of the neurotransmitter-receptor family of proteins, e.g., GABAI receptors. Other members of this family of ion channels include glycine receptors, ryandyne receptors, and ligand gated calcium channels.
[0028] The Voltage-Gated Ion Channel (VIC) Superfamily
[0029] Proteins of the VIC family are ion-selective channel proteins found in a wide range of bacteria, archaea and eukaryotes Hille, B. (1992), Chapter 9: Structure of channel proteins; Chapter 20: Evolution and diversity. In: Ionic Channels of Excitable Membranes, 2nd Ed., Sinaur Assoc. Inc., Pubs., Sunderland, Mass.; Sigworth, F. J. (1993), Quart. Rev. Biophys. 27: 1-40; Salkoff, L. and T. Jegla (1995), Neuron 15: 489-492; Alexander, S. P. H. et al., (1997), Trends Pharmacol. Sci., Elsevier, pp. 76-84; Jan, L. Y. et al., (1997), Annu. Rev. Neurosci. 20: 91-123; Doyle, D. A, et al., (1998) Science 280: 69-77; Terlau, H. and W. Stuihmer (1998), Naturwissenschaften 85: 437-444. They are often homo- or heterooligomeric structures with several dissimilar subunits (e.g., a1-a2-d-b Ca 2+ channels, ab 1 b 2 Na + channels or (a) 4 -b K + channels), but the channel and the primary receptor is usually associated with the a (or a1) subunit. Functionally characterized members are specific for K + , Na + or Ca 2+ . The K + channels usually consist of homotetrameric structures with each a-subunit possessing six transmembrane spanners (TMSs). The a1 and a subunits of the Ca 2+ and Na + channels, respectively, are about four times as large and possess 4 units, each with 6 TMSs separated by a hydrophilic loop, for a total of 24 TMSs. These large channel proteins form heterotetra-unit structures equivalent to the homotetrameric structures of most K + channels. All four units of the Ca 2+ and Na + channels are homologous to the single unit in the homotetrameric K + channels. Ion flux via the eukaryotic channels is generally controlled by the transmembrane electrical potential (hence the designation, voltage-sensitive) although some are controlled by ligand or receptor binding.
[0030] Several putative K + -selective channel proteins of the VIC family have been identified in prokaryotes. The structure of one of them, the KcsA K + channel of Streptomyces lividans , has been solved to 3.2 Å resolution. The protein possesses four identical subunits, each with two transmembrane helices, arranged in the shape of an inverted teepee or cone. The cone cradles the “selectivity filter” P domain in its outer end. The narrow selectivity filter is only 12 Å long, whereas the remainder of the channel is wider and lined with hydrophobic residues. A large water-filled cavity and helix dipoles stabilize K + in the pore. The selectivity filter has two bound K + ions about 7.5 Å apart from each other. Ion conduction is proposed to result from a balance of electrostatic attractive and repulsive forces.
[0031] In eukaryotes, each VIC family channel type has several subtypes based on pharmacological and electrophysiological data. Thus, there are five types of Ca 2+ channels (L, N, P, Q and T). There are at least ten types of K + channels, each responding in different ways to different stimuli: voltage-sensitive [Ka, Kv, Kvr, Kvs and Ksr], Ca 2+ -sensitive [BK Ca , IK Ca and SK Ca ] and receptor-coupled [K M and K ACh ]. There are at least six types of Na + channels (I, II, III, μ1, H1 and PN3). Tetrameric channels from both prokaryotic and eukaryotic organisms are known in which each a-subunit possesses 2 TMSs rather than 6, and these two TMSs are homologous to TMSs 5 and 6 of the six TMS unit found in the voltage-sensitive channel proteins. KcsA of S. lividans is an example of such a 2 TMS channel protein. These channels may include the K Na (Na + -activated) and K Vol (cell volume-sensitive) K + channels, as well as distantly related channels such as the Tok1 K + channel of yeast, the TWIK-1 inward rectifier K + channel of the mouse and the TREK-1 K + channel of the mouse. Because of insufficient sequence similarity with proteins of the VIC family, inward rectifier K + IRK channels (ATP-regulated; G-protein-activated) which possess a P domain and two flanking TMSs are placed in a distinct family. However, substantial sequence similarity in the P region suggests that they are homologous. The b, g and d subunits of VIC family members, when present, frequently play regulatory roles in channel activation/deactivation.
[0032] The Epithelial Na + Channel (ENaC) Family
[0033] The ENaC family consists of over twenty-four sequenced proteins (Canessa, C. M., et al., (1994), Nature 367: 463-467, Le, T. and M. H. Saier, Jr. (1996), Mol. Membr. Biol. 13: 149-157; Garty, H. and L. G. Palmer (1997), Physiol. Rev. 77: 359-396; Waldmann, R., et al., (1997), Nature 386: 173-177; Darboux, I., et al., (1998), J. Biol. Chem. 273: 9424-9429; Firsov, D., et al., (1998), EMBO J. 17: 344-352; Horisberger, J. -D. (1998). Curr. Opin. Struc. Biol. 10: 443-449). All are from animals with no recognizable homologues in other eukaryotes or bacteria. The vertebrate ENaC proteins from epithelial cells cluster tightly together on the phylogenetic tree: voltage-insensitive ENaC homologues are also found in the brain. Eleven sequenced C. elegans proteins, including the degenerins, are distantly related to the vertebrate proteins as well as to each other. At least some of these proteins form part of a mechano-transducing complex for touch sensitivity. The homologous Helix aspersa FMRF-amide)-activated Na + channel is the first peptide neurotransmitter-gated ionotropic receptor to be sequenced.
[0034] Protein members of this family all exhibit the same apparent topology, each with N- and C-termini on the inside of the cell, two amphipathic transmembrane spanning segments, and a large extracellular loop. The extracellular domains contain numerous highly conserved cysteine residues. They are proposed to serve a receptor function.
[0035] Mammalian ENaC is important for the maintenance of Na + balance and the regulation of blood pressure. Three homologous ENaC subunits, alpha, beta, and gamma, have been shown to assemble to form the highly Na + -selective channel. The stoichiometry of the three subunits is alpha 2 , betal, gammal in a heterotetrameric architecture.
[0036] The Glutamate-pated Ion Channel (GIC) Family of Neurotransmitter Receptors
[0037] Members of the GIC family are heteropentameric complexes in which each of the 5 subunits is of 800-1000 amino acyl residues in length (Nakanishi, N., et al, (1990), Neuron 5: 569-581; Unwin, N. (1993), Cell 72: 31-41; Alexander, S. P. H. and J. A. Peters (1997) Trends Pharmacol. Sci., Elsevier, pp. 36-40). These subunits may span the membrane three or five times as putative a-helices with the N-termini (the glutamate-binding domains) localized extracellularly and the C-termini localized cytoplasmically. They may be distantly related to the ligand-gated ion channels, and if so, they may possess substantial b-structure in their transmembrane regions. However, homology between these two families cannot be established on the basis of sequence comparisons alone. The subunits fall into six subfamilies: a, b, g, d, e and z.
[0038] The GIC channels are divided into three types: (1) a-amino-3-hydroxy-5-methyl-4-isoxazole propionate (AMPA)-, (2) kainate- and (3) N-methyl-D-aspartate (NMDA)-selective glutamate receptors. Subunits of the AMPA and kainate classes exhibit 35-40% identity with each other while subunits of the NMDA receptors exhibit 22-24% identity with the former subunits. They possess large N-terminal, extracellular glutamate-binding domains that are homologous to the periplasmic glutamine and glutamate receptors of ABC-type uptake permeases of Gram-negative bacteria. All known members of the GIC family are from animals. The different channel (receptor) types exhibit distinct ion selectivities and conductance properties. The NMDA-selective large conductance channels are highly permeable to monovalent cations and Ca 2+ . The AMPA- and kainate-selective ion channels are permeable primarily to monovalent cations with only low permeability to Ca 2+ .
[0039] The Chloride Channel (ClC) Family
[0040] The ClC family is a large family consisting of dozens of sequenced proteins derived from Gram-negative and Gram-positive bacteria, cyanobacteria, archaea, yeast, plants and animals (Steinmeyer, K., et al., (1991), Nature 354: 301-304; Uchida, S., et al., (1993), J. Biol. Chem. 268: 3821-3824; Huang, M. -E., et al., (1994), J. Mol. Biol. 242: 595-598; Kawasaki, M., et al, (1994), Neuron 12: 597-604; Fisher, W. E., et al., (1995), Genomics. 29:598-606; and Foskett, J. K. (1998), Annu. Rev. Physiol. 60: 689-717). These proteins are essentially ubiquitous, although they are not encoded within genomes of Haemophilus influenzae, Mycoplasma genitalium , and Mycoplasma pneumoniae . Sequenced proteins vary in size from 395 amino acyl residues ( M. jannaschii ) to 988 residues (man). Several organisms contain multiple ClC family paralogues. For example, Synechocystis has two paralogues, one of 451 residues in length and the other of 899 residues. Arabidopsis thaliana has at least four sequenced paralogues, (775-792 residues), humans also have at least five paralogues (820-988 residues), and C. elegans also has at least five (810-950 residues). There are nine known members in mammals, and mutations in three of the corresponding genes cause human diseases. E. coli, Methanococcus jannaschii and Saccharomyces cerevisiae only have one ClC family member each. With the exception of the larger Synechocystis paralogue, all bacterial proteins are small (395492 residues) while all eukaryotic proteins are larger (687-988 residues). These proteins exhibit 10-12 putative transmembrane a-helical spanners (TMSs) and appear to be present in the membrane as homodimers. While one member of the family, Torpedo ClC-O, has been reported to have two channels, one per subunit, others are believed to have just one.
[0041] All functionally characterized members of the ClC family transport chloride, some in a voltage-regulated process. These channels serve a variety of physiological functions (cell volume regulation; membrane potential stabilization; signal transduction; transepithelial transport, etc.). Different homologues in humans exhibit differing anion selectivities, i.e., ClC4 and ClC5 share a NO 3 − >Cl − >Br − >I − conductance sequence, while ClC3 has an I − >Cl − selectivity. The ClC4 and ClC5 channels and others exhibit outward rectifying currents with currents only at voltages more positive than +20 mV.
[0042] Animal Inward Rectifier K + Channel (IRK-C) Family
[0043] IRK channels possess the “minimal channel-forming structure” with only a P domain, characteristic of the channel proteins of the VIC family, and two flanking transmembrane spanners (Shuck, M. E., et al., (1994), J. Biol. Chem. 269: 24261-24270; Ashen, M. D., et al., (1995), Am. J. Physiol. 268: H506-H511; Salkoff, L. and T. Jegla (1995), Neuron 15: 489-492; Aguilar-Bryan, L., et al., (1998), Physiol. Rev. 78: 227-245; Ruknudin, A., et al., (1998), J. Biol. Chem. 273: 14165-14171). They may exist in the membrane as homo- or heterooligomers. They have a greater tendency to let K + flow into the cell than out. Voltage-dependence may be regulated by external K + , by internal Mg 2+ , by internal ATP and/or by G-proteins. The P domains of IRK channels exhibit limited sequence similarity to those of the VIC family, but this sequence similarity is insufficient to establish homology. Inward rectifiers play a role in setting cellular membrane potentials, and the closing of these channels upon depolarization permits the occurrence of long duration action potentials with a plateau phase. Inward rectifiers lack the intrinsic voltage sensing helices found in VIC family channels. In a few cases, those of Kir1.1 a and Kir6.2, for example, direct interaction with a member of the ABC superfamily has been proposed to confer unique functional and regulatory properties to the heteromeric complex, including sensitivity to ATP. The SUR1 sulfonylurea receptor (spQ09428) is the ABC protein that regulates the Kir6.2 channel in response to ATP, and CFTR may regulate Kir1.1a. Mutations in SUR1 are the cause of familial persistent hyperinsulinemic hypoglycemia in infancy (PHHI), an autosomal recessive disorder characterized by unregulated insulin secretion in the pancreas.
[0044] ATP-Gated Cation Channel (ACC) Family
[0045] Members of the ACC family (also called P2X receptors) respond to ATP, a functional neurotransmitter released by exocytosis from many types of neurons (North, R. A. (1996), Curr. Opin. Cell Biol. 8: 474-483; Soto, F., M. Garcia-Guzman and W. Stühmer (1997), J. Membr. Biol. 160: 91-100). They have been placed into seven groups (P2X 1 -P2X 7 ) based on their pharmacological properties. These channels, which function at neuron-neuron and neuron-smooth muscle junctions, may play roles in the control of blood pressure and pain sensation. They may also function in lymphocyte and platelet physiology. They are found only in animals.
[0046] The proteins of the ACC family are quite similar in sequence (>35% identity), but they possess 380-1000 amino acyl residues per subunit with variability in length localized primarily to the C-terminal domains. They possess two transmembrane spanners, one about 30-50 residues from their N-termini, the other near residues 320-340. The extracellular receptor domains between these two spanners (of about 270 residues) are well conserved with numerous conserved glycyl and cysteyl residues. The hydrophilic C-termini vary in length from 25 to 240 residues. They resemble the topologically similar epithelial Na + channel (ENaC) proteins in possessing (a) N- and C-termini localized intracellularly, (b) two putative transmembrane spanners, (c) a large extracellular loop domain, and (d) many conserved extracellular cysteyl residues. ACC family members are, however, not demonstrably homologous with them. ACC channels are probably hetero- or homomultimers and transport small monovalent cations (Me + ). Some also transport Ca 2+ ; a few also transport small metabolites.
[0047] The Ryanodine-Inositol 1,4,5-triphosphate Receptor Ca 2+ Channel (RJR-CaC) Family
[0048] Ryanodine (Ry)-sensitive and inositol 1,4,5-triphosphate (IP3)-sensitive Ca 2+ -release channels function in the release of Ca 2+ from intracellular storage sites in animal cells and thereby regulate various Ca 2+ -dependent physiological processes (Hasan, G. et al., (1992) Development 116: 967-975; Michikawa, T., et al., (1994), J. Biol. Chem. 269: 9184-9189; Tunwell, R. E. A., (1996), Biochem. J. 318: 477-487; Lee, A. G. (1996) Biomembranes , Vol. 6, Transmembrane Receptors and Channels (A. G. Lee, ed.), JAI Press, Denver, Colo., pp 291-326; Mikoshiba, K., et al., (1996) J. Biochem. Biomem. 6: 273-289). Ry receptors occur primarily in muscle cell sarcoplasmic reticular (SR) membranes, and IP3 receptors occur primarily in brain cell endoplasmic reticular (ER) membranes where they effect release of Ca 2+ into the cytoplasm upon activation (opening) of the channel.
[0049] The Ry receptors are activated as a result of the activity of dihydropyridine-sensitive Ca 2+ channels. The latter are members of the voltage-sensitive ion channel (VIC) family. Dihydropyridine-sensitive channels are present in the T-tubular systems of muscle tissues.
[0050] Ry receptors are homotetrameric complexes with each subunit exhibiting a molecular size of over 500,000 daltons (about 5,000 amino acyl residues). They possess C-terminal domains with six putative transmembrane a -helical spanners (TMSs). Putative pore-forming sequences occur between the fifth and sixth TMSs as suggested for members of the VIC family. The large N-terminal hydrophilic domains and the small C-terminal hydrophilic domains are localized to the cytoplasm. Low resolution 3-dimensional structural data are available. Mammals possess at least three isoforms that probably arose by gene duplication and divergence before divergence of the mammalian species. Homologues are present in humans and Caenorabditis elegans.
[0051] IP 3 receptors resemble Ry receptors in many respects. (1) They are homotetrameric complexes with each subunit exhibiting a molecular size of over 300,000 daltons (about 2,700 amino acyl residues). (2) They possess C-terminal channel domains that are homologous to those of the Ry receptors. (3) The channel domains possess six putative TMSs and a putative channel lining region between TMSs 5 and 6. (4) Both the large N-terminal domains and the smaller C-terminal tails face the cytoplasm. (5) They possess covalently linked carbohydrate on extracytoplasmic loops of the channel domains. (6) They have three currently recognized isoforms (types 1, 2, and 3) in mammals which are subject to differential regulation and have different tissue distributions.
[0052] IP 3 receptors possess three domains: N-terminal IP 3 -binding domains, central coupling or regulatory domains and C-terminal channel domains. Channels are activated by IP 3 binding, and like the Ry receptors, the activities of the IP3 receptor channels are regulated by phosphorylation of the regulatory domains, catalyzed by various protein kinases. They predominate in the endoplasmic reticular membranes of various cell types in the brain but have also been found in the plasma membranes of some nerve cells derived from a variety of tissues.
[0053] The channel domains of the Ry and IP 3 receptors comprise a coherent family that in spite of apparent structural similarities, do not show appreciable sequence similarity of the proteins of the VIC family. The Ry receptors and the IP 3 receptors cluster separately on the RIR-CaC family tree. They both have homologues in Drosophila. Based on the phylogenetic tree for the family, the family probably evolved in the following sequence: (1) A gene duplication event occurred that gave rise to Ry and IP 3 receptors in invertebrates. (2) Vertebrates evolved from invertebrates. (3) The three isoforms of each receptor arose as a result of two distinct gene duplication events. (4) These isoforms were transmitted to mammals before divergence of the mammalian species.
[0054] The Organellar Chloride Channel (O-ClC) Family
[0055] Proteins of the O-ClC family are voltage-sensitive chloride channels found in intracellular membranes but not the plasma membranes of animal cells (Landry, D, et al., (1993), J. Biol. Chem. 268: 14948-14955; Valenzuela, Set al., (1997), J. Biol. Chem. 272: 12575-12582; and Duncan, R. R., et al., (1997), J. Biol. Chem. 272: 23880-23886).
[0056] They are found in human nuclear membranes, and the bovine protein targets to the microsomes, but not the plasma membrane, when expressed in Xenopus laevis oocytes. These proteins are thought to function in the regulation of the membrane potential and in transepithelial ion absorption and secretion in the kidney. They possess two putative transmembrane a-helical spanners (TMSs) with cytoplasmic N- and C-termini and a large luminal loop that may be glycosylated. The bovine protein is 437 amino acyl residues in length and has the two putative TMSs at positions 223-239 and 367-385. The human nuclear protein is much smaller (241 residues). A C. elegans homologue is 260 residues long.
[0057] Phosphate Translocators
[0058] The novel human protein, and encoding gene, provided by the present invention is related to the family of phosphate translocators, which are important for transporting phosphate across cellular membranes, particular phosphoenolpyruvate. For a further review of phosphate translocators, see Fischer et al., Plant J February 1994;5(2):215-26 and Fischer et al., Plant Cell March 1997;9(3):453-62.
[0059] Transporter proteins, particularly members of the phosphate translocator subfamily, are a major target for drug action and development. Accordingly, it is valuable to the field of pharmaceutical development to identify and characterize previously unknown transport proteins. The present invention advances the state of the art by providing previously unidentified human transport proteins.
SUMMARY OF THE INVENTION
[0060] The present invention is based in part on the identification of amino acid sequences of human transporter peptides and proteins that are related to the phosphate translocator subfamily, as well as allelic variants and other mammalian orthologs thereof. These unique peptide sequences, and nucleic acid sequences that encode these peptides, can be used as models for the development of human therapeutic targets, aid in the identification of therapeutic proteins, and serve as targets for the development of human therapeutic agents that modulate transporter activity in cells and tissues that express the transporter. Experimental data as provided in FIG. 1 indicates expression in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma.
DESCRIPTION OF THE FIGURE SHEETS
[0061] [0061]FIG. 1 provides the nucleotide sequence of a cDNA molecule or transcript sequence that encodes the transporter protein of the present invention. (SEQ ID NO:1) In addition structure and functional information is provided, such as ATG start, stop and tissue distribution, where available, that allows one to readily determine specific uses of inventions based on this molecular sequence. Experimental data as provided in FIG. 1 indicates expression in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma.
[0062] [0062]FIG. 2 provides the predicted amino acid sequence of the transporter of the present invention. (SEQ ID NO:2) In addition structure and functional information such as protein family, function, and modification sites is provided where available, allowing one to readily determine specific uses of inventions based on this molecular sequence.
[0063] [0063]FIG. 3 provides genomic sequences that span the gene encoding the transporter protein of the present invention. (SEQ ID NO:3) In addition structure and functional information, such as intron/exon structure, promoter location, etc., is provided where available, allowing one to readily determine specific uses of inventions based on this molecular sequence. As illustrated in FIG. 3, SNPs were identified at 26 different nucleotide positions.
DETAILED DESCRIPTION OF THE INVENTION
[0064] General Description
[0065] The present invention is based on the sequencing of the human genome. During the sequencing and assembly of the human genome, analysis of the sequence information revealed previously unidentified fragments of the human genome that encode peptides that share structural and/or sequence homology to protein/peptide/domains identified and characterized within the art as being a transporter protein or part of a transporter protein and are related to the phosphate translocator subfamily. Utilizing these sequences, additional genomic sequences were assembled and transcript and/or cDNA sequences were isolated and characterized. Based on this analysis, the present invention provides amino acid sequences of human transporter peptides and proteins that are related to the phosphate translocator subfamily, nucleic acid sequences in the form of transcript sequences, cDNA sequences and/or genomic sequences that encode these transporter peptides and proteins, nucleic acid variation (allelic information), tissue distribution of expression, and information about the closest art known protein/peptide/domain that has structural or sequence homology to the transporter of the present invention.
[0066] In addition to being previously unknown, the peptides that are provided in the present invention are selected based on their ability to be used for the development of commercially important products and services. Specifically, the present peptides are selected based on homology and/or structural relatedness to known transporter proteins of the phosphate translocator subfamily and the expression pattern observed. Experimental data as provided in FIG. 1 indicates expression in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma.. The art has clearly established the commercial importance of members of this family of proteins and proteins that have expression patterns similar to that of the present gene. Some of the more specific features of the peptides of the present invention, and the uses thereof, are described herein, particularly in the Background of the Invention and in the annotation provided in the Figures, and/or are known within the art for each of the known phosphate translocator family or subfamily of transporter proteins.
[0067] Specific Embodiments
[0068] Peptide Molecules
[0069] The present invention provides nucleic acid sequences that encode protein molecules that have been identified as being members of the transporter family of proteins and are related to the phosphate translocator subfamily (protein sequences are provided in FIG. 2, transcript/cDNA sequences are provided in FIGS. 1 and genomic sequences are provided in FIG. 3). The peptide sequences provided in FIG. 2, as well as the obvious variants described herein, particularly allelic variants as identified herein and using the information in FIG. 3, will be referred herein as the transporter peptides of the present invention, transporter peptides, or peptides/proteins of the present invention.
[0070] The present invention provides isolated peptide and protein molecules that consist of, consist essentially of, or comprising the amino acid sequences of the transporter peptides disclosed in the FIG. 2, (encoded by the nucleic acid molecule shown in FIG. 1, transcript/cDNA or FIG. 3, genomic sequence), as well as all obvious variants of these peptides that are within the art to make and use. Some of these variants are described in detail below.
[0071] As used herein, a peptide is said to be “isolated” or “purified” when it is substantially free of cellular material or free of chemical precursors or other chemicals. The peptides of the present invention can be purified to homogeneity or other degrees of purity. The level of purification will be based on the intended use. The critical feature is that the preparation allows for the desired function of the peptide, even if in the presence of considerable amounts of other components (the features of an isolated nucleic acid molecule is discussed below).
[0072] In some uses, “substantially free of cellular material” includes preparations of the peptide having less than about 30% (by dry weight) other proteins (i.e., contaminating protein), less than about 20% other proteins, less than about 10% other proteins, or less than about 5% other proteins. When the peptide is recombinanfly produced, it can also be substantially free of culture mediun, i.e., culture medium represents less than about 20% of the volume of the protein preparation.
[0073] The language “substantially free of chemical precursors or other chemicals” includes preparations of the peptide in which it is separated from chemical precursors or other chemicals that are involved in its synthesis. In one embodiment, the language “substantially free of chemical precursors or other chemicals” includes preparations of the transporter peptide having less than about 30% (by dry weight) chemical precursors or other chemicals, less than about 20% chemical precursors or other chemicals, less than about 10% chemical precursors or other chemicals, or less than about 5% chemical precursors or other chemicals.
[0074] The isolated transporter peptide can be purified from cells that naturally express it, purified from cells that have been altered to express it (recombinant), or synthesized using known protein synthesis methods. Experimental data as provided in FIG. 1 indicates expression in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma. For example, a nucleic acid molecule encoding the transporter peptide is cloned into an expression vector, the expression vector introduced into a host cell and the protein expressed in the host cell. The protein can then be isolated from the cells by an appropriate purification scheme using standard protein purification techniques. Many of these techniques are described in detail below.
[0075] Accordingly, the present invention provides proteins that consist of the amino acid sequences provided in FIG. 2 (SEQ ID NO:2), for example, proteins encoded by the transcript/cDNA nucleic acid sequences shown in FIG. 1 (SEQ ID NO:1) and the genomic sequences provided in FIG. 3 (SEQ ID NO:3). The amino acid sequence of such a protein is provided in FIG. 2. A protein consists of an amino acid sequence when the amino acid sequence is the final amino acid sequence of the protein.
[0076] The present invention further provides proteins that consist essentially of the amino acid sequences provided in FIG. 2 (SEQ ID NO:2), for example, proteins encoded by the transcript/cDNA nucleic acid sequences shown in FIG. 1 (SEQ ID NO:1) and the genomic sequences provided in FIG. 3 (SEQ ID NO:3). A protein consists essentially of an amino acid sequence when such an amino acid sequence is present with only a few additional amino acid residues, for example from about 1 to about 100 or so additional residues, typically from 1 to about 20 additional residues in the final protein.
[0077] The present invention further provides proteins that comprise the amino acid sequences provided in FIG. 2 (SEQ ID NO:2), for example, proteins encoded by the transcript/cDNA nucleic acid sequences shown in FIG. 1 (SEQ ID NO:1) and the genomic sequences provided in FIG. 3 (SEQ ID NO:3). A protein comprises an amino acid sequence when the amino acid sequence is at least part of the final amino acid sequence of the protein. In such a fashion, the protein can be only the peptide or have additional amino acid molecules, such as amino acid residues (contiguous encoded sequence) that are naturally associated with it or heterologous amino acid residues/peptide sequences. Such a protein can have a few additional amino acid residues or can comprise several hundred or more additional amino acids. The preferred classes of proteins that are comprised of the transporter peptides of the present invention are the naturally occurring mature proteins. A brief description of how various types of these proteins can be made/isolated is provided below.
[0078] The transporter peptides of the present invention can be attached to heterologous sequences to form chimeric or fusion proteins. Such chimeric and fusion proteins comprise a transporter peptide operatively linked to a heterologous protein having an amino acid sequence not substantially homologous to the transporter peptide. “Operatively linked” indicates that the transporter peptide and the heterologous protein are fused in-frame. The heterologous protein can be fused to the N-terminus or C-terminus of the transporter peptide.
[0079] In some uses, the fusion protein does not affect the activity of the transporter peptide per se. For example, the fusion protein can include, but is not limited to, enzymatic fusion proteins, for example beta-galactosidase fusions, yeast two-hybrid GAL fusions, poly-His fusions, MYC-tagged, HI-tagged and Ig fusions. Such fusion proteins, particularly poly-His fusions, can facilitate the purification of recombinant transporter peptide. In certain host cells (e.g., mammalian host cells), expression and/or secretion of a protein can be increased by using a heterologous signal sequence.
[0080] A chimeric or fusion protein can be produced by standard recombinant DNA techniques. For example, DNA fragments coding for the different protein sequences are ligated together in-frame in accordance with conventional techniques. In another embodiment, the fusion gene can be synthesized by conventional techniques including automated DNA synthesizers. Alternatively, PCR amplification of gene fragments can be carried out using anchor primers which give rise to complementary overhangs between two consecutive gene fragments which can subsequently be annealed and re-amplified to generate a chimeric gene sequence (see Ausubel et al, Current Protocols in Molecular Biology, 1992). Moreover, many expression vectors are commercially available that already encode a fusion moiety (e.g., a GST protein). A transporter peptide-encoding nucleic acid can be cloned into such an expression vector such that the fusion moiety is linked in-frame to the transporter peptide.
[0081] As mentioned above, the present invention also provides and enables obvious variants of the amino acid sequence of the proteins of the present invention, such as naturally occurring mature forms of the peptide, allelic/sequence variants of the peptides, non-naturally occurring recombinantly derived variants of the peptides, and orthologs and paralogs of the peptides. Such variants can readily be generated using art-known techniques in the fields of recombinant nucleic acid technology and protein biochemistry. It is understood, however, that variants exclude any amino acid sequences disclosed prior to the invention.
[0082] Such variants can readily be identified/made using molecular techniques and the sequence information disclosed herein. Further, such variants can readily be distinguished from other peptides based on sequence and/or structural homology to the transporter peptides of the present invention. The degree of homology/identity present will be based primarily on whether the peptide is a functional variant or non-functional variant, the amount of divergence present in the paralog family and the evolutionary distance between the orthologs.
[0083] To determine the percent identity of two amino acid sequences or two nucleic acid sequences, the sequences are aligned for optimal comparison purposes (e.g., gaps can be introduced in one or both of a first and a second amino acid or nucleic acid sequence for optimal alignment and non-homologous sequences can be disregarded for comparison purposes). In a preferred embodiment, at least 30%, 40%, 50%, 60%, 70%, 80%, or 90% or more of a reference sequence is aligned for comparison purposes. The amino acid residues or nucleotides at corresponding amino acid positions or nucleotide positions are then compared. When a position in the first sequence is occupied by the same amino acid residue or nucleotide as the corresponding position in the second sequence, then the molecules are identical at that position (as used herein amino acid or nucleic acid “identity” is equivalent to amino acid or nucleic acid “homology”). The percent identity between the two sequences is a function of the number of identical positions shared by the sequences, taking into account the number of gaps, and the length of each gap, which need to be introduced for optimal alignment of the two sequences.
[0084] The comparison of sequences and determination of percent identity and similarity between two sequences can be accomplished using a mathematical algorithm. ( Computational Molecular Biology , Lesk, A. M., ed., Oxford University Press, New York, 1988; Biocomputing: Informatics and Genome Projects , Smith, D. W., ed., Academic Press, New York, 1993; Computer Analysis of Sequence Data, Part 1, Griffin, A. M., and Griffin, H. G., eds., Humana Press, New Jersey, 1994; Sequence Analysis in Molecular Biology , von Heinje, G., Academic Press, 1987; and Sequence Analysis Primer , Gribskov, M. and Devereux, J., eds., M Stockton Press, New York, 1991). In a preferred embodiment, the percent identity between two amino acid sequences is determined using the Needleman and Wunsch ( J. Mol. Biol. ( 48):444-453 (1970)) algorithm which has been incorporated into the GAP program in the GCG software package (available at http://www.gcg.com), using either a Blossom 62 matrix or a PAM250 matrix, and a gap weight of 16, 14, 12, 10, 8, 6, or 4 and a length weight of 1, 2, 3, 4, 5, or 6. In yet another preferred embodiment, the percent identity between two nucleotide sequences is determined using the GAP program in the GCG software package (Devereux, J., et al., Nucleic Acids Res. 12(1):387 (1984)) (available at http://www.gcg.com), using a NWSgapdna.CMP matrix and a gap weight of 40, 50, 60, 70, or 80 and a length weight of 1, 2, 3, 4, 5, or 6. In another embodiment, the percent identity between two amino acid or nucleotide sequences is determined using the algorithm of E. Myers and W. Miller (CABIOS, 4:11-17 (1989)) which has been incorporated into the ALIGN program (version 2.0), using a PAM120 weight residue table, a gap length penalty of 12 and a gap penalty of 4.
[0085] The nucleic acid and protein sequences of the present invention can further be used as a “query sequence” to perform a search against sequence databases to, for example, identify other family members or related sequences. Such searches can be performed using the NBLAST and XBLAST programs (version 2.0) of Altschul, et al. ( J. Mol. Biol. 215:403-10 (1990)). BLAST nucleotide searches can be performed with the NBLAST program, score=100, wordlength=12 to obtain nucleotide sequences homologous to the nucleic acid molecules of the invention. BLAST protein searches can be performed with the XBLAST program, score=50, wordlength=3 to obtain amino acid sequences homologous to the proteins of the invention. To obtain gapped alignments for comparison purposes, Gapped BLAST can be utilized as described in Altschul et al. ( Nucleic Acids Res. 25(17):3389-3402 (1997)). When utilizing BLAST and gapped BLAST programs, the default parameters of the respective programs (e.g., XBLAST and NBLAST) can be used.
[0086] Full-length pre-processed forms, as well as mature processed forms, of proteins that comprise one of the peptides of the present invention can readily be identified as having complete sequence identity to one of the transporter peptides of the present invention as well as being encoded by the same genetic locus as the transporter peptide provided herein.
[0087] Allelic variants of a transporter peptide can readily be identified as being a human protein having a high degree (significant) of sequence homology/identity to at least a portion of the transporter peptide as well as being encoded by the same genetic locus as the transporter peptide provided herein. Genetic locus can readily be determined based on the genomic information provided in FIG. 3, such as the genomic sequence mapped to the reference human. As used herein, two proteins (or a region of the proteins) have significant homology when the amino acid sequences are typically at least about 70-80%, 80-90%, and more typically at least about 90-95% or more homologous. A significantly homologous amino acid sequence, according to the present invention, will be encoded by a nucleic acid sequence that will hybridize to a transporter peptide encoding nucleic acid molecule under stringent conditions as more fully described below.
[0088] [0088]FIG. 3 provides information on SNPs that have been found in the gene encoding the transporter protein of the present invention. SNPs were identified at 26 different nucleotide positions. These SNPs may affect control/regulatory elements.
[0089] Paralogs of a transporter peptide can readily be identified as having some degree of significant sequence homology/identity to at least a portion of the transporter peptide, as being encoded by a gene from humans, and as having similar activity or function. Two proteins will typically be considered paralogs when the amino acid sequences are typically at least about 60% or greater, and more typically at least about 70% or greater homology through a given region or domain. Such paralogs will be encoded by a nucleic acid sequence that will hybridize to a transporter peptide encoding nucleic acid molecule under moderate to stringent conditions as more fully described below.
[0090] Orthologs of a transporter peptide can readily be identified as having some degree of significant sequence homology/identity to at least a portion of the transporter peptide as well as being encoded by a gene from another organism. Preferred orthologs will be isolated from mammals, preferably primates, for the development of human therapeutic targets and agents. Such orthologs will be encoded by a nucleic acid sequence that will hybridize to a transporter peptide encoding nucleic acid molecule under moderate to stringent conditions, as more fully described below, depending on the degree of relatedness of the two organisms yielding the proteins.
[0091] Non-naturally occurring variants of the transporter peptides of the present invention can readily be generated using recombinant techniques. Such variants include, but are not limited to deletions, additions and substitutions in the amino acid sequence of the transporter peptide. For example, one class of substitutions are conserved amino acid substitution. Such substitutions are those that substitute a given amino acid in a transporter peptide by another amino acid of like characteristics. Typically seen as conservative substitutions are the replacements, one for another, among the aliphatic amino acids Ala, Val, Leu, and Ile; interchange of the hydroxyl residues Ser and Thr; exchange of the acidic residues Asp and Glu; substitution between the amide residues Asn and Gln; exchange of the basic residues Lys and Arg; and replacements among the aromatic residues Phe and Tyr. Guidance concerning which amino acid changes are likely to be phenotypically silent are found in Bowie et al., Science 247:1306-1310 (1990).
[0092] Variant transporter peptides can be fully functional or can lack function in one or more activities, e.g. ability to bind ligand, ability to transport ligand, ability to mediate signaling, etc. Fully functional variants typically contain only conservative variation or variation in non-critical residues or in non-critical regions. FIG. 2 provides the result of protein analysis and can be used to identify critical domains/regions. Functional variants can also contain substitution of similar amino acids that result in no change or an insignificant change in function. Alternatively, such substitutions may positively or negatively affect function to some degree.
[0093] Non-functional variants typically contain one or more non-conservative amino acid substitutions, deletions, insertions, inversions, or truncation or a substitution, insertion, inversion, or deletion in a critical residue or critical region.
[0094] Amino acids that are essential for function can be identified by methods known in the art, such as site-directed mutagenesis or alanine-scanning mutagenesis (Cunningham et al, Science 244:1081-1085 (1989)), particularly using the results provided in FIG. 2. The latter procedure introduces single alanine mutations at every residue in the molecule. The resulting mutant molecules are then tested for biological activity such as transporter activity or in assays such as an in vitro proliferative activity. Sites that are critical for binding partner/substrate binding can also be determined by structural analysis such as crystallization, nuclear magnetic resonance or photoaffinity labeling (Smith et al., J. Mol. Biol. 224:899-904 (1992); de Vos et al Science 255:306-312 (1992)).
[0095] The present invention further provides fragments of the transporter peptides, in addition to proteins and peptides that comprise and consist of such fragments, particularly those comprising the residues identified in FIG. 2. The fragments to which the invention pertains, however, are not to be construed as encompassing fragments that may be disclosed publicly prior to the present invention.
[0096] As used herein, a fragment comprises at least 8, 10, 12, 14, 16, or more contiguous amino acid residues from a transporter peptide. Such fragments can be chosen based on the ability to retain one or more of the biological activities of the transporter peptide or could be chosen for the ability to perform a function, e.g. bind a substrate or act as an immunogen. Particularly important fragments are biologically active fragments, peptides that are, for example, about 8 or more amino acids in length. Such fragments will typically comprise a domain or motif of the transporter peptide, e.g., active site, a transmembrane domain or a substrate-binding domain. Further, possible fragments include, but are not limited to, domain or motif containing fragments, soluble peptide fragments, and fragments containing immunogenic structures. Predicted domains and functional sites are readily identifiable by computer programs well known and readily available to those of skill in the art (e.g., PROSITE analysis). The results of one such analysis are provided in FIG. 2.
[0097] Polypeptides often contain amino acids other than the 20 amino acids commonly referred to as the 20 naturally occurring amino acids. Further, many amino acids, including the terminal amino acids, may be modified by natural processes, such as processing and other post-translational modifications, or by chemical modification techniques well known in the art. Common modifications that occur naturally in transporter peptides are described in basic texts, detailed monographs, and the research literature, and they are well known to those of skill in the art (some of these features are identified in FIG. 2).
[0098] Known modifications include, but are not limited to, acetylation, acylation, ADP-ribosylation, amidation, covalent attachment of fiavin, covalent attachment of a heme moiety, covalent attachment of a nucleotide or nucleotide derivative, covalent attachment of a lipid or lipid derivative, covalent attachment of phosphotidylinositol, cross-linking, cyclization, disulfide bond formation, demethylation, formation of covalent crosslinks, formation of cystine, formation of pyroglutamate, formylation, gamma carboxylation, glycosylation, GPI anchor formation, hydroxylation, iodination, methylation, myristoylation, oxidation, proteolytic processing, phosphorylation, prenylation, racemization, selenoylation, sulfation, transfer-RNA mediated addition of amino acids to proteins such as arginylation, and ubiquitination.
[0099] Such modifications are well known to those of skill in the art and have been described in great detail in the scientific literature. Several particularly common modifications, glycosylation, lipid attachment, sulfation, gamma-carboxylation of glutamic acid residues, hydroxylation and ADP-ribosylation, for instance, are described in most basic texts, such as Proteins—Structure and Molecular Properties, 2nd Ed., T. E. Creighton, W. H. Freeman and Company, New York (1993). Many detailed reviews are available on this subject, such as by Wold, F., Posttranslational Covalent Modification of Proteins , B. C. Johnson, Ed., Academic Press, New York 1-12 (1983); Seifter et al. ( Meth. Enzymol. 182: 626-646 (1990)) and Rattan et al. ( Ann. N.Y. Acad Sci. 663:48-62 (1992)).
[0100] Accordingly, the transporter peptides of the present invention also encompass derivatives or analogs in which a substituted amino acid residue is not one encoded by the genetic code, in which a substituent group is included, in which the mature transporter peptide is fused with another compound, such as a compound to increase the half-life of the transporter peptide (for example, polyethylene glycol), or in which the additional amino acids are fused to the mature transporter peptide, such as a leader or secretory sequence or a sequence for purification of the mature transporter peptide or a pro-protein sequence.
[0101] Protein/Peptide Uses
[0102] The proteins of the present invention can be used in substantial and specific assays related to the functional information provided in the Figures; to raise antibodies or to elicit another immune response; as a reagent (including the labeled reagent) in assays designed to quantitatively determine levels of the protein (or its binding partner or ligand) in biological fluids; and as markers for tissues in which the corresponding protein is preferentially expressed (either constitutively or at a particular stage of tissue differentiation or development or in a disease state). Where the protein binds or potentially binds to another protein or ligand (such as, for example, in a transporter-effector protein interaction or transporter-ligand interaction), the protein can be used to identify the binding partner/ligand so as to develop a system to identify inhibitors of the binding interaction. Any or all of these uses are capable of being developed into reagent grade or kit format for commercialization as commercial products.
[0103] Methods for performing the uses listed above are well known to those skilled in the art. References disclosing such methods include “Molecular Cloning: A Laboratory Manual”, 2d ed., Cold Spring Harbor Laboratory Press, Sambrook, J., E. F. Fritsch and T. Maniatis eds., 1989, and “Methods in Enzymology: Guide to Molecular Cloning Techniques”, Academic Press, Berger, S. L. and A. R. Kimmel eds., 1987.
[0104] The potential uses of the peptides of the present invention are based primarily on the source of the protein as well as the class/action of the protein. For example, transporters isolated from humans and their human/mammalian orthologs serve as targets for identifying agents for use in mammalian therapeutic applications, e.g. a human drug, particularly in modulating a biological or pathological response in a cell or tissue that expresses the transporter. Experimental data as provided in FIG. 1 indicates that the transporter proteins of the present invention are expressed in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma, as indicated by virtual northern blot analysis. A large percentage of pharmaceutical agents are being developed that modulate the activity of transporter proteins, particularly members of the phosphate translocator subfamily (see Background of the Invention). The structural and functional information provided in the Background and Figures provide specific and substantial uses for the molecules of the present invention, particularly in combination with the expression information provided in FIG. 1. Experimental data as provided in FIG. 1 indicates expression in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma. Such uses can readily be determined using the information provided herein, that known in the art and routine experimentation.
[0105] The proteins of the present invention (including variants and fragments that may have been disclosed prior to the present invention) are useful for biological assays related to transporters that are related to members of the phosphate translocator subfamily. Such assays involve any of the known transporter functions or activities or properties useful for diagnosis and treatment of transporter-related conditions that are specific for the subfamily of transporters that the one of the present invention belongs to, particularly in cells and tissues that express the transporter. Experimental data as provided in FIG. 1 indicates that the transporter proteins of the present invention are expressed in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma, as indicated by virtual northern blot analysis. The proteins of the present invention are also useful in drug screening assays, in cell-based or cell-free systems ((Hodgson, Bio/technology, Sep. 10, 1992(9);973-80). Cell-based systems can be native, i.e., cells that normally express the transporter, as a biopsy or expanded in cell culture. Experimental data as provided in FIG. 1 indicates expression in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma. In an alternate embodiment, cell-based assays involve recombinant host cells expressing the transporter protein.
[0106] The polypeptides can be used to identify compounds that modulate transporter activity of the protein in its natural state or an altered form that causes a specific disease or pathology associated with the transporter. Both the transporters of the present invention and appropriate variants and fragments can be used in high-throughput screens to assay candidate compounds for the ability to bind to the transporter. These compounds can be further screened against a functional transporter to determine the effect of the compound on the transporter activity. Further, these compounds can be tested in animal or invertebrate systems to determine activity/effectiveness. Compounds can be identified that activate (agonist) or inactivate (antagonist) the transporter to a desired degree.
[0107] Further, the proteins of the present invention can be used to screen a compound for the ability to stimulate or inhibit interaction between the transporter protein and a molecule that normally interacts with the transporter protein, e.g. a substrate or a component of the signal pathway that the transporter protein normally interacts (for example, another transporter). Such assays typically include the steps of combining the transporter protein with a candidate compound under conditions that allow the transporter protein, or fragment, to interact with the target molecule, and to detect the formation of a complex between the protein and the target or to detect the biochemical consequence of the interaction with the transporter protein and the target, such as any of the associated effects of signal transduction such as changes in membrane potential, protein phosphorylation, cAMP turnover, and adenylate cyclase activation, etc.
[0108] Candidate compounds include, for example, 1) peptides such as soluble peptides, including Ig-tailed fusion peptides and members of random peptide libraries (see, e.g., Lam et al., Nature 354:82-84 (1991); Houghten et al., Nature 354:84-86 (1991)) and combinatorial chemistry-derived molecular libraries made of D- and/or L-configuration amino acids; 2) phosphopeptides (e.g., members of random and partially degenerate, directed phosphopeptide libraries, see, e.g., Songyang et al., Cell 72:767-778 (1993)); 3) antibodies (e.g., polyclonal, monoclonal, humanized, anti-idiotypic, chimeric, and single chain antibodies as well as Fab, F(ab′)2, Fab expression library fragments, and epitope-binding fragments of antibodies); and 4) small organic and inorganic molecules (e.g., molecules obtained from combinatorial and natural product libraries).
[0109] One candidate compound is a soluble fragment of the receptor that competes for ligand binding. Other candidate compounds include mutant transporters or appropriate fragments containing mutations that affect taansporter function and thus compete for ligand. Accordingly, a fragment that competes for ligand, for example with a higher affinity, or a fragment that binds ligand but does not allow release, is encompassed by the invention.
[0110] The invention further includes other end point assays to identify compounds that modulate (stimulate or inhibit) transporter activity. The assays typically involve an assay of events in the signal transduction pathway that indicate transporter activity. Thus, the transport of a ligand, change in cell membrane potential, activation of a protein, a change in the expression of genes that are up- or down-regulated in response to the transporter protein dependent signal cascade can be assayed.
[0111] Any of the biological or biochemical functions mediated by the transporter can be used as an endpoint assay. These include all of the biochemical or biochemical/biological events described herein, in the references cited herein, incorporated by reference for these endpoint assay targets, and other functions known to those of ordinary skill in the art or that can be readily identified using the information provided in the Figures, particularly FIG. 2. Specifically, a biological function of a cell or tissues that expresses the transporter can be assayed. Experimental data as provided in FIG. 1 indicates that the transporter proteins of the present invention are expressed in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma, as indicated by virtual northern blot analysis.
[0112] Binding and/or activating compounds can also be screened by using chimeric transporter proteins in which the amino terminal extracellular domain, or parts thereof, the entire transmembrane domain or subregions, such as any of the seven transmembrane segments or any of the intracellular or extracellular loops and the carboxy terminal intracellular domain, or parts thereof, can be replaced by heterologous domains or subregions. For example, a ligand-binding region can be used that interacts with a different ligand then that which is recognized by the native transporter. Accordingly, a different set of signal transduction components is available as an end-point assay for activation. This allows for assays to be performed in other than the specific host cell from which the transporter is derived.
[0113] The proteins of the present invention are also useful in competition binding assays in methods designed to discover compounds that interact with the transporter (e.g. binding partners and/or ligands). Thus, a compound is exposed to a transporter polypeptide under conditions that allow the compound to bind or to otherwise interact with the polypeptide. Soluble transporter polypeptide is also added to the mixture. If the test compound interacts with the soluble transporter polypeptide, it decreases the amount of complex formed or activity from the transporter target. This type of assay is particularly useful in cases in which compounds are sought that interact with specific regions of the transporter. Thus, the soluble polypeptide that competes with the target transporter region is designed to contain peptide sequences corresponding to the region of interest.
[0114] To perform cell free drug screening assays, it is sometimes desirable to immobilize either the transporter protein, or fragment, or its target molecule to facilitate separation of complexes from uncomplexed forms of one or both of the proteins, as well as to accommodate automation of the assay.
[0115] Techniques for immobilizing proteins on matrices can be used in the drug screening assays. In one embodiment, a fusion protein can be provided which adds a domain that allows the protein to be bound to a matrix. For example, glutathione-S-transferase fusion proteins can be adsorbed onto glutathione sepharose beads (Sigma Chemical, St. Louis, Mo.) or glutathione derivatized microtitre plates, which are then combined with the cell lysates (e.g., 35 S-labeled) and the candidate compound, and the mixture incubated under conditions conducive to complex formation (e.g., at physiological conditions for salt and pH). Following incubation, the beads are washed to remove any unbound label, and the matrix immobilized and radiolabel determined directly, or in the supernatant after the complexes are dissociated. Alternatively, the complexes can be dissociated from the matrix, separated by SDS-PAGE, and the level of transporter-binding protein found in the bead fraction quantitated from the gel using standard electrophoretic techniques. For example, either the polypeptide or its target molecule can be immobilized utilizing conjugation of biotin and streptavidin using techniques well known in the art. Alternatively, antibodies reactive with the protein but which do not interfere with binding of the protein to its target molecule can be derivatized to the wells of the plate, and the protein trapped in the wells by antibody conjugation. Preparations of a transporter-binding protein and a candidate compound are incubated in the transporter protein-presenting wells and the amount of complex trapped in the well can be quantitated. Methods for detecting such complexes, in addition to those described above for the GST-immobilized complexes, include immunodetection of complexes using antibodies reactive with the transporter protein target molecule, or which are reactive with transporter protein and compete with the target molecule, as well as enzyme-linked assays which rely on detecting an enzymatic activity associated with the target molecule.
[0116] Agents that modulate one of the transporters of the present invention can be identified using one or more of the above assays, alone or in combination. It is generally preferable to use a cell-based or cell free system first and then confirm activity in an animal or other model system. Such model systems are well known in the art and can readily be employed in this context.
[0117] Modulators of transporter protein activity identified according to these drug screening assays can be used to treat a subject with a disorder mediated by the transporter pathway, by treating cells or tissues that express the transporter. Experimental data as provided in FIG. 1 indicates expression in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma. These methods of treatment include the steps of administering a modulator of transporter activity in a pharmaceutical composition to a subject in need of such treatment, the modulator being identified as described herein.
[0118] In yet another aspect of the invention, the transporter proteins can be used as “bait proteins” in a two-hybrid assay or three-hybrid assay (see, e.g., U.S. Pat. No. 5,283,317; Zervos et al. (1993) Cell 72:223-232; Madura et al. (1993) J. Biol. Chem. 268:12046-12054; Bartel et al. (1993) Biotechniques 14:920-924; Iwabuchi et al. (1993) Oncogene 8:1693-1696; and Brent W094/10300), to identify other proteins, which bind to or interact with the transporter and are involved in transporter activity. Such transporter-binding proteins are also likely to be involved in the propagation of signals by the transporter proteins or transporter targets as, for example, downstream elements of a transporter-mediated signaling pathway. Alternatively, such transporter-binding proteins are likely to be transporter inhibitors.
[0119] The two-hybrid system is based on the modular nature of most transcription factors, which consist of separable DNA-binding and activation domains. Briefly, the assay utilizes two different DNA constructs. In one construct, the gene that codes for a transporter protein is fused to a gene encoding the DNA binding domain of a known transcription factor (e.g., GAL-4). In the other construct, a DNA sequence, from a library of DNA sequences, that encodes an unidentified protein (“prey” or “sample”) is fused to a gene that codes for the activation domain of the known transcription factor. If the “bait” and the “prey” proteins are able to interact, in vivo, forming a transporter-dependent complex, the DNA-binding and activation domains of the transcription factor are brought into close proximity. This proximity allows transcription of a reporter gene (e.g., LacZ) which is operably linked to a transcriptional regulatory site responsive to the transcription factor. Expression of the reporter gene can be detected and cell colonies containing the functional transcription factor can be isolated and used to obtain the cloned gene which encodes the protein which interacts with the transporter protein.
[0120] This invention further pertains to novel agents identified by the above-described screening assays. Accordingly, it is within the scope of this invention to further use an agent identified as described herein in an appropriate animal model. For example, an agent identified as described herein (e.g., a transporter-modulating agent, an antisense transporter nucleic acid molecule, a transporter-specific antibody, or a transporter-binding partner) can be used in an animal or other model to determine the efficacy, toxicity, or side effects of treatment with such an agent. Alternatively, an agent identified as described herein can be used in an animal or other model to determine the mechanism of action of such an agent. Furthermore, this invention pertains to uses of novel agents identified by the above-described screening assays for treatments as described herein.
[0121] The transporter proteins of the present invention are also useful to provide a target for diagnosing a disease or predisposition to disease mediated by the peptide. Accordingly, the invention provides methods for detecting the presence, or levels of, the protein (or encoding mRNA) in a cell, tissue, or organism. Experimental data as provided in FIG. 1 indicates expression in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma. The method involves contacting a biological sample with a compound capable of interacting with the transporter protein such that the interaction can be detected. Such an assay can be provided in a single detection format or a multi-detection format such as an antibody chip array.
[0122] One agent for detecting a protein in a sample is an antibody capable of selectively binding to protein. A biological sample includes tissues, cells and biological fluids isolated from a subject, as well as tissues, cells and fluids present within a subject.
[0123] The peptides of the present invention also provide targets for diagnosing active protein activity, disease, or predisposition to disease, in a patient having a variant peptide, particularly activities and conditions that are known for other members of the family of proteins to which the present one belongs. Thus, the peptide can be isolated from a biological sample and assayed for the presence of a genetic mutation that results in aberrant peptide. This includes amino acid substitution, deletion, insertion, rearrangement, (as the result of aberrant splicing events), and inappropriate post-translational modification. Analytic methods include altered electrophoretic mobility, altered tryptic peptide digest, altered transporter activity in cell-based or cell-free assay, alteration in ligand or antibody-binding pattern, altered isoelectric point, direct amino acid sequencing, and any other of the known assay techniques useful for detecting mutations in a protein. Such an assay can be provided in a single detection format or a multi-detection format such as an antibody chip array.
[0124] In vitro techniques for detection of peptide include enzyme linked immunosorbent assays (ELISAs), Western blots, imrnmunoprecipitations and immunofluorescence using a detection reagent, such as an antibody or protein binding agent. Alternatively, the peptide can be detected in vivo in a subject by introducing into the subject a labeled anti-peptide antibody or other types of detection agent. For example, the antibody can be labeled with a radioactive marker whose presence and location in a subject can be detected by standard imaging techniques. Particularly useful are methods that detect the allelic variant of a peptide expressed in a subject and methods which detect fragments of a peptide in a sample.
[0125] The peptides are also useful in pharmacogenomic analysis. Pharmacogenomics deal with clinically significant hereditary variations in the response to drugs due to altered drug disposition and abnormal action in affected persons. See, e.g., Eichelbaum, M. ( Clin. Exp. Pharmacol. Physiol 23(10-11):983-985 (1996)), and Linder, M. W. ( Clin Chem. 43(2):254-266 (1997)). The clinical outcomes of these variations result in severe toxicity of therapeutic drugs in certain individuals or therapeutic failure of drugs in certain individuals as a result of individual variation in metabolism. Thus, the genotype of the individual can determine the way a therapeutic compound acts on the body or the way the body metabolizes the compound. Further, the activity of drug metabolizing enzymes effects both the intensity and duration of drug action. Thus, the pharmacogenomics of the individual permit the selection of effective compounds and effective dosages of such compounds for prophylactic or therapeutic treatment based on the individual's genotype. The discovery of genetic polymorphisms in some drug metabolizing enzymes has explained why some patients do not obtain the expected drug effects, show an exaggerated drug effect, or experience serious toxicity from standard drug dosages. Polymorphisms can be expressed in the phenotype of the extensive metabolizer and the phenotype of the poor metabolizer. Accordingly, genetic polymorphism may lead to allelic protein variants of the transporter protein in which one or more of the transporter functions in one population is different from those in another population. The peptides thus allow a target to ascertain a genetic predisposition that can affect treatment modality. Thus, in a ligand-based treatment, polymorphism may give rise to amino terminal extracellular domains and/or other ligand-binding regions that are more or less active in ligand binding, and transporter activation. Accordingly, ligand dosage would necessarily be modified to maximize the therapeutic effect within a given population containing a polymorphism. As an alternative to genotyping, specific polymorphic peptides could be identified.
[0126] The peptides are also useful for treating a disorder characterized by an absence of, inappropriate, or unwanted expression of the protein. Experimental data as provided in FIG. 1 indicates expression in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma Accordingly, methods for treatment include the use of the transporter protein or fragments.
[0127] Antibodies
[0128] The invention also provides antibodies that selectively bind to one of the peptides of the present invention, a protein comprising such a peptide, as well as variants and fragments thereof. As used herein, an antibody selectively binds a target peptide when it binds the target peptide and does not significantly bind to unrelated proteins. An antibody is still considered to selectively bind a peptide even if it also binds to other proteins that are not substantially homologous with the target peptide so long as such proteins share homology with a fragment or domain of the peptide target of the antibody. In this case, it would be understood that antibody binding to the peptide is still selective despite some degree of cross-reactivity.
[0129] As used herein, an antibody is defined in terms consistent with that recognized within the art: they are multi-subunit proteins produced by a mammalian organism in response to an antigen challenge. The antibodies of the present invention include polyclonal antibodies and monoclonal antibodies, as well as fragments of such antibodies, including, but not limited to, Fab or F(ab′)2, and Fv fragments.
[0130] Many methods are known for generating and/or identifying antibodies to a given target peptide. Several such methods are described by Harlow, Antibodies, Cold Spring Harbor Press, (1989).
[0131] In general, to generate antibodies, an isolated peptide is used as an immunogen and is administered to a mammalian organism, such as a rat, rabbit or mouse. The full-length protein, an antigenic peptide fragment or a fusion protein can be used. Particularly important fragments are those covering functional domains, such as the domains identified in FIG. 2, and domain of sequence homology or divergence amongst the family, such as those that can readily be identified using protein alignment methods and as presented in the Figures.
[0132] Antibodies are preferably prepared from regions or discrete fragments of the transporter proteins. Antibodies can be prepared from any region of the peptide as described herein. However, preferred regions will include those involved in function/activity and/or transporter/binding partner interaction. FIG. 2 can be used to identify particularly important regions while sequence alignment can be used to identify conserved and unique sequence fragments.
[0133] An antigenic fragment will typically comprise at least 8 contiguous amino acid residues. The antigenic peptide can comprise, however, at least 10, 12, 14, 16 or more amino acid residues. Such fragments can be selected on a physical property, such as fragments correspond to regions that are located on the surface of the protein, e.g., hydrophilic regions or can be selected based on sequence uniqueness (see FIG. 2).
[0134] Detection on an antibody of the present invention can be facilitated by coupling (i.e., physically linking) the antibody to a detectable substance. Examples of detectable substances include various enzymes, prosthetic groups, fluorescent materials, luminescent materials, bioluminescent materials, and radioactive materials. Examples of suitable enzymes include horseradish peroxidase, alkaline phosphatase, 0-galactosidase, or acetylcholinesterase; examples of suitable prosthetic group complexes include streptavidin/biotin and avidin/biotin; examples of suitable fluorescent materials include umbelliferone, fluorescein, fluorescein isothiocyanate, rhodamine, dichlorotriazinylamine fluorescein, dansyl chloride or phycoerythrin; an example of a luminescent material includes luminol; examples of bioluminescent materials include luciferase, luciferin, and aequorin, and examples of suitable radioactive material include 125 I, 131 I, 35 S or 3 H.
[0135] Antibody Uses
[0136] The antibodies can be used to isolate one of the proteins of the present invention by standard techniques, such as affinity chromatography or immunoprecipitation. The antibodies can facilitate the purification of the natural protein from cells and recombinantly produced protein expressed in host cells. In addition, such antibodies are useful to detect the presence of one of the proteins of the present invention in cells or tissues to determine the pattern of expression of the protein among various tissues in an organism and over the course of normal development. Experimental data as provided in FIG. 1 indicates that the transporter proteins of the present invention are expressed in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma, as indicated by virtual northern blot analysis. Further, such antibodies can be used to detect protein in situ, in vitro, or in a cell lysate or supernatant in order to evaluate the abundance and pattern of expression. Also, such antibodies can be used to assess abnormal tissue distribution or abnormal expression during development or progression of a biological condition. Antibody detection of circulating fragments of the full length protein can be used to identify turnover.
[0137] Further, the antibodies can be used to assess expression in disease states such as in active stages of the disease or in an individual with a predisposition toward disease related to the protein's function. When a disorder is caused by an inappropriate tissue distribution, developmental expression, level of expression of the protein, or expressed/processed form, the antibody can be prepared against the normal protein. Experimental data as provided in FIG. 1 indicates expression in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma. If a disorder is characterized by a specific mutation in the protein, antibodies specific for this mutant protein can be used to assay for the presence of the specific mutant protein.
[0138] The antibodies can also be used to assess normal and aberrant subcellular localization of cells in the various tissues in an organism. Experimental data as provided in FIG. 1 indicates expression in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma. The diagnostic uses can be applied, not only in genetic testing, but also in monitoring a treatment modality. Accordingly, where treatment is ultimately aimed at correcting expression level or the presence of aberrant sequence and aberrant tissue distribution or developmental expression, antibodies directed against the protein or relevant fragments can be used to monitor therapeutic efficacy.
[0139] Additionally, antibodies are useful in pharmacogenomic analysis. Thus, antibodies prepared against polymorphic proteins can be used to identify individuals that require modified treatment modalities. The antibodies are also useful as diagnostic tools as an immunological marker for aberrant protein analyzed by electrophoretic mobility, isoelectric point, tryptic peptide digest, and other physical assays known to those in the art.
[0140] The antibodies are also useful for tissue typing. Experimental data as provided in FIG. 1 indicates expression in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma. Thus, where a specific protein has been correlated with expression in a specific tissue, antibodies that are specific for this protein can be used to identify a tissue type.
[0141] The antibodies are also useful for inhibiting protein function, for example, blocking the binding of the transporter peptide to a binding partner such as a ligand or protein binding partner. These uses can also be applied in a therapeutic context in which treatment involves inhibiting the protein's function. An antibody can be used, for example, to block binding, thus modulating (agonizing or antagonizing) the peptides activity. Antibodies can be prepared against specific fragments containing sites required for function or against intact protein that is associated with a cell or cell membrane. See FIG. 2 for structural information relating to the proteins of the present invention.
[0142] The invention also encompasses kits for using antibodies to detect the presence of a protein in a biological sample. The kit can comprise antibodies such as a labeled or labelable antibody and a compound or agent for detecting protein in a biological sample; means for determining the amount of protein in the sample; means for comparing the amount of protein in the sample with a standard; and instructions for use. Such a kit can be supplied to detect a single protein or epitope or can be configured to detect one of a multitude of epitopes, such as in an antibody detection array. Arrays are described in detail below for nucleic acid arrays and similar methods have been developed for antibody arrays.
[0143] Nucleic Acid Molecules
[0144] The present invention further provides isolated nucleic acid molecules that encode a transporter peptide or protein of the present invention (cDNA, transcript and genomic sequence). Such nucleic acid molecules will consist of, consist essentially of, or comprise a nucleotide sequence that encodes one of the transporter peptides of the present invention, an allelic variant thereof, or an ortholog or paralog thereof.
[0145] As used herein, an “isolated” nucleic acid molecule is one that is separated from other nucleic acid present in the natural source of the nucleic acid. Preferably, an “isolated” nucleic acid is free of sequences that naturally flank the nucleic acid (i.e., sequences located at the 5′ and 3′ ends of the nucleic acid) in the genomic DNA of the organism from which the nucleic acid is derived. However, there can be some flanking nucleotide sequences, for example up to about 5 KB, 4 KB, 3 KB, 2 KB, or 1 KB or less, particularly contiguous peptide encoding sequences and peptide encoding sequences within the same gene but separated by introns in the genomic sequence. The important point is that the nucleic acid is isolated from remote and unimportant flanking sequences such that it can be subjected to the specific manipulations described herein such as recombinant expression, preparation of probes and primers, and other uses specific to the nucleic acid sequences.
[0146] Moreover, an “isolated” nucleic acid molecule, such as a transcript/cDNA molecule, can be substantially free of other cellular material, or culture medium when produced by recombinant techniques, or chemical precursors or other chemicals when chemically synthesized. However, the nucleic acid molecule can be fused to other coding or regulatory sequences and still be considered isolated.
[0147] For example, recombinant DNA molecules contained in a vector are considered isolated. Further examples of isolated DNA molecules include recombinant DNA molecules maintained in heterologous host cells or purified (partially or substantially) DNA molecules in solution. Isolated RNA molecules include in vivo or in vitro RNA transcripts of the isolated DNA molecules of the present invention. Isolated nucleic acid molecules according to the present invention further include such molecules produced synthetically.
[0148] Accordingly, the present invention provides nucleic acid molecules that consist of the nucleotide sequence shown in FIG. 1 or 3 (SEQ ID NO:1, transcript sequence and SEQ ID NO:3, genomic sequence), or any nucleic acid molecule that encodes the protein provided in FIG. 2, SEQ ID NO:2. A nucleic acid molecule consists of a nucleotide sequence when the nucleotide sequence is the complete nucleotide sequence of the nucleic acid molecule.
[0149] The present invention further provides nucleic acid molecules that consist essentially of the nucleotide sequence shown in FIG. 1 or 3 (SEQ ID NO:1, transcript sequence and SEQ ID NO:3, genomic sequence), or any nucleic acid molecule that encodes the protein provided in FIG. 2, SEQ ID NO:2. A nucleic acid molecule consists essentially of a nucleotide sequence when such a nucleotide sequence is present with only a few additional nucleic acid residues in the final nucleic acid molecule.
[0150] The present invention further provides nucleic acid molecules that comprise the nucleotide sequences shown in FIG. 1 or 3 (SEQ ID NO:1, transcript sequence and SEQ ID NO:3, genomic sequence), or any nucleic acid molecule that encodes the protein provided in FIG. 2, SEQ ID NO:2. A nucleic acid molecule comprises a nucleotide sequence when the nucleotide sequence is at least part of the final nucleotide sequence of the nucleic acid molecule. In such a fashion, the nucleic acid molecule can be only the nucleotide sequence or have additional nucleic acid residues, such as nucleic acid residues that are naturally associated with it or heterologous nucleotide sequences. Such a nucleic acid molecule can have a few additional nucleotides or can comprise several hundred or more additional nucleotides. A brief description of how various types of these nucleic acid molecules can be readily made/isolated is provided below.
[0151] In FIGS. 1 and 3, both coding and non-coding sequences are provided. Because of the source of the present invention, humans genomic sequence (FIG. 3) and cDNA/transcript sequences (FIG. 1), the nucleic acid molecules in the Figures will contain genomic intronic sequences, 5′ and 3′ non-coding sequences, gene regulatory regions and non-coding intergenic sequences. In general such sequence features are either noted in FIGS. 1 and 3 or can readily be identified using computational tools known in the art. As discussed below, some of the non-coding regions, particularly gene regulatory elements such as promoters, are useful for a variety of purposes, e.g. control of heterologous gene expression, target for identifying gene activity modulating compounds, and are particularly claimed as fragments of the genomic sequence provided herein.
[0152] The isolated nucleic acid molecules can encode the mature protein plus additional amino or carboxyl-terminal amino acids, or amino acids interior to the mature peptide (when the mature form has more than one peptide chain, for instance). Such sequences may play a role in processing of a protein from precursor to a mature form, facilitate protein trafficking, prolong or shorten protein half-life or facilitate manipulation of a protein for assay or production, among other things. As generally is the case in situ, the additional amino acids may be processed away from the mature protein by cellular enzymes.
[0153] As mentioned above, the isolated nucleic acid molecules include, but are not limited to, the sequence encoding the transporter peptide alone, the sequence encoding the mature peptide and additional coding sequences, such as a leader or secretory sequence (e.g., a pre-pro or pro-protein sequence), the sequence encoding the mature peptide, with or without the additional coding sequences, plus additional non-coding sequences, for example introns and non-coding 5′ and 3′ sequences such as transcribed but non-translated sequences that play a role in transcription, mRNA processing (including splicing and polyadenylation signals), ribosome binding and stability of mRNA. In addition, the nucleic acid molecule may be fused to a marker sequence encoding, for example, a peptide that facilitates purification.
[0154] Isolated nucleic acid molecules can be in the form of RNA, such as mRNA, or in the form DNA, including cDNA and genomic DNA obtained by cloning or produced by chemical synthetic techniques or by a combination thereof. The nucleic acid, especially DNA, can be double-stranded or single-stranded. Single-stranded nucleic acid can be the coding strand (sense strand) or the non-coding strand (anti-sense strand).
[0155] The invention further provides nucleic acid molecules that encode fragments of the peptides of the present invention as well as nucleic acid molecules that encode obvious variants of the transporter proteins of the present invention that are described above. Such nucleic acid molecules may be naturally occurring, such as allelic variants (same locus), paralogs (different locus), and orthologs (different organism), or may be constructed by recombinant DNA methods or by chemical synthesis. Such non-naturally occurring variants may be made by mutagenesis techniques, including those applied to nucleic acid molecules, cells, or organisms. Accordingly, as discussed above, the variants can contain nucleotide substitutions, deletions, inversions and insertions. Variation can occur in either or both the coding and non-coding regions. The variations can produce both conservative and non-conservative amino acid substitutions.
[0156] The present invention further provides non-coding fragments of the nucleic acid molecules provided in FIGS. 1 and 3. Preferred non-coding fragments include, but are not limited to, promoter sequences, enhancer sequences, gene modulating sequences and gene termination sequences. Such fragments are useful in controlling heterologous gene expression and in developing screens to identify gene-modulating agents. A promoter can readily be identified as being 5′ to the ATG start site in the genomic sequence provided in FIG. 3.
[0157] A fragment comprises a contiguous nucleotide sequence greater than 12 or more nucleotides. Further, a fragment could at least 30, 40, 50, 100, 250 or 500 nucleotides in length. The length of the fragment will be based on its intended use. For example, the fragment can encode epitope bearing regions of the peptide, or can be useful as DNA probes and primers. Such fragments can be isolated using the known nucleotide sequence to synthesize an oligonucleotide probe. A labeled probe can then be used to screen a cDNA library, genomic DNA library, or mRNA to isolate nucleic acid corresponding to the coding region. Further, primers can be used in PCR reactions to clone specific regions of gene.
[0158] A probe/primer typically comprises substantially a purified oligonucleotide or oligonucleotide pair. The oligonucleotide typically comprises a region of nucleotide sequence that hybridizes under stringent conditions to at least about 12, 20, 25, 40, 50 or more consecutive nucleotides.
[0159] Orthologs, homologs, and allelic variants can be identified using methods well known in the art. As described in the Peptide Section, these variants comprise a nucleotide sequence encoding a peptide that is typically 60-70%, 70-80%, 80-90%, and more typically at least about 90-95% or more homologous to the nucleotide sequence shown in the Figure sheets or a fragment of this sequence. Such nucleic acid molecules can readily be identified as being able to hybridize under moderate to stringent conditions, to the nucleotide sequence shown in the Figure sheets or a fragment of the sequence. Allelic variants can readily be determined by genetic locus of the encoding gene.
[0160] [0160]FIG. 3 provides information on SNPs that have been found in the gene encoding the transporter protein of the present invention. SNPs were identified at 26 different nucleotide positions. These SNPs may affect control/regulatory elements.
[0161] As used herein, the term “hybridizes under stringent conditions” is intended to describe conditions for hybridization and washing under which nucleotide sequences encoding a peptide at least 60-70% homologous to each other typically remain hybridized to each other. The conditions can be such that sequences at least about 60%, at least about 70%, or at least about 80% or more homologous to each other typically remain hybridized to each other. Such stringent conditions are known to those skilled in the art and can be found in Current Protocols in Molecular Biology , John Wiley & Sons, N.Y. (1989), 6.3.1-6.3.6. One example of stringent hybridization conditions are hybridization in 6× sodium chloride/sodium citrate (SSC) at about 45 C, followed by one or more washes in 0.2×SSC, 0.1% SDS at 50-65 C. Examples of moderate to low stringency hybridization conditions are well known in the art.
[0162] Nucleic Acid Molecule Uses
[0163] The nucleic acid molecules of the present invention are useful for probes, primers, chemical intermediates, and in biological assays. The nucleic acid molecules are useful as a hybridization probe for messenger RNA, transcript/cDNA and genomic DNA to isolate full-length cDNA and genomic clones encoding the peptide described in FIG. 2 and to isolate cDNA and genomic clones that correspond to variants (alleles, orthologs, etc.) producing the same or related peptides shown in FIG. 2. As illustrated in FIG. 3, SNPs were identified at 26 different nucleotide positions.
[0164] The probe can correspond to any sequence along the entire length of the nucleic acid molecules provided in the Figures. Accordingly, it could be derived from 5′ noncoding regions, the coding region, and 3′ noncoding regions. However, as discussed, fragments are not to be construed as encompassing fragments disclosed prior to the present invention.
[0165] The nucleic acid molecules are also useful as primers for PCR to amplify any given region of a nucleic acid molecule and are useful to synthesize antisense molecules of desired length and sequence.
[0166] The nucleic acid molecules are also useful for constructing recombinant vectors. Such vectors include expression vectors that express a portion of, or all of, the peptide sequences. Vectors also include insertion vectors, used to integrate into another nucleic acid molecule sequence, such as into the cellular genome, to alter in situ expression of a gene and/or gene product. For example, an endogenous coding sequence can be replaced via homologous recombination with all or part of the coding region containing one or more specifically introduced mutations.
[0167] The nucleic acid molecules are also useful for expressing antigenic portions of the proteins.
[0168] The nucleic acid molecules are also useful as probes for determining the chromosomal positions of the nucleic acid molecules by means of in situ hybridization methods.
[0169] The nucleic acid molecules are also useful in making vectors containing the gene regulatory regions of the nucleic acid molecules of the present invention.
[0170] The nucleic acid molecules are also useful for designing ribozymes corresponding to all, or a part, of the mRNA produced from the nucleic acid molecules described herein.
[0171] The nucleic acid molecules are also useful for making vectors that express part, or all, of the peptides.
[0172] The nucleic acid molecules are also useful for constructing host cells expressing a part, or all, of the nucleic acid molecules and peptides.
[0173] The nucleic acid molecules are also useful for constructing transgenic animals expressing all, or a part, of the nucleic acid molecules and peptides.
[0174] The nucleic acid molecules are also useful as hybridization probes for determining the presence, level, form and distribution of nucleic acid expression. Experimental data as provided in FIG. 1 indicates that the transporter proteins of the present invention are expressed in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma, as indicated by virtual northern blot analysis.
[0175] Accordingly, the probes can be used to detect the presence of, or to determine levels of, a specific nucleic acid molecule in cells, tissues, and in organisms. The nucleic acid whose level is determined can be DNA or RNA. Accordingly, probes corresponding to the peptides described herein can be used to assess expression and/or gene copy number in a given cell, tissue, or organism. These uses are relevant for diagnosis of disorders involving an increase or decrease in transporter protein expression relative to normal results.
[0176] In vitro techniques for detection of mRNA include Northern hybridizations and in situ hybridizations. In vitro techniques for detecting DNA include Southern hybridizations and in situ hybridization.
[0177] Probes can be used as a part of a diagnostic test kit for identifying cells or tissues that express a transporter protein, such as by measuring a level of a transporter-encoding nucleic acid in a sample of cells from a subject e.g., mRNA or genomic DNA, or determining if a transporter gene has been mutated. Experimental data as provided in FIG. 1 indicates that the transporter proteins of the present invention are expressed in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma, as indicated by virtual northern blot analysis.
[0178] Nucleic acid expression assays are useful for drug screening to identify compounds that modulate transporter nucleic acid expression.
[0179] The invention thus provides a method for identifying a compound that can be used to treat a disorder associated with nucleic acid expression of the transporter gene, particularly biological and pathological processes that are mediated by the transporter in cells and tissues that express it. Experimental data as provided in FIG. 1 indicates expression in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma. The method typically includes assaying the ability of the compound to modulate the expression of the transporter nucleic acid and thus identifying a compound that can be used to treat a disorder characterized by undesired transporter nucleic acid expression. The assays can be performed in cell-based and cell-free systems. Cell-based assays include cells naturally expressing the transporter nucleic acid or recombinant cells genetically engineered to express specific nucleic acid sequences.
[0180] The assay for transporter nucleic acid expression can involve direct assay of nucleic acid levels, such as mRNA levels, or on collateral compounds involved in the signal pathway. Further, the expression of genes that are up- or down-regulated in response to the transporter protein signal pathway can also be assayed. In this embodiment the regulatory regions of these genes can be operably linked to a reporter gene such as luciferase.
[0181] Thus, modulators of transporter gene expression can be identified in a method wherein a cell is contacted with a candidate compound and the expression of mRNA determined. The level of expression of transporter mRNA in the presence of the candidate compound is compared to the level of expression of transporter mRNA in the absence of the candidate compound. The candidate compound can then be identified as a modulator of nucleic acid expression based on this comparison and be used, for example to treat a disorder characterized by aberrant nucleic acid expression. When expression of mRNA is statistically significantly greater in the presence of the candidate compound than in its absence, the candidate compound is identified as a stimulator of nucleic acid expression. When nucleic acid expression is statistically significantly less in the presence of the candidate compound than in its absence, the candidate compound is identified as an inhibitor of nucleic acid expression.
[0182] The invention further provides methods of treatment, with the nucleic acid as a target, using a compound identified through drug screening as a gene modulator to modulate transporter nucleic acid expression in cells and tissues that express the transporter. Experimental data as provided in FIG. 1 indicates that the transporter proteins of the present invention are expressed in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma, as indicated by virtual northern blot analysis. Modulation includes both up-regulation (i.e. activation or agonization) or down-regulation (suppression or antagonization) or nucleic acid expression.
[0183] Alternatively, a modulator for transporter nucleic acid expression can be a small molecule or drug identified using the screening assays described herein as long as the drug or small molecule inhibits the transporter nucleic acid expression in the cells and tissues that express the protein. Experimental data as provided in FIG. 1 indicates expression in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma
[0184] The nucleic acid molecules are also usefull for monitoring the effectiveness of modulating compounds on the expression or activity of the transporter gene in clinical trials or in a treatment regimen. Thus, the gene expression pattern can serve as a barometer for the continuing effectiveness of treatment with the compound, particularly with compounds to which a patient can develop resistance. The gene expression pattern can also serve as a marker indicative of a physiological response of the affected cells to the compound. Accordingly, such monitoring would allow either increased administration of the compound or the administration of alternative compounds to which the patient has not become resistant. Similarly, if the level of nucleic acid expression falls below a desirable level, administration of the compound could be commensurately decreased.
[0185] The nucleic acid molecules are also useful in diagnostic assays for qualitative changes in transporter nucleic acid expression, and particularly in qualitative changes that lead to pathology. The nucleic acid molecules can be used to detect mutations in transporter genes and gene expression products such as mRNA. The nucleic acid molecules can be used as hybridization probes to detect naturally occurring genetic mutations in the transporter gene and thereby to determine whether a subject with the mutation is at risk for a disorder caused by the mutation. Mutations include deletion, addition, or substitution of one or more nucleotides in the gene, chromosomal rearrangement, such as inversion or transposition, modification of genomic DNA, such as aberrant methylation patterns or changes in gene copy number, such as amplification. Detection of a mutated form of the transporter gene associated with a dysfunction provides a diagnostic tool for an active disease or susceptibility to disease when the disease results from overexpression, underexpression, or altered expression of a transporter protein.
[0186] Individuals carrying mutations in the transporter gene can be detected at the nucleic acid level by a variety of techniques. FIG. 3 provides information on SNPs that have been found in the gene encoding the transporter protein of the present invention. SNPs were identified at 26 different nucleotide positions. These SNPs may affect control/regulatory elements. Genomic DNA can be analyzed directly or can be amplified by using PCR prior to analysis. RNA or cDNA can be used in the same way. In some uses, detection of the mutation involves the use of a probe/primer in apolymerase chain reaction (PCR) (see, e.g. U.S. Pat. Nos. 4,683,195 and 4,683,202), such as anchor PCR or RACE PCR, or, alternatively, in a ligation chain reaction (LCR) (see, e.g., Landegran et al., Science 241:1077-1080 (1988); and Nakazawa et al., PNAS 91:360-364 (1994)), the latter of which can be particularly useful for detecting point mutations in the gene (see Abravaya et al., Nucleic Acids Res. 23:675-682 (1995)). This method can include the steps of collecting a sample of cells from a patient, isolating nucleic acid (e.g., genomic, mRNA or both) from the cells of the sample, contacting the nucleic acid sample with one or more primers which specifically hybridize to a gene under conditions such that hybridization and amplification of the gene (if present) occurs, and detecting the presence or absence of an amplification product, or detecting the size of the amplification product and comparing the length to a control sample. Deletions and insertions can be detected by a change in size of the amplified product compared to the normal genotype. Point mutations can be identified by hybridizing amplified DNA to normal RNA or antisense DNA sequences.
[0187] Alternatively, mutations in a transporter gene can be directly identified, for example, by alterations in restriction enzyme digestion patterns determined by gel electrophoresis.
[0188] Further, sequence-specific ribozymes (U.S. Pat. No. 5,498,531) can be used to score for the presence of specific mutations by development or loss of a ribozyme cleavage site. Perfectly matched sequences can be distinguished from mismatched sequences by nuclease cleavage digestion assays or by differences in melting temperature.
[0189] Sequence changes at specific locations can also be assessed by nuclease protection assays such as RNase and S1 protection or the chemical cleavage method. Furthermore, sequence differences between a mutant transporter gene and a wild-type gene can be determined by direct DNA sequencing. A variety of automated sequencing procedures can be utilized when performing the diagnostic assays Naeve, C. W., (1995) Biotechniques 19:448), including sequencing by mass spectrometry (see, e.g., PCT International Publication No. WO 94/16101; Cohen et al., Adv. Chromatogr. 36:127-162 (1996); and Griffin et al., Appl. Biochem. Biotechnol. 38:147-159 (1993)).
[0190] Other methods for detecting mutations in the gene include methods in which protection from cleavage agents is used to detect mismatched bases in RNA/RNA or RNA/DNA duplexes (Myers et al., Science 230:1242 (1985)); Cotton et al., PNAS 85:4397 (1988); Saleeba et al., Meth. Enzymol. 217:286-295 (1992)), electrophoretic mobility of mutant and wild type nucleic acid is compared (Orita et al., PNAS 86:2766 (1989); Cotton et al., Mutat. Res. 285:125-144 (1993); and Hayashi et al., Genet. Anal. Tech Appl. 9:73-79 (1992)), and movement of mutant or wild-type fragments in polyacrylamide gels containing a gradient of denaturant is assayed using denaturing gradient gel electrophoresis (Myers et al, Nature 313:495 (1985)). Examples of other techniques for detecting point mutations include selective oligonucleotide hybridization, selective amplification, and selective primer extension.
[0191] The nucleic acid molecules are also useful for testing an individual for a genotype that while not necessarily causing the disease, nevertheless affects the treatment modality. Thus, the nucleic acid molecules can be used to study the relationship between an individual's genotype and the individual's response to a compound used for treatment (pharmacogenomic relationship). Accordingly, the nucleic acid molecules described herein can be used to assess the mutation content of the transporter gene in an individual in order to select an appropriate compound or dosage regimen for treatment. FIG. 3 provides information on SNPs that have been found in the gene encoding the transporter protein of the present invention. SNPs were identified at 26 different nucleotide positions. These SNPs may affect control/regulatory elements.
[0192] Thus nucleic acid molecules displaying genetic variations that affect treatment provide a diagnostic target that can be used to tailor treatment in an individual. Accordingly, the production of recombinant cells and animals containing these polymorphisms allow effective clinical design of treatment compounds and dosage regimens.
[0193] The nucleic acid molecules are thus useful as antisense constructs to control transporter gene expression in cells, tissues, and organisms. A DNA antisense nucleic acid molecule is designed to be complementary to a region of the gene involved in transcription, preventing transcription and hence production of transporter protein. An antisense RNA or DNA nucleic acid molecule would hybridize to the mRNA and thus block translation of mRNA into transporter protein.
[0194] Alternatively, a class of antisense molecules can be used to inactivate mRNA in order to decrease expression of transporter nucleic acid. Accordingly, these molecules can treat a disorder characterized by abnormal or undesired transporter nucleic acid expression. This technique involves cleavage by means of ribozymes containing nucleotide sequences complementary to one or more regions in the mRNA that attenuate the ability of the mRNA to be translated. Possible regions include coding regions and particularly coding regions corresponding to the catalytic and other functional activities of the transporter protein, such as ligand binding.
[0195] The nucleic acid molecules also provide vectors for gene therapy in patients containing cells that are aberrant in transporter gene expression. Thus, recombinant cells, which include the patient's cells that have been engineered ex vivo and returned to the patient, are introduced into an individual where the cells produce the desired transporter protein to treat the individual.
[0196] The invention also encompasses kits for detecting the presence of a transporter nucleic acid in a biological sample. Experimental data as provided in FIG. 1 indicates that the transporter proteins of the present invention are expressed in humans in ovary adenocarcinomas, ovary tumors, germinal center B cells (including those in the lymph), brain glioblastomas, lung small cell carcinomas, and pancreas epitheloid carcinoma, as indicated by virtual northern blot analysis. For example, the kit can comprise reagents such as a labeled or labelable nucleic acid or agent capable of detecting transporter nucleic acid in a biological sample; means for determining the amount of transporter nucleic acid in the sample; and means for comparing the amount of transporter nucleic acid in the sample with a standard. The compound or agent can be packaged in a suitable container. The kit can further comprise instructions for using the kit to detect transporter protein mRNA or DNA.
[0197] Nucleic Acid Arrays
[0198] The present invention further provides nucleic acid detection kits, such as arrays or microarrays of nucleic acid molecules that are based on the sequence information provided in FIGS. 1 and 3 (SEQ ID NOS:1 and 3).
[0199] As used herein “Arrays” or “Microarrays” refers to an array of distinct polynucleotides or oligonucleotides synthesized on a substrate, such as paper, nylon or other type of membrane, filter, chip, glass slide, or any other suitable solid support. In one embodiment, the microarray is prepared and used according to the methods described in U.S. Pat. No. 5,837,832, Chee et al., PCT application WO95/11995 (Chee et al.), Lockhart, D. J. et al. (1996; Nat. Biotech. 14: 1675-1680) and Schena, M. et al. (1996; Proc. Natl. Acad. Sci. 93: 10614-10619), all of which are incorporated herein in their entirety by reference. In other embodiments, such arrays are produced by the methods described by Brown et al., U.S. Pat. No. 5,807,522.
[0200] The microarray or detection kit is preferably composed of a large number of unique, single-stranded nucleic acid sequences, usually either synthetic antisense oligonucleotides or fragments of cDNAs, fixed to a solid support. The oligonucleotides are preferably about 6-60 nucleotides in length, more preferably 15-30 nucleotides in length, and most preferably about 20-25 nucleotides in length. For a certain type of microarray or detection kit, it may be preferable to use oligonucleotides that are only 7-20 nucleotides in length. The microarray or detection kit may contain oligonucleotides that cover the known 5′, or 3′, sequence, sequential oligonucleotides that cover the full length sequence; or unique oligonucleotides selected from particular areas along the length of the sequence. Polynucleotides used in the microarray or detection kit may be oligonucleotides that are specific to a gene or genes of interest.
[0201] In order to produce oligonucleotides to a known sequence for a microarray or detection kit, the gene(s) of interest (or an ORF identified from the contigs of the present invention) is typically examined using a computer algorithm which starts at the 5′ or at the 3′ end of the nucleotide sequence. Typical algorithms will then identify oligomers of defined length that are unique to the gene, have a GC content within a range suitable for hybridization, and lack predicted secondary structure that may interfere with hybridization. In certain situations it may be appropriate to use pairs of oligonucleotides on a microarray or detection kit. The “pairs” will be identical, except for one nucleotide that preferably is located in the center of the sequence. The second oligonucleotide in the pair (mismatched by one) serves as a control. The number of oligonucleotide pairs may range from two to one million. The oligomers are synthesized at designated areas on a substrate using a light-directed chemical process. The substrate may be paper, nylon or other type of membrane, filter, chip, glass slide or any other suitable solid support.
[0202] In another aspect, an oligonucleotide may be synthesized on the surface of the substrate by using a chemical coupling procedure and an ink jet application apparatus, as described in PCT application W095/251116 (Baldeschweiler et al.) which is incorporated herein in its entirety by reference. In another aspect, a “gridded” array analogous to a dot (or slot) blot may be used to arrange and link cDNA fragments or oligonucleotides to the surface of a substrate using a vacuum system, thermal, UV, mechanical or chemical bonding procedures. An array, such as those described above, may be produced by hand or by using available devices (slot blot or dot blot apparatus), materials (any suitable solid support), and machines (including robotic instruments), and may contain 8, 24, 96, 384, 1536, 6144 or more oligonucleotides, or any other number between two and one million which lends itself to the efficient use of commercially available instrumentation.
[0203] In order to conduct sample analysis using a microarray or detection kit, the RNA or DNA from a biological sample is made into hybridization probes. The mRNA is isolated, and cDNA is produced and used as a template to make antisense RNA (aRNA). The aRNA is amplified in the presence of fluorescent nucleotides, and labeled probes are incubated with the microarray or detection kit so that the probe sequences hybridize to complementary oligonucleotides of the microarray or detection kit. Incubation conditions are adjusted so that hybridization occurs with precise complementary matches or with various degrees of less complementarity. After removal of nonhybridized probes, a scanner is used to determine the levels and patterns of fluorescence. The scanned images are examined to determine degree of complementarity and the relative abundance of each oligonucleotide sequence on the microarray or detection kit. The biological samples may be obtained from any bodily fluids (such as blood, urine, saliva, phlegm, gastric juices, etc.), cultured cells, biopsies, or other tissue preparations. A detection system may be used to measure the absence, presence, and amount of hybridization for all of the distinct sequences simultaneously. This data may be used for large-scale correlation studies on the sequences, expression patterns, mutations, variants, or polymorphisms among samples.
[0204] Using such arrays, the present invention provides methods to identify the expression of the transporter proteins/peptides of the present invention. In detail, such methods comprise incubating a test sample with one or more nucleic acid molecules and assaying for binding of the nucleic acid molecule with components within the test sample. Such assays will typically involve arrays comprising many genes, at least one of which is a gene of the present invention and or alleles of the transporter gene of the present invention. FIG. 3 provides information on SNPs that have been found in the gene encoding the transporter protein of the present invention. SNPs were identified at 26 different nucleotide positions. These SNPs may affect control/regulatory elements.
[0205] Conditions for incubating a nucleic acid molecule with a test sample vary. Incubation conditions depend on the format employed in the assay, the detection methods employed, and the type and nature of the nucleic acid molecule used in the assay. One skilled in the art will recognize that any one of the commonly available hybridization, amplification or array assay formats can readily be adapted to employ the novel fragments of the Human genome disclosed herein. Examples of such assays can be found in Chard, T, An Introduction to Radioimmunoassay and Related Techniques , Elsevier Science Publishers, Amsterdam, The Netherlands (1986); Bullock, G. R. et al., Techniques in Immunocytochemistry , Academic Press, Orlando, Fla. Vol. 1 (1 982), Vol. 2 (1983), Vol. 3 (1985); Tijssen, P., Practice and Theory ofEnzyme Immunoassays: Laboratory Techniques in Biochemistry and Molecular Biology , Elsevier Science Publishers, Amsterdam, The Netherlands (1985).
[0206] The test samples of the present invention include cells, protein or membrane extracts of cells. The test sample used in the above-described method will vary based on the assay format, nature of the detection method and the tissues, cells or extracts used as the sample to be assayed. Methods for preparing nucleic acid extracts or of cells are well known in the art and can be readily be adapted in order to obtain a sample that is compatible with the system utilized.
[0207] In another embodiment of the present invention, kits are provided which contain the necessary reagents to carry out the assays of the present invention.
[0208] Specifically, the invention provides a compartmentalized kit to receive, in close confinement, one or more containers which comprises: (a) a first container comprising one of the nucleic acid molecules that can bind to a fragment of the Human genome disclosed herein; and (b) one or more other containers comprising one or more of the following: wash reagents, reagents capable of detecting presence of a bound nucleic acid.
[0209] In detail, a compartmentalized kit includes any kit in which reagents are contained in separate containers. Such containers include small glass containers, plastic containers, strips of plastic, glass or paper, or arraying material such as silica. Such containers allows one to efficiently transfer reagents from one compartment to another compartment such that the samples and reagents are not cross-contaminated, and the agents or solutions of each container can be added in a quantitative fashion from one compartment to another. Such containers will include a container which will accept the test sample, a container which contains the nucleic acid probe, containers which contain wash reagents (such as phosphate buffered saline, Tris-buffers, etc.), and containers which contain the reagents used to detect the bound probe. One skilled in the art will readily recognize that the previously unidentified transporter gene of the present invention can be routinely identified using the sequence information disclosed herein can be readily incorporated into one of the established kit formats which are well known in the art, particularly expression arrays.
[0210] Vectors/Host Cells
[0211] The invention also provides vectors containing the nucleic acid molecules described herein. The term “vector” refers to a vehicle, preferably a nucleic acid molecule, which can transport the nucleic acid molecules. When the vector is a nucleic acid molecule, the nucleic acid molecules are covalently linked to the vector nucleic acid. With this aspect of the invention, the vector includes a plasmid, single or double stranded phage, a single or double stranded RNA or DNA viral vector, or artificial chromosome, such as a BAC, PAC, YAC, OR MAC.
[0212] A vector can be maintained in the host cell as an extrachromosomal element where it replicates and produces additional copies of the nucleic acid molecules. Alternatively, the vector may integrate into the host cell genome and produce additional copies of the nucleic acid molecules when the host cell replicates.
[0213] The invention provides vectors for the maintenance (cloning vectors) or vectors for expression (expression vectors) of the nucleic acid molecules. The vectors can function in procaryotic or eukaryotic cells or in both (shuttle vectors).
[0214] Expression vectors contain cis-acting regulatory regions that are operably linked in the vector to the nucleic acid molecules such that transcription of the nucleic acid molecules is allowed in a host cell. The nucleic acid molecules can be introduced into the host cell with a separate nucleic acid molecule capable of affecting transcription. Thus, the second nucleic acid molecule may provide a trans-acting factor interacting with the cis-regulatory control region to allow transcription of the nucleic acid molecules from the vector. Alternatively, a trans-acting factor may be supplied by the host cell. Finally, a trans-acting factor can be produced from the vector itself. It is understood, however, that in some embodiments, transcription and/or translation of the nucleic acid molecules can occur in a cell-free system.
[0215] The regulatory sequence to which the nucleic acid molecules described herein can be operably linked include promoters for directing mRNA transcription. These include, but are not limited to, the left promoter from bacteriophage λ, the lac, TRP, and TAC promoters from E. coli , the early and late promoters from SV40, the CMV immediate early promoter, the adenovirus early and late promoters, and retrovirus long-terminal repeats.
[0216] In addition to control regions that promote transcription, expression vectors may also include regions that modulate transcription, such as repressor binding sites and enhancers. Examples include the SV40 enhancer, the cytomegalovirus immediate early enhancer, polyoma enhancer, adenovirus enhancers, and retrovirus LTR enhancers.
[0217] In addition to containing sites for transcription initiation and control, expression vectors can also contain sequences necessary for transcription termination and, in the transcribed region a ribosome binding site for translation. Other regulatory control elements for expression include initiation and termination codons as well as polyadenylation signals. The person of ordinary skill in the art would be aware of the numerous regulatory sequences that are useful in expression vectors. Such regulatory sequences are described, for example, in Sambrook et al, Molecular Cloning: A Laboratory Manual. 2nd. ed., Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y., (1989).
[0218] A variety of expression vectors can be used to express a nucleic acid molecule. Such vectors include chromosomal, episomal, and virus-derived vectors, for example vectors derived from bacterial plasmids, from bacteriophage, from yeast episomes, from yeast chromosomal elements, including yeast artificial chromosomes, from viruses such as baculoviruses, papovaviruses such as SV40, Vaccinia viruses, adenoviruses, poxvinises, pseudorabies viruses, and retroviruses. Vectors may also be derived from combinations of these sources such as those derived from plasmid and bacteriophage genetic elements, e.g. cosmids and phagemids. Appropriate cloning and expression vectors for prokaryotic and eukaryotic hosts are described in Sambrook et al., Molecular Cloning: A Laboratory Manual. 2nd ed, Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y., (1989).
[0219] The regulatory sequence may provide constitutive expression in one or more host cells (i.e. tissue specific) or may provide for inducible expression in one or more cell types such as by temperature, nutrient additive, or exogenous factor such as a hormone or other ligand. A variety of vectors providing for constitutive and inducible expression in prokaryotic and eukaryotic hosts are well known to those of ordinary skill in the art.
[0220] The nucleic acid molecules can be inserted into the vector nucleic acid by well-known methodology. Generally, the DNA sequence that will ultimately be expressed is joined to an expression vector by cleaving the DNA sequence and the expression vector with one or more restriction enzymes and then ligating the fragments together. Procedures for restriction enzyme digestion and ligation are well known to those of ordinary skill in the art.
[0221] The vector containing the appropriate nucleic acid molecule can be introduced into an appropriate host cell for propagation or expression using well-known techniques. Bacterial cells include, but are not limited to, E. coli , Streptomyces, and Salmonella typhimurium . Eukaryotic cells include, but are not limited to, yeast, insect cells such as Drosophila, animal cells such as COS and CHO cells, and plant cells.
[0222] As described herein, it may be desirable to express the peptide as a fusion protein. Accordingly, the invention provides fusion vectors that allow for the production of the peptides. Fusion vectors can increase the expression of a recombinant protein, increase the solubility of the recombinant protein, and aid in the purification of the protein by acting for example as a ligand for affinity purification. A proteolytic cleavage site may be introduced at the junction of the fusion moiety so that the desired peptide can ultimately be separated from the fusion moiety. Proteolytic enzymes include, but are not limited to, factor Xa, thrombin, and enterotransporter. Typical fusion expression vectors include pGEX (Smith et al., Gene 67:3140 (1988)), pMAL (New England Biolabs, Beverly, Mass.) and pRIT5 (Pharmacia, Piscataway, N.J.) which fuse glutathione S-transferase (GST), maltose E binding protein, or protein A, respectively, to the target recombinant protein. Examples of suitable inducible non-fusion E. coli expression vectors include pTrc (Amann et al., Gene 69:301-315 (1988)) and pET 11d (Studier et al., Gene Expression Technology: Methods in Enzymology 185:60-89 (1990)).
[0223] Recombinant protein expression can be maximized in host bacteria by providing a genetic background wherein the host cell has an impaired capacity to proteolytically cleave the recombinant protein. (Gottesman, S., Gene Expression Technology: Methods in Enzymology 185, Academic Press, San Diego, Calif. (1990)119-128). Alternatively, the sequence of the nucleic acid molecule of interest can be altered to provide preferential codon usage for a specific host cell, for example E. coli . (Wada et al., Nucleic Acids Res. 20:2111-2118 (1992)).
[0224] The nucleic acid molecules can also be expressed by expression vectors that are operative in yeast. Examples of vectors for expression in yeast e.g., S. cerevisiae include pYepSec1 (Baldari, et al., EMBO J. 6:229-234 (1987)), pMFa (Kudan et al., Cell 30:933-943(1982)), pJRY88 (Schultz et al., Gene 54:113-123 (1987)), and pYES2 (Invitrogen Corporation, San Diego, Calif.).
[0225] The nucleic acid molecules can also be expressed in insect cells using, for example, baculovirus expression vectors. Baculovirus vectors available for expression of proteins in cultured insect cells (e.g., Sf 9 cells) include the pAc series (Smith et al., Mol. Cell Biol. 3:2156-2165 (1983)) and the pVL series (Lucklow et a., Virology 170:31-39 (1989)).
[0226] In certain embodiments of the invention, the nucleic acid molecules described herein are expressed in mammalian cells using mammalian expression vectors. Examples of mammalian expression vectors include pCDM8 (Seed, B. Nature 329:840(1987)) and pMT2PC (Kaufman et al., EMBO J. 6:187-195 (1987)).
[0227] The expression vectors listed herein are provided by way of example only of the well-known vectors available to those of ordinary skill in the art that would be useful to express the nucleic acid molecules. The person of ordinary skill in the art would be aware of other vectors suitable for maintenance propagation or expression of the nucleic acid molecules described herein. These are found for example in Sambrook, J., Fritsh, E. F., and Maniatis, T. Molecular Cloning: A Laboratory Manual. 2 nd, ed, Cold Spring Harbor Laboratory , Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y., 1989.
[0228] The invention also encompasses vectors in which the nucleic acid sequences described herein are cloned into the vector in reverse orientation, but operably linked to a regulatory sequence that permits transcription of antisense RNA. Thus, an antisense transcript can be produced to all, or to a portion, of the nucleic acid molecule sequences described herein, including both coding and non-coding regions. Expression of this antisense RNA is subject to each of the parameters described above in relation to expression of the sense RNA (regulatory sequences, constitutive or inducible expression, tissue-specific expression).
[0229] The invention also relates to recombinant host cells containing the vectors described herein. Host cells therefore include prokaryotic cells, lower eukaryotic cells such as yeast, other eukaryotic cells such as insect cells, and higher eukaryotic cells such as mammalian cells.
[0230] The recombinant host cells are prepared by introducing the vector constructs described herein into the cells by techniques readily available to the person of ordinary skill in the art. These include, but are not limited to, calcium phosphate transfection, DEAE-dextran-mediated transfection, cationic lipid-mediated transfection, electroporation, transduction, infection, lipofection, and other techniques such as those found in Sambrook, et al. ( Molecular Cloning: A Laboratory Manual. 2 nd, ed, Cold Spring Harbor Laboratory , Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y., 1989).
[0231] Host cells can contain more than one vector. Thus, different nucleotide sequences can be introduced on different vectors of the same cell. Similarly, the nucleic acid molecules can be introduced either alone or with other nucleic acid molecules that are not related to the nucleic acid molecules such as those providing trans-acting factors for expression vectors. When more than one vector is introduced into a cell, the vectors can be introduced independently, co-introduced or joined to the nucleic acid molecule vector.
[0232] In the case of bacteriophage and viral vectors, these can be introduced into cells as packaged or encapsulated virus by standard procedures for infection and transduction. Viral vectors can be replication-competent or replication-defective. In the case in which viral replication is defective, replication will occur in host cells providing functions that complement the defects.
[0233] Vectors generally include selectable markers that enable the selection of the subpopulation of cells that contain the recombinant vector constructs. The marker can be contained in the same vector that contains the nucleic acid molecules described herein or may be on a separate vector. Markers include tetracycline or ampicillin-resistance genes for prokaryotic host cells and dihydrofolate reductase or neomycin resistance for eukaryotic host cells. However, any marker that provides selection for a phenotypic trait will be effective.
[0234] While the mature proteins can be produced in bacteria, yeast, mammalian cells, and other cells under the control of the appropriate regulatory sequences, cell-free transcription and translation systems can also be used to produce these proteins using RNA derived from the DNA constructs described herein.
[0235] Where secretion of the peptide is desired, which is difficult to achieve with multi-transmembrane domain containing proteins such as transporters, appropriate secretion signals are incorporated into the vector. The signal sequence can be endogenous to the peptides or heterologous to these peptides.
[0236] Where the peptide is not secreted into the medium, which is typically the case with transporters, the protein can be isolated from the host cell by standard disruption procedures, including freeze thaw, sonication, mechanical disruption, use of lysing agents and the like. The peptide can then be recovered and purified by well-known purification methods including ammonium sulfate precipitation, acid extraction, anion or cationic exchange chromatography, phosphocellulose chromatography, hydrophobic-interaction chromatography, affinity chromatography, hydroxylapatite chromatography, lectin chromatography, or high performance liquid chromatography.
[0237] It is also understood that depending upon the host cell in recombinant production of the peptides described herein, the peptides can have various glycosylation patterns, depending upon the cell, or maybe non-glycosylated as when produced in bacteria. In addition, the peptides may include an initial modified methionine in some cases as a result of a host-mediated process.
[0238] Uses of Vectors and Host Cells
[0239] The recombinant host cells expressing the peptides described herein have a variety of uses. First, the cells are useful for producing a transporter protein or peptide that can be further purified to produce desired amounts of transporter protein or fragments. Thus, host cells containing expression vectors are useful for peptide production.
[0240] Host cells are also useful for conducting cell-based assays involving the transporter protein or transporter protein fragments, such as those described above as well as other formats known in the art. Thus, a recombinant host cell expressing a native transporter protein is useful for assaying compounds that stimulate or inhibit transporter protein function.
[0241] Host cells are also useful for identifying transporter protein mutants in which these functions are affected. If the mutants naturally occur and give rise to a pathology, host cells containing the mutations are usefull to assay compounds that have a desired effect on the mutant transporter protein (for example, stimulating or inhibiting function) which may not be indicated by their effect on the native transporter protein.
[0242] Genetically engineered host cells can be further used to produce non-human transgenic animals. A transgenic animal is preferably a mammal, for example a rodent, such as a rat or mouse, in which one or more of the cells of the animal include a transgene. A transgene is exogenous DNA that is integrated into the genome of a cell from which a transgenic animal develops and which remains in the genome of the mature animal in one or more cell types or tissues of the transgenic animal. These animals are useful for studying the function of a transporter protein and identifying and evaluating modulators of transporter protein activity. Other examples of transgenic animals include non-human primates, sheep, dogs, cows, goats, chickens, and amphibians.
[0243] A transgenic animal can be produced by introducing nucleic acid into the male pronuclei of a fertilized oocyte, e.g., by microinjection, retroviral infection, and allowing the oocyte to develop in a pseudopregnant female foster animal. Any of the transporter protein nucleotide sequences can be introduced as a transgene into the genome of a non-human animal, such as a mouse.
[0244] Any of the regulatory or other sequences useful in expression vectors can form part of the tralsgenic sequence. This includes intronic sequences and polyadenylation signals, if not already included. A tissue-specific regulatory sequence(s) can be operably linked to the transgene to direct expression of the transporter protein to particular cells.
[0245] Methods for generating transgenic animals via embryo manipulation and microinjection, particularly animals such as mice, have become conventional in the art and are described, for example, in U.S. Pat. Nos. 4,736,866 and 4,870,009, both by Leder et al., U.S. Pat. No. 4,873,191 by Wagner et al. and in Hogan, B., Manipulating the Mouse Embryo , (Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y., 1986). Similar methods are used for production of other transgenic animals. A transgenic founder animal can be identified based upon the presence of the transgene in its genome and/or expression of transgenic mRNA in tissues or cells of the animals. A transgenic founder animal can then be used to breed additional animals carrying the transgene. Moreover, transgenic animals carrying a transgene can further be bred to other transgenic animals carrying other transgenes. A transgenic animal also includes animals in which the entire animal or tissues in the animal have been produced using the homologously recombinant host cells described herein.
[0246] In another embodiment, transgenic non-human animals can be produced which contain selected systems that allow for regulated expression of the transgene. One example of such a system is the cre/loxP recombinase system of bacteriophage P1. For a description of the cre/loxP recombinase system, see, e.g., Lakso et al. PNAS 89:6232-6236 (1992). Another example of a recombinase system is the FLP recombinase system of S. cerevisiae (O'Gorman et al. Science 251:1351-1355 (1991). If a crefloxP recombinase system is used to regulate expression of the transgene, animals containing transgenes encoding both the Cre recombinase and a selected protein is required. Such animals can be provided through the construction of “double” transgenic animals, e.g., by mating two transgenic animals, one containing a transgene encoding a selected protein and the other containing a transgene encoding a recombinase.
[0247] Clones of the non-human transgenic animals described herein can also be produced according to the methods described in Wilmut, I. et al. Nature 385:810-813 (1997) and PCT International Publication Nos. WO 97/07668 and WO 97/07669. In brief, a cell, e.g., a somatic cell, from the transgenic animal can be isolated and induced to exit the growth cycle and enter G. phase. The quiescent cell can then be fused, e.g., through the use of electrical pulses, to an enucleated oocyte from an animal of the same species from which the quiescent cell is isolated. The reconstructed oocyte is then cultured such that it develops to morula or blastocyst and then transferred to pseudopregnant female foster animal. The offspring born of this female foster animal will be a clone of the animal from which the cell, e.g., the somatic cell, is isolated.
[0248] Transgenic animals containing recombinant cells that express the peptides described herein are useful to conduct the assays described herein in an in vivo context. Accordingly, the various physiological factors that are present in vivo and that could effect ligand binding, transporter protein activation, and signal transduction, may not be evident from in vitro cell-free or cell-based assays. Accordingly, it is useful to provide non-human transgenic animals to assay in vivo transporter protein function, including ligand interaction, the effect of specific mutant transporter proteins on transporter protein function and ligand interaction, and the effect of chimeric transporter proteins. It is also possible to assess the effect of null mutations, that is mutations that substantially or completely eliminate one or more transporter protein functions.
[0249] All publications and patents mentioned in the above specification are herein incorporated by reference. Various modifications and variations of the described method and system of the invention will be apparent to those skilled in the art without departing from the scope and spirit of the invention. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the above-described modes for carrying out the invention which are obvious to those skilled in the field of molecular biology or related fields are intended to be within the scope of the following claims.
1
10
1
1092
DNA
Homo sapiens
1
atgccactgc ctctgtttgc tccctaccca gccactgtca ggccagtgtt gtctgtcatg 60
tgccagaagc ttctcagctg tggacgcaga agggagcaac tttgctattt ggtccatccg 120
catccgtcgt ccggcccgct gctgccgccg cgcttctacc cgcgctacgt gctaccgctc 180
gccttcggca agtacttcgc gtccgtgtca gcgcacgtca gcatctggaa ggtgcccgtg 240
tcctatgcac acaccgtcaa ggccaccatg cccatctggg tggtcctcct gtcccggatc 300
attatgaagg agaagcagag caccaaggta tacttgtcac tcatccccat catcagcggt 360
gtcctgctgg ccaccgtcac cgagttgtct tttgacatgt ggggactcgt cagcgccctc 420
gccgccacgc tgtgcttctc gcttcagaac attttctcca aaaaggtctt gcgagattca 480
cggatccacc atctccggct gctcaacatc ctgggctgcc acgccgtctt ctttatgatc 540
cccacctggg ttctggtgga cctctcggct ttcctggtca gcagcgactt gcctggacat 600
gaggcagctc agaagaccta cgtctaccag tggccctgga cgctcctgct cctggctgtc 660
agcggcttct gtaactttgc ccagaatgtt atcgccttca gcatcctcaa cctcgttagc 720
ccgctgagct actcggtcgc caatgccacc aaaagaatca tggtcatcac ggtgtccctg 780
atcatgctgc gcaacccagt caccagcacc aacgtcctgg gcatgatgac cgccatcctg 840
ggggtcttcc tctataacaa gaccaagtac gatgcaaacc agcaagccag gaagcacctc 900
ctccccgtca ccacagcaga cctgagcagc aaggagcgtc accggagccc actggagaag 960
ccccacaacg gcctcctctt cccccagcac ggggactatc agtacggccg caacaacatc 1020
ttaacagacc acttccaata cagccggcag agctacccaa actcgtacag tttgaaccgc 1080
tatgatgtgt ag 1092
2
363
PRT
Homo sapiens
2
Met Pro Leu Pro Leu Phe Ala Pro Tyr Pro Ala Thr Val Arg Pro Val
1 5 10 15
Leu Ser Val Met Cys Gln Lys Leu Leu Ser Cys Gly Arg Arg Arg Glu
20 25 30
Gln Leu Cys Tyr Leu Val His Pro His Pro Ser Ser Gly Pro Leu Leu
35 40 45
Pro Pro Arg Phe Tyr Pro Arg Tyr Val Leu Pro Leu Ala Phe Gly Lys
50 55 60
Tyr Phe Ala Ser Val Ser Ala His Val Ser Ile Trp Lys Val Pro Val
65 70 75 80
Ser Tyr Ala His Thr Val Lys Ala Thr Met Pro Ile Trp Val Val Leu
85 90 95
Leu Ser Arg Ile Ile Met Lys Glu Lys Gln Ser Thr Lys Val Tyr Leu
100 105 110
Ser Leu Ile Pro Ile Ile Ser Gly Val Leu Leu Ala Thr Val Thr Glu
115 120 125
Leu Ser Phe Asp Met Trp Gly Leu Val Ser Ala Leu Ala Ala Thr Leu
130 135 140
Cys Phe Ser Leu Gln Asn Ile Phe Ser Lys Lys Val Leu Arg Asp Ser
145 150 155 160
Arg Ile His His Leu Arg Leu Leu Asn Ile Leu Gly Cys His Ala Val
165 170 175
Phe Phe Met Ile Pro Thr Trp Val Leu Val Asp Leu Ser Ala Phe Leu
180 185 190
Val Ser Ser Asp Leu Pro Gly His Glu Ala Ala Gln Lys Thr Tyr Val
195 200 205
Tyr Gln Trp Pro Trp Thr Leu Leu Leu Leu Ala Val Ser Gly Phe Cys
210 215 220
Asn Phe Ala Gln Asn Val Ile Ala Phe Ser Ile Leu Asn Leu Val Ser
225 230 235 240
Pro Leu Ser Tyr Ser Val Ala Asn Ala Thr Lys Arg Ile Met Val Ile
245 250 255
Thr Val Ser Leu Ile Met Leu Arg Asn Pro Val Thr Ser Thr Asn Val
260 265 270
Leu Gly Met Met Thr Ala Ile Leu Gly Val Phe Leu Tyr Asn Lys Thr
275 280 285
Lys Tyr Asp Ala Asn Gln Gln Ala Arg Lys His Leu Leu Pro Val Thr
290 295 300
Thr Ala Asp Leu Ser Ser Lys Glu Arg His Arg Ser Pro Leu Glu Lys
305 310 315 320
Pro His Asn Gly Leu Leu Phe Pro Gln His Gly Asp Tyr Gln Tyr Gly
325 330 335
Arg Asn Asn Ile Leu Thr Asp His Phe Gln Tyr Ser Arg Gln Ser Tyr
340 345 350
Pro Asn Ser Tyr Ser Leu Asn Arg Tyr Asp Val
355 360
3
27754
DNA
Homo sapiens
misc_feature
(1)...(27754)
n = A,T,C or G
3
tcctcttgct ctggggttgg ggagagactg gagcaggctg gggcagggtg ttccagcctc 60
ccagtggaga aggacaggga cctgacaaat ggctttttat ttccacagat ccggaacatg 120
gtggcggtgc tggaagtcat ctccagcctg gagaaatacc ctattaccaa agaggcactt 180
gaggtgagta tcccagaccc cagcatttgg gagggcagaa cggggggcag gggatggtac 240
caaccaggtc cttccgcagc ttctgggagc atcagtgtct ttgcttcgga ggaccaagag 300
aggcggtgtg ccctcacagc tcgtgcctcg cgatcttgct ctcccacggg cactgcagag 360
accaagtggt gttactccca tcctacatgc ccagcacact tcgtgggcac gtggggacat 420
caggagaggt gtgcttggag gaggctccag tgagaggcac catccccaac cctccacttg 480
aagcggaccc tctgtgctgt cgcctcggcc acagcaccct ctcacccagg aagcctctct 540
ggcagtgtcc ttacagtggc cttgatggtc cacagccccc tgacaccagg agcctgggtg 600
acagcactgc tgagaagcca cctgggaccc tgaaggtctg ggaactaggt ttgagaattt 660
atattgtcac aaaggaccgg aaatccccag aagttttgtg tcagggaagc tggcagttta 720
gggctcagtg ggaaccgggt catttcactg tcagggccac ttcccaccat ttctggctca 780
gctcatggag aagttcctgt cccgaaagta tgtcatcatc tccctctggt tgtaggaaac 840
acgacttggg aagctcatca acgacgtccg caagaaaacc aagaacgagg agctcgccaa 900
gcgggccaag aagctgctgc ggagctggca gaagctcatc gagccggcac accagcatga 960
ggcggcgctg cgggggctgg cgggggccac cggctctgcc aacgggggcg cacacaactg 1020
ccggccggag gtgggggcgg ctggcccacc caggagcatc catgacctga agagccgcaa 1080
tgacctccag aggctgcccg ggcagcggct ggacaggctg ggcagccgca agcgccgggg 1140
tgaccagcgt gacctcggcc acccagggcc gccacccaag gtctccaaag ctagccacga 1200
ccccctggtc cccaactcat cccccctccc caccaacggg atcagtggga gtccagagag 1260
cttcgccagc tccctggatg gcagtgggca tgcaggccca gagggcagcc gcctggagcg 1320
tgacgagaat gacaagcaca gtggcaagat ccccgtcaac gccgtgcgac cgcacaccag 1380
ctccccgggc ctgggcaagc cccctggacc ctgcttgcag ccaaaggctt cggtgctgca 1440
gcagctggac agggtggacg agactccggg gcctccccat cccaagggac cccctcgctg 1500
ctctttcagt cctcggaact cacggcatga gggctccttt gcccggcagc agagcttgta 1560
tgcacccaag ggctccgtgc ccagcccctc accgcggccc caggcactcg atgccacaca 1620
ggtgccgtca ccgcttccac tggcacagcc gtccacaccc cccgtacggc ggctcgagct 1680
gctgcccagt gcggaaagcc cagtgtgctg gcttgagcag cctgagagcc accagcggct 1740
ggcggggccg ggctgcaagg cagggctgtc cccagccgag cccctcctgt cccgggcagg 1800
cttttcccca gactcctcca aggcggacag tgatgctgcc tcctcagggg gctcggacag 1860
taaaaagaag aagaggtacc gacctcgaga ctatacggtt aacttggacg ggcaggtggc 1920
tgaggcgggc gtcaagcctg tccggttaaa agagcggaag ctcacctttg accccatgac 1980
gagacagatc aaacctctga cccagaaaga gccagtgcgg gcagacagcc ctgtgcacat 2040
ggagcagcag tccaggacag agctggacaa gcaggaggcc aaggccagcc tccagagccc 2100
cttcgaacag acgaactgga aggagctgtc acgcaacgag atcatccagt cctacctgag 2160
ccggcagagc agcctgctct catcatcggg cgcgcagacc ccaggggctc accacttcat 2220
gtctgagtac ctgaagcagg aggagagcac ccggcaaggg gccaggcagc tgcatgtgct 2280
ggtgcctcaa agcccgccca cggacctccc tggtctgacc cgggaggtca cacaggacga 2340
tctcgacaga atccaggcca gccagtggcc gggggtgaac gggtgtcagg acacacaggg 2400
taactggtat gactggacgc agtgcatatc gctcgatccg cacggcgacg acgggcgctt 2460
gaacattctg ccttatgtct gcttggactg accggcctgt cagccacaaa gtgcattccc 2520
atcttgcaga agccgggtgg gcgggcaggc aggtgggcag gtggccgggg cccagctgnn 2580
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 2640
nnnngcggga gggagggggc gggagtcacg cggtctctct gcgctcttcc ctcaaaactc 2700
tttttgtgaa atgctgctac cagtttacta acaaaattgc gaagaaggac cgcgtggaag 2760
gaaggacggc aaagtgagtt cagaactcta tagcaaacca gctataaaaa gcgttagtcc 2820
ctcaccccca aagaggtgcg gacactttcc agcacctgaa agctggggcc tcagttgcag 2880
gcaggcacag aaaacctgtg ggagaggtca cctttaacac agcaacagaa gcacgcatct 2940
catctctctt gcattttctg ttctttaatt tggccctgag tgtcttgaga cagtgggcca 3000
tgccactgcc tctgtttgct ccctacccag ccactgtcag gccagtgttg tctgtcatgt 3060
gccagaagct tctcagctgt ggtgagccac tggcattggg caggcgggcc agctggccag 3120
ccagtgtgac ccacactcca tgggcagcca cctgtttata tctggtttca gttataaccc 3180
agtttttaaa gaaatgctgc aaaaatttaa gttttctcat gtttatttta aacaattcct 3240
cttccatcag accaccagac aaaaaaacct ttcctttctt cctccctttt cttttttccc 3300
ttcctgtaca catctagaaa acttcacctt tctagagtcc ccccaaaaca acacaaaagt 3360
tattgtgggt gctactggtt ttatgctgta ctgtggggcg agggggaaga cctgtctgta 3420
cgctggaaac actcataacc attcctttag attcgtttgc cttatggtta tttgtcataa 3480
acgcgatttg caaaaacaag gagccttagt gaatgtacag tacctagact tctgtgttct 3540
caggacgcag aagggagcaa ctttgctatt tggtccagta agtggacacc ttgtgatata 3600
aatgtggaaa taaaaaaaaa aaaaaaacca tttgcacaaa ccagtctgag aatcttttct 3660
catttggacc ttcacaacca aatcagccct ttcctggatt gtggattatt agccaggaac 3720
acccagaccc caacagctgc aatgcaggga gacagggcag ggcacagcct tgcagtccac 3780
ctgttagcct gctgctgcat ttgggaggac ctccacattt tattcattca gggccacatt 3840
aaggaatgtt ttcttgtctc acccagactt tacctggcct agagagcagc cctctgtagg 3900
aggctcccat agcacaggtc tcagtgacta cccccacctc aacaaaatac ctagttctta 3960
caaggtatgg cccagaggct cagagctgtg tgtgtgtgtc tgaaaggcca ccccatggcc 4020
ctggccccca gctgccttat tagctggttg gtgctgactc caaaaaaatt tttctccctt 4080
gactataaag tgctcatctt ttagttcccc ctcgtccctg aaactgtagg ctaagacttt 4140
ggttttccag tttttcactt tggaataggt catcttaccc atatctgctt aatttcacaa 4200
atgaagaaac agctacacct taagacatgc agtctcacag ggcaaaccaa aggttccttc 4260
cagcctgtaa gactacagtc agtccagagc cagtttgaga gctagcaggg attcctggca 4320
aaagcttggt gcagaacaca ctcccctccc caacaaaagg ccatgggcaa agtggctttg 4380
aaggcaggat gaggttgaac ccaggcctac cacccaccag ctgtgtggct ctgagctcat 4440
ctcttcactc ctgtgcacat gtccccattt ggggggtgag aataccccag agttgtgaga 4500
actaaaacac aaagcatgtc agtgtgtcag tggaagtatc tgacactcag ctgtgctgta 4560
gggtgcctat agttatactt tcctaatttc actgtgccta tgtttaacag ctctgctgag 4620
acatggtgtc ccaaggatgt gactttactc tgatccacag agggtacagc tggaggatat 4680
tagggtgcag agcttggcct cctatcagca tctctagagt tttgggatag gttgcagctc 4740
cccactaccc ctgcctgcag ggactaccat gcctgtgtcc atgtatccag aagggcctag 4800
ggcctttgag aatgcaagga taagctaaga taccttccaa catttgggga gccaagttgg 4860
gttgctgctt tctacttttc tttgagactg ggtctcgctc tgtcacccag gctgcagtgc 4920
agtggcgcca tcatagctca ctggaacctt gacctgggct caagccgatc cacccacctc 4980
agtctcccta gtagtgggta ccacaggcgt gcgccaccac gcctggctaa tttttgtatt 5040
ttttgcaaag atgaggttct gccatgttat cgatgccacg atctccaact cctgagctca 5100
agcaatccgc ccaccttggc ctcccaaagt gctgggattc caagcttgac tcactgcacc 5160
cagccggttg ctgcttctaa tttgacaagt aaaaacactg taacggaatt ttaacaccct 5220
ttccccgaaa aagttggagg cacacgatgt ggagaacaaa ttatagccct tgaattagta 5280
taagatcatc ttactgaaaa cctcgtcctg ttttcctcca ctggggcctc ctggggctgg 5340
tccatcccgg ctggtccttg gacatcagcc gtcagggccc ggcacctccc ccttctgcag 5400
agccttggag acaggtgtcc aaggacgcta ccatgaccac ggtccccagt gtggccagga 5460
agcctaagac aagtcgcttc cccattctgg acttcggtct gtgaaatgcg gacagtgata 5520
cctaccgcac cgcgttccta ggattcagtg ggatgatacc agggccacgc ccgagaactg 5580
cgcacgtcgc ggtggtttcc agaacatgat tccagggatc gggtgctccg ggatagtccc 5640
actgccagag tttggccacg agcgtgcgcc cccagtttgc agagcgagtt tagcccaaga 5700
gcttttcaca aatggtttct ttccctaaaa ggccttttac ctttggtgtc agccgccgcc 5760
agccatcagg aatcaggaat ctagttagcg gttgcccttg tatccctggt cgaggccctg 5820
atgtttggcc cacgcacaga cgccgacgct gcgaagccct ccgcgcttct gttcgcccgt 5880
cccgttcgag ctccggctcc cggtcactgg gaccgcccac gtctcaggtg gcacagcttg 5940
gacgcaggtc tgtgtcccct tcttccgctt ccggcctcgg ctccgccgga agcgcatcta 6000
cagtggactg ggcctgcact cgagacgtgg tggctggcgc gtcggccggc gcggagggat 6060
gacgcgagga ggcagcgacc aatgggaaac ggcgtagacc ggggcgcctg cccccccgcc 6120
cagccccgcc cccgcccggc gtcgggccgt cggacgggct ggaaggggcg gccgctcggg 6180
caggatgnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 6240
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 6300
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 6360
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 6420
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 6480
nnnnnnnnnn nnnnnncctg gcgcgtgccc cccgcgccgc ccgtctcggg ccccggaccc 6540
agtccgcatc cgtcgtccgg cccgctgctg ccgccgcgct tctacccgcg ctacgtgcta 6600
ccgctcgcct tcggcaagta cttcgcgtcc gtgtcagcgc acgtcagcat ctggaaggtg 6660
cccgtgtcct atgcacacac cggtaggttc cgcgcccggc ctcgggggcg gcggccgggc 6720
ccgccgcttc gggtttgggc gcatggatag gagtgcgccg cccggggcgc gtcccgccgg 6780
actgagaagt cagcagaggg gctgccaagg gtttggtagg ggagggacac gcacggggtt 6840
ctcagggaga agaggagctg agaagagagc tgagaggtaa gcaggacaga ccacaacagc 6900
cgtggcagga ggaagcccta ccgaaagaga aggggcgaag aggtgttgag gggctgccag 6960
gccctcccat cccgccgtgg aggtggaaca ggttgggccc tgaaattcag gcagccccct 7020
gagtgcccat ccctctcttt gcagtcaagg ccaccatgcc catctgggtg gtcctcctgt 7080
cccggatcat tatgaaggag aagcagagca ccaaggtaac cccgggcagg gactctgggc 7140
agatgggagc tccagggggt tcctccctgt tgccaactgg tgacgtggtc aggatcctgg 7200
tctgcaggct gcctggcttc ccgtcaaata gggaagtcag tgtagaggtc tccagtggcc 7260
ttttactact caagttctag aatcaccctg tgagcagtgg tgtgtggagt atgtgtccct 7320
ctgtgatctc tgctgtgtgg tcttaggaac actgttgtcc ctttcagatc caattttcct 7380
ccccgttttg attccctacc tgggtttgct ggtaggtgat gggttggtca catcttggcc 7440
atacacccca tgtgtggcct ttccagtggg actagggatg gatggatcag aacgctgtcg 7500
gttaggtgtt cacttttttt tttttttttt tgagacggag ttttactctt gcccagcctg 7560
aagtccagtg acacaatctc agctcactgc aacctccgcc tcccaggttc aagcagttct 7620
cctgcctcag cctctcaagt agttgggact acagacgtgc actaccacac ctggctaatt 7680
tttttgtatt tttaatagag acagggtttc accatgttgc caggctggtc tcaaactcct 7740
gacctcaagt gatccgtccg cctcagcctc ccaaagtgct ggtattacag gcgtcagcca 7800
ctgcacttgg ctaggttttc acttcttgac aagagatttc tgtcagggga cctctgggat 7860
cagaagccag acgcgatcca aggagttcga tcttggcaaa atccagcaaa gtcttagaaa 7920
ttaaaacagc cagaagttgt gatggtctgg gaacggaagc gaaagtggca cacaggactc 7980
agggctgcat aaggaggatg ctttgggcac agtccaaatt ctgttcaaga tgccaagcca 8040
gggtatttcc tggcttgggg caagaatagc catggcttta gccggagaca gctttatccc 8100
gtattcttaa gtggaagttg ggcgcttgtt gtctcagccg gaatccattt catgctgatg 8160
ctggacaccg tgcctctttt ccaagtggtt ggtttctggc atgttgtatt ttatgtaact 8220
cagagaggta gtgccctgga tcggcttata gaaattgggc cacctatggc tgattttttt 8280
ttattcctgc ctgtctttgt ctcagcaaga cctgtgtgtg ctctgtagcc ctgctccccc 8340
agggtgatgt caggctgtga cttggctcct gagaagtcag agttgtccct gaggtgtgta 8400
gctgcatcac cggatatcat cgtgtgtatc aggtttcccc gttgtacggg acattgtacc 8460
cagcttgggc aaggagccgg aacttcacac agtgaggaaa gactgggaat tggcccggtt 8520
aggcagccag actaattata atgacatcat aacttctagg aacctgccct gcaaggcaga 8580
taaggccagt agtcatcatt cctgatctca ggttttcctg agatggactg agaggggaga 8640
atcatgtgcc tgagggccac agcctgatat tcgggaagct ggaattcagg tccacagccc 8700
tcggtctgcc ctccttgtgg catgaccact ccctcctaaa atctccacct ctcctatctc 8760
tccttaagag tgtttgtttt tctgagacgg agtctccctc tgttgcccag attggagtgc 8820
cgtggtgcga tctcagctta ctgcaagctc cgcctcctgg gttcaagcga ttcttgcctc 8880
agcctcccga gtagccggga ttgcaggcgc gttccatcac tcctggctaa tttttgtatt 8940
ttcaatacag acagggtttt accatgttgg ccaggctggt ctcaaactcc tgacttcaag 9000
tgatctgccc tcctcagcct cccaaagtga agagtgttct ttgtaggaca ggattgagcc 9060
gagagtcaga agagctggac acgcgggaat ggatcnnnnn nnnnnnnnnn nnnnnnnnnn 9120
nnnnnnnnnn nnnnnnttgt ttagccctgc atgccagacc ttctagaagg ctctctgtca 9180
ctatgtttgc tactcgttca ttcagctagc agctattgag tgcctactga gtgctaggca 9240
ccaggataaa gcagtgaaca aggacctgct ctaaggtaca ctaacgggac cggatgatgt 9300
aacagacaga gtgggtggag aggctgggca cggtggccca cgcttgtaat cccagcactt 9360
tgggaggcca aggtgggcag atcacgaggt caagagatcg agaccatcct ggccaacatg 9420
gcaaaacccc atctttacta aaaatacaaa aattagttgg gcgtggtggt aggcacctgt 9480
agtcccagct actcagaaag ctgaggcaga agaatcggtt gaacctggga ggcagaggtt 9540
gcagtgagcc gagatcatgc cactgcattc catcctggtg acagagcgag actccgtctc 9600
aaaaaaaaaa aaaaagagtg agtggagagc tctctgctgg ggaagtccag gcagtggccc 9660
tgggagcaca gcacaggagc ctcccaaggt ggaggtgggt tggagaaagc actccttgtg 9720
gaggcaggag gtcactggga ggagaaggca tcagtggagt gtgccagcca ggagtaacca 9780
tactggaaga gcctgaagta agagggaatg ggggctgggc acagtggctc acacctgtaa 9840
tcccagtact ttgggaggcc aaggtggatg gatgacgtgg atcaggcgtt caagactagc 9900
ctggctaaca tggcgaaatc ctgtctctac taaaagtaca aaaaaattgg ccgggcgtgg 9960
tggcacatcc ctgtaatccc agctactggg gagtctgagg caggagaatc gcttgaaccc 10020
gggaagcaga ggttgcagtg agccacgatt gtgccactac actccagcct gggcgacaga 10080
gcgagacttt gtctcaaaaa aactattttt taaaaagagg gaatggggga gccttataga 10140
ggatcagggc ttcaaaccct ggtgcgtcag tggcagctga acagatctgt ggagttagga 10200
ccagccccgg gctgtggccc tgagcagagg ctcttaatgg gggtgacggt atggggatgg 10260
ggctacccac aaataagccc tgcccctggc gctctgataa ccacctgccc ccagccaccc 10320
accagagcgt cactggcaca gcaaacacca ctttcaaagt gttaggtggt atccctttgc 10380
tgagggagga gaggggctct tccctgggca tctgtggcat gtggcccagc tctagtctgg 10440
cctgtgagcc cttcttgatg acctcttcct gcaggtatac ttgtcactca tccccatcat 10500
cagcggtgtc ctgctggcca ccgtcaccga gttgtctttt gacatgtggg gactcgtcag 10560
cgccctcgcc gccacgctgt gcttctcgct tcagaacatt ttctccaaaa aggtatttgg 10620
tcaccatcag cggacatgca tggggtttca ggggtgtgcg ggcagcaaac tggtggcatt 10680
gggaaaacag gcggagtaga aatttctttg ctattagagc agaaaaatct tgattgccat 10740
tctgctgatt ttctgtttgt cattttgctt tttaaatagt ttgtttttct ggccgggcgc 10800
agtggctcat gcctataatc ccagcacttt gggaggccaa ggcgggcggt tcacttgagg 10860
ccaggagttc aacaccagcc tgaccaatat ggcaaaaccc catctctact aaaaacataa 10920
aaattagcca ggcacgcatc tgtaatccca gctactccag acactgaggc acaagaattg 10980
cttgaaccca ggaagcgggg cttgcagtga gctgagattt tgcatcactg cactccaacc 11040
tgggcaagag tgagtctcca tctcaaaaac aaaaaaaagt ttttctatta taaagttaat 11100
gtgctcaata agaaaaaaat aaagaaaagc tcttttattg agaccaaggc tcactgtcgc 11160
ccaggctgga gtgcagtggc acaatcatag cttactgcag cctcagtctt cgaagctcaa 11220
gtgatcctca cacctcagcc tcataaagca ctgggattac aggcattagc caccaggcct 11280
agctaaaaac ttcaatttaa aacaagattt taaaacttgt tgaagcctag tgcagtggct 11340
cacatctata atcccagcac tttgggaggc caaggcagga ggatcacttg aggctaggag 11400
ttcgagacca gcctaggcaa taggaataga gtgagacccc gtctcaaaaa aaaaaattgc 11460
tcttaactcc tgtgataatc acacactttt caggtaccac agttaatgca gtctctctat 11520
tggaaatacc acttatttcc aacttttcat tgtaatgtag aaacaatcac gtgtgtgatg 11580
ttttcctgtc tcagttattt cattatgata ggcttacagt tctcaggtta gagggtatga 11640
aacgttaatc actcttaata tggtttgtct ggtcgtattt tagaaaggtt ataccaattc 11700
agcctcaaac cagtggaatt tcagagtgcc tacttcactt catcctcacc agcactgagt 11760
gttactgttt tatttttgtt ttcttttctc agtcgtttat gcgtggagca tggtgcttgt 11820
ttcaggcctg tgctgtgtat gtcctcacaa atgcacttgc aggtttggtg tccaagctca 11880
gatgtcaggg ttaatgtcca gtcactgtgt ttggggcctg agtcactgga gccctttttg 11940
ccacatatag ttttaatcac cctctaaaga ggctttccct ttccaggtct tgcgagattc 12000
acggatccac catctccggc tgctcaacat cctgggctgc cacgccgtct tctttatgat 12060
ccccacctgg gttctggtgg acctctcggc tttcctggtc agcagcgact tggtgagttg 12120
tacagcacca agaacacgcc attttcttgg ctagttccag aataggtgct ttgttgagga 12180
gctgtagctg catgttaaca ttgtggtatc ttttgggcac ctgacagcca gcgctttcag 12240
cagtcagtcc tctgtaatgc ctcacggtga cgatgcacgc catcgaggaa gtgggtttcc 12300
tgtgtatttc cttctctggt gtgcttgatc ccaggtgctg atagctgctg tgtgtgcgcc 12360
agtagcgtca aggaagagaa ggtgactctt tcacctcctg acagtatagt ccagatagca 12420
cattgacttt ttatttttac tcatttttta ttttaaatgt ttatttttta gagacagaac 12480
ctcgctctgt tgccagggct ggagtgcagt ggcacaatca tggctcactg cagccttgac 12540
ctcaatccgg ggctcaagcg atcctcccac agcctcccga gtaactggga ctgcaggcga 12600
ataccaccat gcctggctaa tttttttttg tttgattttt gtttttttac tgtttttgga 12660
gagacagggt ctcactatgt tgcccaggct ggtcctgaac tcctggcgtt aagagatctg 12720
ccttggcctc ccaaagtgct gggattacag atgtgagcca ctgtgccttg ccagccctgg 12780
aannnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 12840
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 12900
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 12960
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 13020
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 13080
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 13140
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 13200
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 13260
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnttcagaga atgtgttata 13320
aatgaatgca agtgcctgcg gtgaggagga ggccagtgcg attcttccag actcgagtta 13380
gaaaggaaaa gtaaatattt attgaggtct taatgtggtc tagctggatt tgtgacattt 13440
cttatcttta atccttggct ccacctgctg aagtagtgga tattacctct attttcccaa 13500
tcagtaaacc atggctcact tttctaactt tcgtttcaca ttgatgagct gtaattcttc 13560
tgtgaagaac tttccatctt ccaggactag tttgttacct tgaagtatgg tacgagaaag 13620
gcagtttaat gcttaactgt tccttttgat gactaatttt caggatagag agttggagct 13680
tactccaaat gttgaccaga gttgagggtt tgtttggggg tagggaaggg gttctctttt 13740
tttctccagc atcattgtga acttttatgt gtttgtcagt tgcatgaatt attcgttttc 13800
ctagtcaaat tgtcctgtct tggccaggcg cagtggctcc agcctgtaat cccagcactt 13860
tgggaggccg aggtgggcag atcacttgag gtcaggagtt caagaccagc ctggccaacg 13920
tggtgaaacc ccatctctac agaaaataca aaaatttgcc aggcatggtg gtgcacgcct 13980
gtaatcccag ctactcagga ggctgaggca ggagaattgc ttgaacctgg aaggcggagg 14040
ttgcggtgag ctgagatcgt accactgcac tccagcctgg gcgacagagc gagactccat 14100
cttaaaaaaa aagaagaaaa aaaaattgtc ctgtcttagc cattggagcc cttctgattg 14160
gctccttgcc cttctagcac tgtgggtcag cgtttctccc agcgggatgc ccgccttcac 14220
cttgtgtact tcccatccca gagctgcagt cagcccctcc ttcaggactc caggtgccgt 14280
tagtggggag cggtatttag agacacaatc caggtgccat gggtgctttt tgctgctggg 14340
tggtcattgt tgttaggcct ttactgtgaa aaattaggaa gtacacactt ggggcagcag 14400
caaagagttc ctagcaatta gcgtcacttt cagttgaaca gtccagatct ttgctgtttt 14460
gaatttcata tttagatctc gtcgctggta tgcttggttc cgctcctcgt ttcttagttg 14520
cttattctac ccgttattca ctgatgttat tctactgtac actcactcat ataattgctt 14580
cagaatgagc attctcacag cacaattgca actggagtgc tgagaaaagg ttagtatttc 14640
tttgcaggct gggtgtggtg gctcacacct ggaatcccag cactttagga gaccgaggta 14700
ggtggatccc ttgaggccag gagttcgaaa ccagcctggc caacgtgggg aaaccccatc 14760
tctagaaaaa atataaaaat tatctggtgt ggtggcgtac gcctataatc ctagctacta 14820
ggtaggtgga ggttgcagtg agctgagatc acgacactgc actccaacct gggtgacaaa 14880
gtgagactgt ctcataaaaa taaaaaaaaa gaagaagtct ggtcatgatt cctgtactct 14940
ccctgtcccc tccctgacca tggataacat ttcttaggct cctagttcac ctgttccata 15000
tttttgcaaa tataagcaaa tttgcatgta taatcaccct ctgtccttat tacacacaga 15060
gtagcttttt attttattat tttattttat tttattttat tttttgagac ggagtttttc 15120
tgtctcctag gctagaatgc aatggcatgt tctcggctca ctgcagcctc cgcctcccgg 15180
attcaagcag ttctcctgcc tcagcctccc gagtagctgg gactacagac acccaccacc 15240
gcgcccagct aattttttgt gtgtttttac tagaggtggg gtttctccat tttggccagg 15300
ctagtctcaa actcctgaca ttaggtgatc cacccacttc ggcctcccaa agtgctggaa 15360
ttataggcgt aagcgaccac gcccagccca aaaagtagct ttttaaattt acaggtcagg 15420
cacagtgcct cacacatgta atcccagtat tttggaaggc agaggcaggc agactgcttt 15480
agcctcagga gtttgagacc agcctggtca acatggtgaa accccgtctc tacgtaaaac 15540
aaaaccaaaa attaacccgg catggtggca catgcctgta gtccgagcta cttgggagcc 15600
tgaggtggga agatcacttg agcccgggaa ggtcaaagct gcagtgagcc atgtttgagc 15660
cactgcaccc cagccagcat gacagagcaa gaccctatct caaaaataaa tataaacata 15720
cagtcatcct tccatatctg tgggttccac actagtggat tcagccaact gcgaattgaa 15780
aatatatggt agaaaaacaa acaaaatact ataataaaga ataagacatt ttaaaataat 15840
acagtataac aattatttgt atagcagttt tattgtatta gggattacaa gtaatctagc 15900
gatgatttca agtatatggg aggatgtgca tggattacat gcaaatacta aaccatttta 15960
taaaagggac ttgaatatct gtagattttg gcatccgcag gggtccctag aaccagtcct 16020
ccgtggatac tgaaggggag ctgaactatt ctgcaccttg ttcatttcat ctcatcgtcc 16080
cagagagctc ttcataacga catagaaggc ctttctcatt tcttgtacgg ctgtgtaata 16140
gtgtcagtgg gtttcctgtc agttcctctg ctgttctgtg ttacagctca ttagagtatg 16200
tatgtgtcca cacatggaca gaaacataca ggcttttgct gtgttttttt gtctttgctt 16260
ttcttgcact taggacattt tgtgttgtta ttgttgttct agtcattatc ttttttgttg 16320
ttgtaatacc ttaagtaacc tttttttttt agttgaggct atgtatgtta tgtttggtgg 16380
tgttttgttt ggttggttct tttttttcgt agagactgtc tcccactgtt gcctaggttg 16440
gtcttgaact cctggcctta agccatcctc ccgccttggc ctctcaaagt gctgggatta 16500
cagctgtgag ccaccacact tggcccatat gttttttaac atgagcatga ctttgtgtat 16560
tttaatagca gccctaggca tacaccatat tcactaatgt tgcagtctga agatggggtt 16620
cccacatgtc tgggttcccc ctctttgtct tgtgtctccc acatagacta cacagacagc 16680
aggttagtta gcaccgtcgc agtcctgttc tccagaacag gcgggaagag gatgagatgg 16740
gagaatgtca gctggtgtct gctgctctcc agtctaccaa gaatcaaagg ctgcagtggg 16800
cagttcccag agacgcctgg cccagttgcc aaatggcttg gcaaaagaca ggcggggatt 16860
cctagactct ggagcaggtg gcctggtttc aaaacttgga cagaatgcat gaagcagcta 16920
cttgagaacc gagaaataaa tggtagcagg cagatgggcg gaggaaagac cagaattcag 16980
agtgccttgg agccaccagt gagttcgtca ttcttcttcc tcctgtgtct tcagcctgga 17040
catgaggcag ctcagaaggt agatgtgggc actgaatgag aacagagatg ttctctgctt 17100
ggagtctgga gaatgggaaa ggagactcct aaccctcaga gagaatggag gaaatcccct 17160
gttaggcttt ctcttttctt ttctttcctt tttttttttt tttttttttt tttttttgag 17220
atggagtctt gatctgttgc ccaggctgga gcgcagtggc gtgatctcag ctcgctgcaa 17280
cctctgcctc cagggttcaa gagattgtcc tgccccagcc tcccatatag ctgggattac 17340
aggcacatgc catcatgccc agctaatttt tatgtattct tttttttttt ttagtagaga 17400
tgggtttcac catgttggcc aggctggtct tgaactcccg acctcaggtg atctgcctgc 17460
ctcgacctcc caaagagata ggattacagg cgtgagccac cacacctgga tgcctgttag 17520
gctttttctc tttttttttt tttttttttg gttttttttt tttgtttttg agatggagtc 17580
tcactctgtc acccagactg gagtgcagtg gcacgatctt agcttactct aacctccacc 17640
tcccaggttc aagtgattct cccacctcag cttcctgagt agctggaatt gtaggcgcgc 17700
accaccactc ctggctaatt tttgtgtttt tagtagagac ggggtttcac catgttggcc 17760
aggctggtct cgaactcctg acctcagatc atctccctgc ctcagcctcc caaagtgccg 17820
ggattacagg cgccagccgg cacgcccggc tgtctgttag gtttttttct attttctttt 17880
ttgccttcat ctcttgcttc ccaggctcct gacaatccta cgttggtggc agcagcagca 17940
ggttccacag ccacctaaaa ccctgagaag ggcgactctt cctctgctgt ttgaggacat 18000
atagtcctca gaggatggga tgagcccttt tgcagcttgt tctctgtact gtcactgctt 18060
gaccctcaaa tgggggtgta atcacaggaa gtgaacagca gagtacggtg attaaacctc 18120
agctttctga ctggagggcc atgaaaggga gggactagga aactagaaag tactcaggag 18180
attgtgtgga gggaggagct gaggacagcg acctcataaa gtcgcccatg gaatcccagg 18240
ctcgcccctg agcgtcacac atgtgaggat gagatcttaa acagcatacc aaagactaag 18300
aacagaactg tgggagagac caccgcttgg ctttcagact gaccacgggc ggcacagact 18360
caggacagag ccaaatacca ctggaaaggc tttgaaaaca taactgacat tggaaccaca 18420
acccacagaa ggctggtcaa gcctgcagcc tgaacccagc atcatcaatt gcctgctaaa 18480
acaaaacatc aacattcttc ataggattta aataagaccc agacttttat aatatgcgaa 18540
atgcccggga ttccagccaa aattacgtag tttacgaaga cccaggaaat tccaggtggt 18600
tgggaaaaga caatcaacaa gggccaacag tgcaatgata cagatgttgg gattatcaga 18660
cagactttaa agcagtgatt accatcgtgc tccaaggagc aaagtaaaga ctctggagac 18720
aaatgtgaac agatagaaga tagagtgaag aaccaaatgg aaatttttta aattcctttg 18780
agagagggtc tcattctgtg ctcaggctgg agtgcagtgg tacaatcaca gctcactgcc 18840
acctcaacct ctctgggctc agtgatcctc ccacctcaac ctcttgagta gctgggacta 18900
cacgttcaca ccagcatatc tggttaactc tgtgtgtgtg tgtgtgtgtg tgtgtgtgta 18960
ttttttgtag aaagaaggtt ttgccatatt gcccagtctg gtctcaaact tctgggctta 19020
agtgatccac ccgcctcagc ctcccaaagt gctgggacta tagacatgag ccaccaaact 19080
tggctagaaa ttttcttttt tttcccttag acggagtctt gctctgtcac ccaggctgga 19140
gtgcagtggc gggatctcgg ctcactgcaa cctctgcctc ccaggctcaa gtgattctcc 19200
tacctcagcc tcccgagcaa ctgggattac aggcgcctgc caccatgcct ggctaatttt 19260
tatattttta gtagagatgg ggtttcacca tgttggccag gctggaggcc agaaattttt 19320
aaatggaaga tagtaactta aaaactcacg ggattggctg ggcgtggtgg ctcatgcctg 19380
taatcccaga actttgggag gccaaggcag atggatcaca nnnnnnnnnn nnnnnnnnnn 19440
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 19500
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 19560
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 19620
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 19680
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 19740
nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn 19800
nnnntggttc atgcatataa tccaatccca gcactttgga aggccgagcc aggtggatca 19860
cttgaggtca ggagttcgag accagcctgc ccaatatagt gaaactcctc ctctactaaa 19920
aatagaaaaa ttagccaggt gtggtgcggc acacctgtag tcccagctac ttggcaggct 19980
gaggcaggtg aattgcttga acctgggagg cagaggttgc agtgagccaa gatcgtgcca 20040
ctgcactcca aacctgggtg acagagtgag actccgtctc aagaaaaaat aggccgggtg 20100
tggtggctca cacctgtagt cccagcactt tgggaggcca aggtgggcgg atcacctgag 20160
gtcaggagtt cgagaccagc ctggccaaca tggtgaaacc ccatctctac taaaaataca 20220
aaaattagct gggcatggtg gtggttgcct gtaatcccag ctactcggga ggctgaaaca 20280
ggagaatcac ttgaacccgg gaggcagagg ttgcagtgag ctgagatcgc accattgcac 20340
tccagccagg gtgacaagag caaaactcta tctcaaaaaa aaacaaaaac aaaaaaaaaa 20400
cttcaccatc ctggctaaca cgatgaaacc ctgtctctac taaaaataca acaattagcc 20460
gggcatggtg gcgggcgcct gtagtcccag ctatgcggga ggctgaggca ggagaatggc 20520
gtgaacccag gaggcggagc ttactgtaag cagagatccc accactgcac tgcagcctag 20580
gtgacagagc aagactccgt ctcaaaacaa aacaaaacaa aaaacttcag tacatggaat 20640
gttacacaca gtggagcatt actcagcaat gaaaaggtac caactcttgt ccctcacaac 20700
atggatgaat ggcagagttg ccacactgag tgaaagcagc ctgtctccaa aggttcccag 20760
ccatgtgatt ccagctccat gacagtctcc caaggacaca cggatcatga cagaaaacat 20820
ggatggttgc caggtttagg aggagggggt taggacaaaa gagaagcccc ccaggagtgt 20880
cctaatccct gatggtcatg gtggttccat gaattgatgc atttgttaaa atgcctggaa 20940
ttggccaggc gtggtggctc atgccagtaa tcccagcact ttgggaggcc gaggcaggtg 21000
gatcacgagg tcaggagatc gagaccatcc tggctaacac ggtgaaaccc cgtctctact 21060
aaaaatacaa aaaattagcc gggcgcggtg gcgggcgcct gtagtcccgg ctactcggga 21120
ggctgaggca ggagaatggc gtgaacccag gaggcggagc ttgcagtgag cagagatcgc 21180
gccactgcac tccagcctgg gcgacagagc aaaactctgt ctcaaaaaaa aaaaaatgcc 21240
tggaattgtg caccgtgctg ccaaatcagt ccattttatt atgtatcttt ttttttgttt 21300
taaaccagat tggttgggtt cccttcccag aagatagata tctatgcaag caggaagaaa 21360
atagcatgga aatcctaacc gatcacctta gggagcgacc cctgggagaa caggctggcc 21420
caacatgaag gcatcctggt gggctcatat atattacagg ggctattcct ccagtgaggt 21480
tccccgcaga agctgcaggg tgtatggcac aggtaaatgg atttgcattt gggagttcca 21540
gtcttgagtt ggttgacatt gagctggtcg cctaagcgtg tcttcttgca tttgagagga 21600
ccgtgtgatc cttctctctt ggagtgcagt ggagatggag tcaggtagac atcctgcagc 21660
tccagcaggg ccgccaatca cggtcaccct gggctgagcc agctctgtcc tcctgtggcc 21720
aaggtcagcg tggcctggaa attggcctac agggcagtgt ctacctggtt ctcacctgtc 21780
tgcctgtcct gggaccagcc taggctcttt gggggattcc atggtcccga tgtctgctag 21840
ttgtgatttc ttaatttctg gatcccttag tcagaatggc ctcattctgg tcagggtcag 21900
atggtaaagt tttgtggggt ttttttgaaa cagtgtctta cactgtcgcc caggctgggg 21960
tgctatggcg ccatcgtagc tcactgtagc cttgaactcc taggctcaag cgatcctccc 22020
acctcagcct cccaggtagc tgggaccaca ggtgtgcacc accatgcctg gctaattttt 22080
tttttttttt gtagagacag ggtctcactg tgttgcccag gctgccctcg aatgattttt 22140
tttccttagc ctcccagagt gctgggatta caggcatgag ccaccacgcc caacctaaac 22200
tggttttttt gtttgttttt ttgagacaga gtctcgctct gttgccctgg ctggagtgca 22260
gtggtgcaat ctcagctcac tgcaacctcc acctcccagg ttcaagagat tgtcctgcct 22320
cagctgggat tacaggcatg cgccaccaca ccacaccaca cccgaccaat tttgtatttt 22380
taatagagac acagttttac catgttggtc aggctggtct tgaactcctg acctcagatg 22440
atccagctgc atcggcctcc caaagtgctg ggattacagg tgtgagccac tgcacctggc 22500
ctcagctgtt gatggtaacg tcacctcttg tgtttgtttg gcttgagatt gttgtaaagc 22560
acttcaaaag ccatgattct gttcatcctc gcagcaatag gtgcagaccc gtggctttcg 22620
tattaccagg tacttcgcag gctcagagcc accttcccag gacctccaac cctgtagaat 22680
gcattgcgtc caacaagcag atccctgctt tgccaaaccc agggttcctg gctgttcact 22740
gccagggaag gctttggctt acgtcttgct tggtgccctt tggggacctg gcttcacctg 22800
tttccttggc aggagacggc gggtgattcc catgctgtgt ggtgtcatga ggttctgagg 22860
tcatggacct aaagcaccta gtgtctcttg gtgacacatc tggactggct gcctgtggac 22920
catgaggctc cagatgagcc cctccacatc ccttccccta accctgccag gtggatacag 22980
ggaggcaggg tcaccgctgc ccactgaagt gctgtcttta ccttccggtc tctgcagacc 23040
tacgtctacc agtggccctg gacgctcctg ctcctggctg tcagcggctt ctgtaacttt 23100
gcccagaatg ttatcgcctt cagcatcctc aacctcgtta gcccgctgag ctactcggtc 23160
gccaatgcca ccaaaagaat catggtcatc acggtgtccc tgatcatgct gcgcaaccca 23220
gtcaccagca ccaacgtcct gggcatgatg accgccatcc tgggggtctt cctctataac 23280
aaggtgagag tctgagaggc tgggcaggga aggaagccgg ccccccaaca cccaggaagt 23340
cagaaaagga agggcctccc gggcgctcaa ggctggggtt gtatgtcaga gctttgccac 23400
tgactggttt atgatcttgg cgtagcccca tcccactctg gcttcctttt tcctgcatag 23460
gcaacctcag gtcctcaaat cattccggct gtgtctcagc tggggttttc cctccctcct 23520
ctcaaaggct ctgtttagtg cggtgtaagg acatgggatg gccaacaggg agggcttgcc 23580
ttcttttcct tttctttttt tttttttttt ttttcgagat ggagtctggc tctgtcaccc 23640
aggctggatt gcagtggcgc tccatcccag cttactgcaa cctccgcctc ccggggtcaa 23700
gcgattctcc tgcctcagcc tcccgagtag ctgggactac aggcgcctac cacacctggc 23760
taatttttgt atttttagta gagatggggt ttcaccatct tggccaggcc agcctccaac 23820
tcctgacctc agttgatcca cctgccttgg cctcccaaag tgtagggatt acaggcatga 23880
gccaccacac ctggcctctt catttgtttc ttaacacatg tagatatggg gtctctctat 23940
tttgtccagt ctggtctcca actcctagcc tcaagtgatc ctcccgccta ggcctcccaa 24000
agcacttgaa ctacaggcat aagccactgc gcctggccaa ggacttgtct tctgagtctg 24060
tccatgcact gtggtctggt ccattcaagt ctgctttcct tgctcaagcc ctatgactta 24120
tgccggcccc ggaggttaac tgactttttt tttttttttt tttttttctg agacagcgtc 24180
ttgctctgtc tcccaggctg gagtgcagtg gtatggtccc agctcactgc aacctccgcc 24240
tcctgggttc aagtgattct tgtgcctcag aacgcctgag tagctggaac tacagcatgc 24300
gccaccacac ccggttaatt ttttgtattt ttagtagaga cggggttttg ccatgttgcc 24360
caggctggtc tcaaactcct gagctcaggt gatcctcccg cctcgacctc ccaaagtgct 24420
gggattacag gtgtgagcca ccgcagccag ccagttgatt gactttgaat tacgagctct 24480
tatgccccgg gcatgtcctg tctcattgct ctctttctgg cacagaccaa gtacgatgca 24540
aaccagcaag ccaggaagca cctcctcccc gtcaccacag cagacctgag cagcaaggag 24600
cgtcaccgga gcccactgga gaagccccac aacggcctcc tcttccccca gcacggggac 24660
tatcagtacg gccgcaacaa catcttaaca gaccacttcc aatacagccg gcagagctac 24720
ccaaactcgt acagtttgaa ccgctatgat gtgtagagtc caaaggacag gaccagactg 24780
ttggtgactc cttccccggc ccccacagca gtatcagaaa cttctgacaa tcagtgaatg 24840
tacaacccag ccgaggggac ggtgcataac tctccatcag aagccctggg gttcctggcc 24900
ccccgtgagc cgcaggagga tgcgttgcct gcagtgcaga cggccgtgag ctctgggcaa 24960
acctaaacag agaccagtgt ctcatgctct ttcttcctgg agtctgtcat ctgagggccg 25020
tgtccctgcg gagatcttgg ccacgttgta cctttccatg tggaattatt ccccaagcag 25080
tgtagctcag agcacttgtg tctgcattcc agataacatt caggacctgt gtgaaaagct 25140
ggggtcactg tggctgtaga ccatgaactg gcagtggggg tgtccagggc ggtgcttgag 25200
aacgtcagac tggctagttt aattccctgg cgcagatacg cataggacca acagggtcac 25260
caagcagaca gggagcccgc gagaatcatt caaaacatcc ccagccacag agatggatcc 25320
agtttcctgg tcatcccctt agcagttcac aagttcctgg caaatgttcc aaagcaaaaa 25380
gcgattgcaa ttagcatcca gttcctgcag cctggtgctc tgccctgcac gtcagggttg 25440
gcatccannn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnnnnnnnnn nnntgttcag 25500
tatttcaagc tctatttctg tggcacatgt cttttgagag gcatcttcac ctcttctgtg 25560
atgacttggt atgttgtttg gtagagagat cttgattttc ggaggatctt gcatttttct 25620
agggaatatt ttgtagttgt gtgtgtgtgt ttttgccttg gtccccatta tgggatgcat 25680
taggactggc ctatgcatcg aaaatctttt tgtttgtaaa cgtttaaaaa caaagttccc 25740
cggccaggca cagtggctca cacctgtaat cccagcactt tgggaggcca agatgggcgg 25800
atcacgaggt caggagttcg agaccagcct ggccaacata gtgaaacccc atctctacta 25860
aaaatacaga aattagccgg gcatggtgtc gcgtgcctgt agtcccagct cctcaggctg 25920
ctgaggcagg cgaattgctt gaacctggga ggcagaagtt gtggtgagcc gagattgtgc 25980
actccagcct gggtaacaga gcgagactcc atctcaaaaa aaaaaacaaa acaaaaccaa 26040
gttcccactg gtgatgcctg tctgacacgt tttggtattt agtaggaaat gaagtgtttc 26100
gaagcttcga gagaagcttc aaaattgtca caattgctga aaacagaatg aatcgtgaac 26160
attatctcaa tattttgtat aatagacaag accacagtgt tttggttccc tgacctgttt 26220
ttgtgtttat gttaggatct gaatcatgtt ctgggtaagg ggacgaggag cgaacactgc 26280
actaagattt ggtttgccaa atcagattct ttggtcaaga gtcagtttgg ggccaggcgt 26340
ggtggctcat gcctgtaatc tcagcacttt gggaggctga ggtgggtgga tcactggagt 26400
ttgagaccac cctggccaac atggtgaaac cccatctcta ctaaaacaaa aattagccag 26460
gcatggtggc acctgcctgt aatcccagct acttgggagg ctgaggcagg agaatcactt 26520
gagcccagga ggtggaggtt tcagcgagct gagatcacac cactgcactc cagccttggt 26580
gacagagtga gactctgtct caaaaaaaaa aaaaaaaaaa aggaatcagt ttgggtcttg 26640
gcagaaatca acataaggaa tatgacaaga ccccagtagg taaccctgag tgctcaggtc 26700
cgagctgtgg tctcttttac ggcttcatga aaggaccgtg ccctcacgga ggggaccacg 26760
gcttggcttg tggggtctta ggtgatggct gccttctttc ttcatcacca cacccagctt 26820
cttgctggca cttaggggaa gagagcagca aatgagagat ttacctttta tctcccagcg 26880
agcgagatgt ttccctgttc agagaggaag taacatcact tatgcttgac tggtgtttct 26940
tttgttgttg tttgtttttc tttcaattgg aattctgtat ttaagatgtt atgtcagctg 27000
acacatggga cactcctgaa gaggtgactg gccccccacc ctgtttggcg gtgagtttcc 27060
gcaccaccgg cctcagaagt gtccctcttg cttcgtctct tgttcgcttg ctttgtaaat 27120
actttggtcc caagctgaga caattgctgt gtaaaacgtg aagagtcaat cccaaagggt 27180
gttatttgtc agaagaactt gccgtgtgcc ttcaccgaag gcagtcaagt ctgcagttgg 27240
atttttctca ctggtgaatg acaagaaaca gggataattt tgcactgcgg agatattacg 27300
ggagttgtct atatgattat atatagtacc tgattctttg aacatattat tgaactccaa 27360
aatgaattcg acctccattc aggcttcctg aaatctctga agttgctgaa atttgtatat 27420
tattttcctt ttccaatgca agatctgctg gtgacgggaa atgactgtct ggttttatta 27480
tggtttataa attaataaat gggctattta attctgtata taaatttaca gcaagtacgt 27540
acactggaat gaatgaggca atcacgttac accaaatcag cagatcaaaa gacaaacaca 27600
tatttctgag acttgaaggt ccacatcccc ccgccccctg ccaagatgga gtcttgcttt 27660
gttgctcagg ctggagtgca gtggcgcagt ctcagctcac tacaacctcc atcccccggg 27720
ttcaggtgat tctcgtgcct cagcctcccg agta 27754
4
258
PRT
Drosophila melanogaster
4
Ile Pro Arg Pro Tyr Tyr Tyr Arg Leu Ile Val Pro Leu Ala Leu Gly
1 5 10 15
Lys Leu Leu Ala Ser Val Thr Ser His Ile Ser Leu Trp Lys Val Pro
20 25 30
Val Ser Tyr Ala His Thr Val Lys Ala Thr Met Pro Leu Phe Thr Val
35 40 45
Val Leu Thr Arg Val Phe Phe Gly Glu Lys Gln Pro Thr Leu Val Tyr
50 55 60
Leu Ser Leu Leu Pro Ile Ile Thr Gly Val Gly Ile Ala Thr Val Thr
65 70 75 80
Glu Ile Ser Phe Asp Met Met Gly Leu Ile Ser Ala Leu Ile Ser Thr
85 90 95
Met Gly Phe Ser Met Gln Asn Ile Phe Ser Lys Lys Val Leu Lys Asp
100 105 110
Thr Asn Ile His His Leu Arg Leu Leu His Leu Leu Gly Lys Leu Ser
115 120 125
Leu Phe Ile Phe Leu Pro Leu Trp Leu Tyr Met Asp Ser Phe Ala Val
130 135 140
Phe Arg His Thr Ala Ile Lys Asn Leu Asp Tyr Arg Val Ile Ala Leu
145 150 155 160
Leu Phe Ala Asp Gly Val Leu Asn Trp Leu Gln Asn Ile Ile Ala Phe
165 170 175
Ser Val Leu Ser Leu Val Thr Pro Leu Thr Tyr Ala Val Ala Ser Ala
180 185 190
Ser Lys Arg Ile Phe Val Ile Ala Val Ser Leu Leu Ile Leu Gly Asn
195 200 205
Pro Val Thr Trp Val Asn Cys Val Gly Met Thr Leu Ala Ile Val Gly
210 215 220
Val Leu Cys Tyr Asn Arg Ala Lys Gln Leu Thr Arg Gly Arg Glu Gln
225 230 235 240
Pro Thr Leu Pro Leu Ser Gln Thr Ser Tyr Val Lys Tyr Ser Pro Leu
245 250 255
Glu Gln
5
108
PRT
Homo sapiens
5
Met Pro Ile Trp Val Val Leu Leu Ser Arg Ile Ile Met Lys Glu Lys
1 5 10 15
Gln Ser Thr Lys Val Tyr Leu Ser Leu Ile Pro Ile Ile Ser Gly Val
20 25 30
Leu Leu Ala Thr Val Thr Glu Leu Ser Phe Asp Met Trp Gly Leu Val
35 40 45
Ser Ala Leu Ala Ala Thr Leu Cys Phe Ser Leu Gln Asn Ile Phe Ser
50 55 60
Lys Lys Val Leu Arg Asp Ser Arg Ile His His Leu Arg Leu Leu Asn
65 70 75 80
Ile Leu Gly Cys His Ala Val Phe Phe Met Ile Pro Thr Trp Val Leu
85 90 95
Val Asp Leu Ser Ala Phe Leu Val Ser Ser Asp Leu
100 105
6
265
PRT
Arabidopsis thaliana
6
Pro Tyr Pro Ala Thr Val Thr Ala Phe Gln Leu Gly Cys Gly Thr Leu
1 5 10 15
Met Ile Ala Ile Met Trp Leu Leu Lys Leu His Pro Arg Pro Lys Phe
20 25 30
Ser Pro Ser Gln Phe Thr Val Ile Val Gln Leu Ala Val Ala His Thr
35 40 45
Leu Gly Asn Leu Leu Thr Asn Val Ser Leu Gly Arg Val Asn Val Ser
50 55 60
Phe Thr His Thr Ile Lys Ala Met Glu Pro Phe Phe Thr Val Leu Leu
65 70 75 80
Ser Val Leu Leu Leu Gly Glu Trp Pro Ser Leu Trp Ile Val Cys Ser
85 90 95
Leu Leu Pro Ile Val Ala Gly Val Ser Leu Ala Ser Phe Thr Glu Ala
100 105 110
Ser Phe Asn Trp Ile Gly Phe Cys Ser Ala Met Ala Ser Asn Val Thr
115 120 125
Asn Gln Ser Arg Asn Val Leu Ser Lys Lys Phe Met Val Gly Lys Asp
130 135 140
Ala Leu Asp Asn Ile Asn Leu Phe Ser Ile Ile Thr Ile Ile Ser Phe
145 150 155 160
Ile Leu Leu Val Pro Leu Ala Ile Leu Ile Asp Gly Phe Lys Val Thr
165 170 175
Pro Ser His Leu Gln Val Ala Gly Leu Ser Val Lys Glu Phe Cys Ile
180 185 190
Met Ser Leu Leu Ala Gly Val Cys Leu His Ser Tyr Gln Gln Val Ser
195 200 205
Tyr Met Ile Leu Glu Met Val Ser Pro Val Thr His Ser Val Gly Asn
210 215 220
Cys Val Lys Arg Val Val Val Ile Thr Ser Ser Ile Leu Phe Phe Lys
225 230 235 240
Thr Pro Val Ser Pro Leu Asn Ser Ile Gly Thr Ala Thr Ala Leu Ala
245 250 255
Gly Val Tyr Leu Tyr Ser Arg Ala Lys
260 265
7
226
PRT
Arabidopsis thaliana
7
Leu Phe Pro Val Ala Val Ala His Thr Ile Gly His Val Ala Ala Thr
1 5 10 15
Val Ser Met Ser Lys Val Ala Val Ser Phe Thr His Ile Ile Lys Ser
20 25 30
Gly Glu Pro Ala Phe Ser Val Leu Val Ser Arg Phe Ile Leu Gly Glu
35 40 45
Thr Phe Pro Thr Ser Val Tyr Leu Ser Leu Ile Pro Ile Ile Gly Gly
50 55 60
Cys Ala Leu Ser Ala Leu Thr Glu Leu Asn Phe Asn Met Ile Gly Phe
65 70 75 80
Met Gly Ala Met Ile Ser Asn Leu Ala Phe Val Phe Arg Asn Ile Phe
85 90 95
Ser Lys Lys Gly Met Lys Gly Lys Ser Val Ser Gly Met Asn Tyr Tyr
100 105 110
Ala Cys Leu Ser Met Leu Ser Leu Leu Ile Leu Thr Pro Phe Ala Ile
115 120 125
Ala Val Glu Gly Pro Gln Met Trp Val Asp Gly Trp Gln Thr Ala Leu
130 135 140
Ala Thr Val Gly Pro Gln Phe Val Trp Trp Val Val Ala Gln Ser Val
145 150 155 160
Phe Tyr His Leu Tyr Asn Gln Val Ser Tyr Met Ser Leu Asp Gln Ile
165 170 175
Ser Pro Leu Thr Phe Ser Val Gly Asn Thr Met Lys Arg Ile Ser Val
180 185 190
Ile Val Ser Ser Ile Ile Ile Phe Arg Thr Pro Val Gln Pro Val Asn
195 200 205
Ala Leu Gly Ala Ala Ile Ala Ile Leu Gly Thr Phe Leu Tyr Ser Gln
210 215 220
Ala Lys
225
8
224
PRT
Arabidopsis thaliana
8
Leu Phe Pro Val Ala Val Ala His Thr Ile Gly His Val Ala Ala Thr
1 5 10 15
Val Ser Met Ser Lys Val Ala Val Ser Phe Thr His Ile Ile Lys Ser
20 25 30
Gly Glu Pro Ala Phe Ser Val Leu Val Ser Arg Phe Ile Leu Gly Glu
35 40 45
Thr Phe Pro Thr Ser Val Tyr Leu Ser Leu Ile Pro Ile Ile Gly Gly
50 55 60
Cys Ala Leu Ser Ala Leu Thr Glu Leu Asn Phe Asn Met Ile Gly Phe
65 70 75 80
Met Gly Ala Met Ile Ser Asn Leu Ala Phe Val Phe Arg Asn Ile Phe
85 90 95
Ser Lys Lys Gly Met Lys Gly Lys Ser Val Ser Gly Met Asn Tyr Tyr
100 105 110
Ala Cys Leu Ser Met Leu Ser Leu Leu Ile Leu Thr Pro Phe Ala Ile
115 120 125
Ala Val Glu Gly Pro Gln Met Trp Val Asp Gly Trp Gln Thr Ala Leu
130 135 140
Ala Thr Val Gly Pro Gln Phe Val Trp Trp Val Val Ala Gln Ser Val
145 150 155 160
Phe Tyr His Leu Tyr Asn Gln Val Ser Tyr Met Ser Leu Asp Gln Ile
165 170 175
Ser Pro Leu Thr Phe Ser Val Gly Asn Thr Met Lys Arg Ile Ser Val
180 185 190
Ile Val Ser Ser Ile Ile Ile Phe Arg Thr Pro Val Gln Pro Val Asn
195 200 205
Ala Leu Gly Ala Ala Ile Ala Ile Leu Gly Thr Phe Leu Tyr Ser Gln
210 215 220
9
228
PRT
Zea mays
9
Lys Val Leu Phe Pro Val Ala Val Ala His Thr Ile Gly His Val Ala
1 5 10 15
Ala Thr Val Ser Met Ser Lys Val Ala Val Ser Phe Thr His Ile Ile
20 25 30
Lys Ser Ala Glu Pro Ala Phe Ser Val Leu Val Ser Arg Phe Phe Leu
35 40 45
Gly Glu Thr Phe Pro Ile Pro Val Tyr Leu Ser Leu Leu Pro Ile Ile
50 55 60
Gly Gly Cys Ala Leu Ala Ala Val Thr Glu Leu Asn Phe Asn Met Val
65 70 75 80
Gly Phe Met Gly Ala Met Ile Ser Asn Leu Ala Phe Val Phe Arg Asn
85 90 95
Ile Phe Ser Lys Arg Gly Met Lys Gly Lys Ser Val Ser Gly Met Asn
100 105 110
Tyr Tyr Ala Cys Leu Ser Ile Met Ser Leu Val Ile Leu Thr Pro Phe
115 120 125
Ala Ile Ala Met Glu Gly Pro Gln Met Trp Ala Ala Gly Trp Gln Lys
130 135 140
Ala Leu Ala Glu Val Gly Pro Asn Val Val Trp Trp Ile Ala Ala Gln
145 150 155 160
Ser Val Phe Tyr His Leu Tyr Asn Gln Val Ser Tyr Met Ser Leu Asp
165 170 175
Gln Ile Ser Pro Leu Thr Phe Ser Ile Gly Asn Thr Met Lys Arg Ile
180 185 190
Ser Val Ile Val Ser Ser Ile Ile Ile Phe His Thr Pro Val Arg Ala
195 200 205
Val Asn Ala Leu Gly Ala Ala Ile Ala Ile Leu Gly Thr Phe Leu Tyr
210 215 220
Ser Gln Ala Lys
225
10
235
PRT
Schizosaccharomyces pombe
10
Pro Ser Lys Tyr Val Leu Tyr Thr Thr Leu Pro Leu Ser Ile Phe Gln
1 5 10 15
Ile Gly Gly His Val Phe Gly Ser Leu Ala Thr Thr Lys Ile Pro Val
20 25 30
Ser Thr Val His Thr Val Lys Ala Leu Ser Pro Leu Phe Thr Val Leu
35 40 45
Ala Tyr Arg Phe Met Phe Arg His Val Tyr Ser Ala Met Thr Tyr Phe
50 55 60
Ser Leu Val Pro Leu Thr Phe Gly Val Thr Leu Ala Cys Ser Phe Glu
65 70 75 80
Leu Ser Ala Asp Ile Val Gly Leu Leu Tyr Ala Leu Ile Ser Thr Cys
85 90 95
Ile Phe Val Ser Gln Asn Ile Phe Gly Ser Lys Ile Phe Met Glu Ala
100 105 110
Lys Ser His Ser Thr His Thr Lys Lys His Tyr Asn Lys Leu Asn Leu
115 120 125
Leu Leu Tyr Ser Ser Gly Val Ala Phe Ile Val Met Ile Pro Val Trp
130 135 140
Leu Tyr Gln Glu Gly Phe Ala Tyr Leu Pro Glu Val Gly Ser Pro Val
145 150 155 160
Phe Leu Asn Leu Ile Tyr Asn Gly Leu Ser His Phe Phe Gln Asn Ile
165 170 175
Leu Ala Phe Thr Leu Leu Ser Ile Ile Ser Pro Val Ala Tyr Ser Ile
180 185 190
Ala Ser Leu Ile Lys Arg Ile Phe Val Ile Val Val Ser Ile Ile Trp
195 200 205
Phe Gln Gln Ala Thr Asn Phe Thr Gln Gly Ser Gly Ile Phe Leu Thr
210 215 220
Ala Ile Gly Leu Trp Leu Tyr Asp Arg Ser Lys
225 230 235
|
1
ATGCCACTGC CTCTGTTTGC TCCCTACCCA GCCACTGTCA
GGCCAGTGTT
51
GTCTGTCATG TGCCAGAAGC TTCTCAGCTG TGGACGCAGA
AGGGAGCAAC
101
TTTGCTATTT GGTCCATCCG CATCCGTCGT CCGGCCCGCT
GCTGCCGCCG
151
CGCTTCTACC CGCGCTACGT GCTACCGCTC GCCTTCGGCA
AGTACTTCGC
201
GTCCGTGTCA GCGCACGTCA GCATCTGGAA GGTGCCCGTG
TCCTATGCAC
251
ACACCGTCAA GGCCACCATG CCCATCTGGG TGGTCCTCCT
GTCCCGGATC
301
ATTATGAAGG AGAAGCAGAG CACCAAGGTA TACTTGTCAC
TCATCCCCAT
351
CATCAGCGGT GTCCTGCTGG CCACCGTCAC CGAGTTGTCT
TTTGACATGT
401
GGGGACTCGT CAGCGCCCTC GCCGCCACGC TGTGCTTCTC
GCTTCAGAAC
451
ATTTTCTCCA AAAAGGTCTT GCGAGATTCA CGGATCCACC
ATCTCCGGCT
501
GCTCAACATC CTGGGCTGCC ACGCCGTCTT CTTTATGATC
CCCACCTGGG
551
TTCTGGTGGA CCTCTCGGCT TTCCTGGTCA GCAGCGACTT
GCCTGCACAT
601
GAGGCAGCTC AGAAGACCTA CGTCTACCAG TGGCCCTGCA
CGCTCCTGCT
651
CCTGGCTGTC AGCGGCTTCT GTAACTTTGC CCAGAATGTT
ATCGCCTTCA
701
GCATCCTCAA CCTCGTTAGC CCGCTGAGCT ACTCGGTCGC
CAATGCCACC
751
AAAAGAATCA TCGTCATCAC CGTGTCCCTG ATCATGCTGC
GCAACCCAGT
801
CACCAGCACC AACGTCCTGG GCATGATGAC CGCCATCCTG
GCGGTCTTCC
851
TCTATAACAA GACCAAGTAC GATGCAAACC AGCAAGCCAG
GAAGCACCTC
901
CTCCCCGTCA CCACAGCAGA CCTGAGCAGC AAGGAGCGTC
ACCGGAGCCC
951
ACTGGAGAAG CCCCACAACG GCCTCCTCTT CCCCCAGCAC
GGGGACTATC
1001
AGTACGGCCG CAACAACATC TTAACAGACC ACTTCCAATA
CAGCCGGCAG
1051
AGCTACCCAA ACTCGTACAG TTTGAACCGC TATGATGTGT
AG
FEATURES:
Start Codon: 1
Stop Codon: 1090
The present invention provides amino acid sequences of peptides that are encoded by genes within the human genome, the transporter peptides of the the present invention. The present invention specifically provides isolated peptide and nucleic acid molecules, methods of identifying orthlogs and paralogs or the transporter peptides, and methods of identifying modulators of the transporter peptides.
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BACKGROUND OF THE INVENTION
The present invention is generally directed to switches for use in superconducting current paths. More particularly, the present invention is directed to a superconducting loop switch which is capable of exhibiting rapid turn-on and turn-off responses so as to be able to permit precise control of the current in the loop.
In applications requiring a highly stable magnetic field, such as in nuclear magnetic resonance (NMR) imaging or spectroscopy, it is customary to join the two ends of a superconducting electromagnet to each other through a length of superconductive material configured to operate as a superconducting switch. Any electrical joints in the circuit are also made to be superconducting so that once a current is established in such a magnet, it can be maintained constant for very long periods of time. The aforementioned switch is referred to herein as a main switch. It has two possible functions, both of which are based on its ability to be switched from a superconducting state to a conventional resistive state. This main switch is in effect connected across the terminals of the superconductive electromagnet. Once a power supply has established a desired current level in the superconducting loop, the main switch is switched from the resistive state to the superconducting state. Once this transition occurs, the current in the superconducting electromagnet coil can no longer change. The current from the power supply may be reduced to zero, establishing a current in the loop comprising the switch and the coil. This current is referred to as a persistent current the properties of which are more particularly described below. Additionally, the main switch may also be switched to the resistive state, for example by heating a part of the superconductive element. The main switch may actually be configured from part of the same superconductive conductor employed in the electromagnet coil or coils. It is desirable that the heater power required to maintain the superconductive switch in the resistive state be moderate, both to keep the switching power supply small and, more importantly to minimize coolant consumption (boil-off). Accordingly, the main switch is disposed so as to be thermally insulated from the cryogenic coolant. The present invention, however, is not directly concerned with the construction of this main switch, but rather with the construction of a second switch to be employed in the superconducting loop so as to be able to permit precise control of the superconducting current.
Although the superconducting phenomenon gives rise to very stable magnetic fields exhibiting deviations of less than one part in ten million per hour, the ability to initially determine the current and field value is limited by the power supply. In particular, the setability of the current and field level is limited by the setability of the power supply. Power supplies, particularly constant current power supplies, are generally limited to an accuracy of no more than one part in 1,000 or one part in 10,000. This is particularly true with respect to power supplies providing the level of superconductive current considered herein. Typically the current levels considered herein for the main electromagnet are between approximately 1,000 amperes and 2,000 amperes. However, in certain applications, such as NMR imaging, it is desirable to be able to set the current more accurately, for example, to one part in one million. Such an accuracy in current setability is not achievable simply through the use of the main switch described above. In particular, since this switch must be thermally isolated from the cryogenic medium, its response time characteristics cannot be sufficiently controlled to effect the desired current adjustment. In particular, it is commonly the case that once a transition to the resistive state has been initiated, a main switch cannot be returned to the superconducting state independently of the heater input, until after the main coil circuit current has been essentially reduced to zero.
Accordingly, it is seen that there is a need for precise adjustment of the current in a superconducting loop. This precision is also seen not to be readily providable through the control of the power supply or the main current switch.
SUMMARY OF THE INVENTION
In accordance with a preferred embodiment of the present invention, the switch for fine adjustment of current in a persistent current superconducting loop comprises a length of superconductor disposed on a substrate on which there is provided means to heat at least a portion of the superconductor. The superconductor is mounted on an external portion of the substrate so as to be readily exposable to a cryogenic coolant, such as liquid helium. The superconductive segment also preferably has attached thereto a parallel, resistive path which acts as a stabilizer to control heat and current flow in such a way that the device of the present invention is cryostable in the absence of heater input power. Furthermore, the superconductor is preferably electrically insulated from the means for heating, which is preferably disposed within a recess or channel machined or molded into the substrate which preferably comprises a material such as epoxy and glass fiber. In accordance with another embodiment of the present invention, a superconductive electromagnet circuit employs the switch of the present invention in series with either an electromagnet coil or the main superconducting current switch.
Accordingly, it is an object of the present invention to provide a means for precise control of electrical current and magnetic fields, particularly in NMR imaging and spectroscopic systems.
It is still a further object of the present invention to provide an electric circuit for use in NMR imaging and spectroscopy.
It is yet another object of the present invention to provide a superconducting switch element exhibiting a rapid transition from the superconductive and to the resistive state and vice versa.
It is still a further object of the present invention to provide a rapidly controllable switch for precisely dissipating measured amounts of electrical energy in a superconducting circuit carrying a persistent current.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. This invention, however, both as to organization and method of practice, together with further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings in which:
FIG. 1 is a plan view illustrating the switch of the present invention;
FIG. 2 is a cross-sectional side elevation view of the switch of FIG. 1;
FIG. 3 is a cross-sectional view taken through a portion of the view in FIG. 2; and
FIG. 4 is an electric circuit employing the switch of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The design of the switch of the present invention is based upon the desirability to achieve rapid switching between the resistive and superconducting states in a conductor which is capable of exhibiting both. Another important object of the present invention is the dissipation of relatively small amounts of energy in the switch, during its operation in the resistive state. For example, by controllably introducing a very small resistance in the superconducting circuit path, the current can be reduced at a very slow rate, for example one part per million per second. The total current change can then be readily controlled by controlling the length of time that the switch of the present invention is permitted to operate in the resistive state. This controllability is not present in main current switches, such as are described above, and which are used for establishing the persistent current in the loop, since these switches must be thermally isolated from the cryogenic fluid. Accordingly, their transition response times are inadequate to achieve the results desired in switches of the present design. Moreover, they are designed so that once a transition to the resistive state has been initiated by a heater, the resistive state can not be recovered simply by removing the source of heater power. Rather, the current through the main current path through the switch must be substantially reduce because of I 2 R heating effects.
FIG. 1 illustrates one embodiment of the present invention showing the construction of current adjustment switch 10. In particular there is shown length 14 of superconductor material. This length of superconductive material preferably comprises an existing lead portion from a superconducting device such as an electromagnet coil. Superconductor 14 is disposed against substrate 15 by means of hold-down brackets 12a, 12b, and 12c (the exact number of brackets being optional). The brackets are fixed to substrate 15 by means of screw fastening means 11 or any other convenient fastening device. Although not visible in FIG. 1, a strip of heater material 20 is disposed beneath superconductive conductor 14. Superconductor 14 is electrically insulated from heater 20 by means of insulating sheet 16 comprising material such as Kapton®. In general, though, insulating sheet 16 preferably comprises material having sufficient electrical insulating properties. The electrically insulating properties of sheet 16 are not critical in that large potential differences across this sheet are not generally developed. However, it is generally desirable that sheet 16 comprise a material which does not exhibit excessive levels of thermal insulation. In part, to the extent that the thermally insulating properties of the material in sheet 16 are excessive, it may be possible to reduce the thickness of the sheet so as to maximize thermal transfer between the heater element and the length of superconductor 15. Substrate 15 preferably comprises a material such as epoxy and glass fiber. Likewise, brackets 12a, 12b, and 12c preferably comprise the same or similar material. Nonetheless, it is also possible to employ metal in brackets 12a, 12b, and 12c.
There are two significant aspects of the present invention illustrated in FIG. 1. The first is that the length of superconductor 14 is disposed on an external portion of the substrate. This provides the capability for superconductor 14 to be in close thermal contact with the cryogenic fluid. This permits a rapid and controlled return to the superconducting state. Furthermore, stabilizing conductors 18 also comprise a significant aspect of the present invention. The active section of the switch must be cryostable at the maximum operating current. That is, if the superconducting circuit is presumed to be carring the maximum operating current with the superconductor 14 presumed to be in a resistive state, the steady state temperature of the conductor must be below the superconducting transition temperature for that conductor at the operating current, taking into account any magnetic field at the conductor. To achieve this condition it is generally necessary to provide a parallel conductive path for the current. In FIG. 1 this path is provided by stabilizing conductors 18 shown soldered to opposite sides of superconductor 14. Additionally, it is also possible to provide this parallel conducting path in the form of a separate circuit element. More particularly, when the heating element of the switch of the present invention is turned on there are two heat sources for the length of superconductor 4. In particular, there is the heating element itself which is disposed directly below it beneath insulating sheet 16. Furthermore, there is the co-called I 2 R heating which occurs in the resistive state of superconductor 14. This aspect does not pose problems when the switch is being changed from the superconducting to the resistive state. However, thermal balance considerations must be considered in the transition from the resistive state to the superconducting state so that I 2 R heating loss is not sufficient to prevent return of superconductor 14 to the superconducting state. Naturally, the dimensions of the stabilizing conductor or conductors depend upon the size of the current in the cross-section of the superconductor together with heat flow rates and the specific geometry of the device.
With respect to device geometry, it is specifically noted that while superconductor 14 is disposed on a flat, electrically insulating substrate, it is also possible to dispose superconductor 14 on other substrate geometries. For example, a cylindrical substrate may also be provided, particularly if the current level dictates a relatively long length for superconductor 14.
The placement of heater 20 in channel 19 in substrate 15 is more particularly illustrated in FIG. 2. Heater 20 is shown disposed so as to lie in close proximity to the length of superconductor 14 which is disposed between fold-down brackets 12a and 12b. This placement provides rapid heating of superconductor 14 while at the same time substrate 15 acts to thermally insulate the cryogenic fluid from an exposure to undesirable temperatures on the lower side of the substrate. Heater 20 preferably comprises a resistive strip comprising material such as nichrome. Leads 21 are affixed to the strip and extend through vertical channels in substrate 15 for connection to an external electrical power source. To provide further thermal insulation between the heater and the cryogenic fluid, the channels for leads 21 are preferably filled with a plug of material such as wax or sealing grease 17. Such materials are naturally quite solid at cryogenic temperatures. The length of superconductor 14 which is in close thermal contact with heater 20 is also illustrated in FIG. 2.
An additional view of the switch of the present invention is provided in FIG. 3. In particular, FIG. 3 is particularly illustrative of the relative dimensions for stabilizing conductors 18 and superconductor 14.
As shown in FIGS. 1-3, it is particularly seen that the close proximity of superconductor 14 to heater 20 provides a means to rapidly switch the device from the superconducting to the resistive state. On the other hand, the close proximity and exposure of superconductor 14 to a cryogenic fluid together with its presence in close proximity to stabilizing conductors 18 provide a means for rapid transition of the device from the resistive to the superconducting state in spite of the presence of I 2 R losses which may still nonetheless be present in conductor 14 which may be in the resistive state for a period even after heater 20 has been turned off. Thus the ability to rapidly and precisely control the on and off times of switch 10 is seen to make it particularly suitable for controlling and adjusting persistent currents in superconducting current loops.
A circuit in which switch 10 is particularly employable is shown in FIG. 4. In particular, there are shown therein three superconductive current loops, each of which includes coil (such as an electromagnet coil) 110a, 110b, or 110c together with a main switch 120a, 120b, or 120c respectively disposed across the corresponding coil. Additionally, joints 121a, 121b, 121c, 121d, 121e, and 121f are particularly seen to be superconducting joints. The superconductive paths are shown as heavy lines in FIG. 4. Small circles indicate resistive joints either between resistive conductors or between a resistive conductor and a superconductor. Where a resistive joint is shown joining a superconductive element, it is understood that the superconductive path exists between the superconductive elements at that point. Power is supplied to establish the current in the respective coils through conventional resistive connections T 1 , T 2 , T 3 , and T 4 , as shown. Additionally, conventional protective resistive elements 115a, 115b, and 115c are also shown disposed in parallel with main switches 120a, 120b, and 120c respectively. More particularly, with respect to the present invention, switch 10 is shown disposed in a series connection with coil 110a, 110b and 110c. In general, in such a multicoil electromagnet circuit as illustrated in FIG. 4, it is generally desirable to employ switch 10 in each one of the persistent current loops. However, while switch 10 is shown connected in series in a position immediately adjacent to the coils, it is also possible to employ switch 10 in circuit locations immediately adjacent, and in series with, switches 120a, 120b, and 120c. Furthermore, as indicated above, it is also preferable to employ the coil or switch conductor itself as part of the fine adjustment switch.
From the above, it should be appreciated that the fine adjustment switch of the present invention achieves its stated objects. In particular, it is seen that the switch of the present invention provides a means for a rapid transition to and from the resistive and superconductive states. It is further seen that the time for which the switch of the present invention is in the resistive state may be carefully controlled so as to easily permit the adjustment of persistent current in the superconducting loop. However, it should be borne in mind that the adjustment of the present invention is, of necessity, an adjustment in one direction only. However, if the current is reduced to a level below that which is desired, it is always possible to reconnect the current power supply to the circuit to effect the desired change. It is also seen that the present invention is readily fabricatable from inexpensive materials and may in fact be advantageously formed in part from existing portions of the superconducting coil leads.
While the invention has been described in detail herein, in accordance with certain preferred embodiments thereof, many modifications and changes therein may be effected by those skilled in the art. Accordingly, it is intended by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention.
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A small portion of a lead for a superconducting coil is made to function as a controllable resistor with a low resistance value and fast thermal response so as to be capable of rapidly being switched between the superconducting and resistive states. The device is thus capable of fine adjustment of the current flowing in a superconducting loop. The switch includes lengths of parallel conductor so that the resulting section of superconductive material is cryostable. The superconducting oil lead is disposed on a substrate so as to permit ready access for helium or other cryogenic coolant to most lead surfaces. The small mass and close contact with the coolant produce rapid turn-on and turn-off response characteristics. Furthermore, the low overall resistance causes the coil current to decay slowly, thus preventing precise control of the superconducting current.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This non-provisional patent application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/947,652, entitled “Method For Entity Enrichment Of Digital Content To Enable Advanced Search Functionality In Content Management Systems,” filed Mar. 4, 2014, which hereby incorporated in its entirety herein.
[0002] This application is related to U.S. patent application______[QBS-ENED-001-US], entitled “Method for Disambiguating Features in Unstructured Text,” filed Dec. 2, 2014; U.S. patent application______[QBS-EVDT-001-US], entitled “Event Detection Through Text Analysis Using Trained Event Template Models,” filed Dec. 2, 2014; and U.S. patent application______[QBS-IMDB-001-US], entitled “Method for Facet Searching and Search Suggestions,” filed Dec. 2, 2014; each of which are incorporated herein by reference in their entirety.
TECHNICAL FIELD
[0003] The invention generally refers to search engines and content management. More specifically, extending a content management system's search engine technology to enable geotagging and named entities enrichment of digital content.
BACKGROUND
[0004] Content management and document management systems for document versioning and collaborative project management are known. One non-limiting example may be Microsoft's Sharepoint 2013® software and application suite of tools. Microsoft SharePoint 2013® is a family of software products developed by Microsoft Corporation for collaboration, file sharing and web publishing. SharePoint 2013® may provide a user with a vast amount of content or information and it may become difficult for a user to find the most relevant information for a particular circumstance. To mitigate these issues SharePoint 2013® provides a search engine in order to assist users in finding the content that they need. A user may enter a keyword based search query and the search engine in SharePoint 2013® may return to the user a list of the most relevant results found within the context of the SharePoint 2013® platform once the content has been indexed.
[0005] At times a user may desire to find content related to geographic entities in SharePoint 2013® or other type of entity such as organizations or people referred to within a document. SharePoint 2013® does not provide out of the box functionality to automatically extract entities from documents. Particularly, it does not support geotagging content to extract geographic entities and resolve them to a geographic location. Also, SharePoint 2013 does not support entity tagging in order to identify, disambiguate and extract named entities, such as, organizations or people in a document. However, SharePoint 2013® search may be extended to enable effective geographic searches and other entity related searches, including entity-based search facets. Previous versions of SharePoint 2013® included “FAST Search” for SharePoint, from which it was possible to extend the content processing pipeline through sandboxed applications, but this was both slow and limited in the information it could access.
[0006] SharePoint 2013® introduces a much more open API which makes it possible to add specialized linguistics such as concept extraction, relationship extraction, geotagging, summarization and as well as sophisticated text analytics. Thus, an opportunity exists to extend the capabilities of SharePoint 2013® search engine to enable geographic and other entity based searches.
SUMMARY
[0007] Disclosed herein are systems and methods for enabling geographic entity-based searches in content management systems, like Microsoft's SharePoint 2013®. Embodiments described The method involves extending the SharePoint 2013® search architecture by adding a geographic tagging web service. The system includes a computer processor operatively associated with a computer memory and one or more I/O device, in which the processor and memory are configured to operate one or more SharePoint 2013® processes. The system also includes another computer processor operatively associated with a computer memory and one or more I/O devices, in which the processor and memory are configured to host and provide processing for a geotagging web service. The SharePoint 2013® system may include a crawling component, a content processing component and a search indexing component in order to enable search of content. The content processing component in SharePoint 2013® search may extend its functionality by using the Content Enrichment Web Service (CEWS) feature.
[0008] The method involves crawling content from the different sources in order to obtain an array of crawled properties that are sent for content processing. During content processing, a trigger condition may determine if crawled properties may benefit from additional processing in order to enrich the original content with additional geographic metadata properties. If the crawled properties don't benefit from additional processing the crawled properties may be mapped to managed processing and sent to a search index. If the crawled properties benefit from external web services processing, the CEWS may make a simple object access protocol (SOAP) request to a configurable endpoint using hypertext transfer protocol (HTTP) or any other web service call method. An entity enrichment service may determine the type of content. If the content is in an image format, its metadata such as file location may be sent to an optical character recognition (OCR) engine so that the original document can be retrieved and processed asynchronously to convert to text and sent back to the crawl component to be re-crawled in text format. If the content is in text format the geotagging web service may identify geographic metadata and associate it with the content as managed properties. After the content has been geotagged, it may be sent to the indexing component.
[0009] An additional search user interface (UI) may be added using either SharePoint 2013® web parts or by modifying the standard layout of SharePoint 2013® search with standard web development tools such as HTML, HTML 5, JavaScript and CSS among others. The search UI may assist a user in performing geographic search queries or displaying geographic search results using digital geographic features such as for example and without limitation, digital maps. The search UI can also be enhanced to perform faceted search using the additional enriched entities or their associated metadata.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present disclosure can be better understood by referring to the following figures. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the disclosure. In the figures, reference numerals designate corresponding parts throughout the different views.
[0011] Content capture is essential for searches. SharePoint 2013® search architecture involves a step of crawling and content processing in which components may be
[0012] FIG. 1 is a system architecture for tagging and entity enrichment of content in a content management system.
[0013] FIG. 2 is a process by which content is tagged and indexed for named and geographic entity searches.
[0014] The present disclosure is here described in detail with reference to embodiments illustrated in the drawings, which form a part here. Other embodiments may be used and/or other changes may be made without departing from the spirit or scope of the present disclosure. The illustrative embodiments described in the detailed description are not meant to be limiting of the subject matter presented here.
DEFINITIONS
[0015] As used here, the following terms may have the following definitions:
[0016] “Geotagging” refers to the process of extracting geographic entities from unstructured text files. Geotagging may include disambiguating the entity to a specific geographic place and appending geographic metadata such as geographic coordinates, geographic feature type and other metadata.
[0017] “Entity Tagging” refers to the process of extracting named entities from unstructured text. Entity Tagging may include entity disambiguation, entity name normalization and appending entity metadata.
[0018] “Named Entity” refers to a person, organization or topic.
[0019] “Geographic Entity” refers to geographic location or geographic places.
[0020] “Crawled Properties” refers to content management system metadata obtained from inspecting documents during crawls.
DETAILED DESCRIPTION
[0021] Reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used here to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Alterations and further modifications of the inventive features illustrated here, and additional applications of the principles of the inventions as illustrated here, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.
[0022] FIG. 1 is a system architecture 100 for geotagging content in SharePoint 2013®. A Search index 124 is one of a number of key components in order to enable search in SharePoint 102 . Another key part of enabling search in SharePoint 2013® 102 may be content capturing in order to index the content. SharePoint 102 includes a crawler 104 component in order to enable content capturing.
[0023] Crawler 104 may crawl through different content sources 106 adding a list of metadata properties to each content. Examples of content sources may include without limitation, SharePoint content, network file-share or user or intranet content. Crawler 104 may be configured perform the functions of connecting securely to a content source 106 , associating document from the sources to their metadata as crawled properties. The crawler 104 may be configured to full or incremental crawls to content. Examples of crawled properties may include for example and without limitation author, title, creation date among others.
[0024] SharePoint 2013® includes a content processing 108 component. The content processing 108 component takes content from the crawler 104 and prepares it for indexing. Content processing 108 may involve stages of linguistic processing (language detection), parsing, entity extraction management, content-based file format detection, content processing error reporting, natural language processing and mapping crawled properties to managed properties among others.
[0025] Content processing 108 may be extended by means of a content enrichment web service (CEWS 110 ). CEWS 110 may enable the enrichment of content processing 108 by allowing a web service callout 112 to call external web service to perform additional actions and enrich the crawled data properties. Web service callout 112 may be a standard simple object access protocol (SOAP) request or any other web service call method used to exchange structured information of the crawled data with an entity enrichment service 114 . Web service callout 112 may include trigger conditions configured in the content enrichment configuration object that control when to call an external web service for enrichment processing. Entity enrichment service 114 may also determine the document type of the crawled data in order to determine content that may come in the form of an image (scanned documents, pictures, etc.). Whenever content in the form of an image is found the entity enrichment service 114 may send the location of the crawled document to an OCR processing engine 116 such as for example and without limitation an optical character recognition component or other image processing component. OCR processing engine 116 may then retrieve and process the image files and convert them to text files asynchronously. The OCR'd processed files 118 may subsequently be re-fed to crawler 104 in order to be crawled as text files and sent back to content processing 108 and proceed with the rest of the workflow.
[0026] System architecture 100 may include an external geotagger web service 120 and a named entity tagger service 122 . Both geotagger web service 120 and named entity tagger service 122 may be a software module configured to function as a web service application provider and to respond to web service callout 112 . Geotagger web service 120 may use natural language processing entity extraction techniques, machine learning models and other techniques in order to identify and disambiguate geographic entities from crawled content. For example, geotagger web service 120 may disambiguate geographic entities by analyzing statistical co-occurrence of entities found in a gazetteer. Geotagger web service 120 may include a database of statistical co-occurring entities which may be linked against content found by crawler 104 . Following the same technique, named entity tagger service 122 may be used to extract additional entities or text features such as organizations, people or topics.
[0027] Geotagger web service 120 may analyze an array of managed properties sent as input properties by CEWS 110 and identify any geographic entities referred in text. Non-limiting examples of input properties may include: FileType, IsDocument, OriginalPath and body among others. Geotagger web service 120 may then geotag the text by creating or modifying managed properties with reference to each geographic entity found. Geotagger web service 120 may send modified or new managed properties to the entity enrichment service 114 where a conversion is made that maps the modified managed properties and returns them as output properties back to CEWS 110 . The same process may be used to interact with the named entity tagger service 122 for the extraction and entity tagging of other entities or text features such as organizations, people or topics.
[0028] After the augmented managed properties are returned by the entity enrichment service 114 the properties are merged with the crawled file managed properties and sent to a search index 124 .
[0029] Once geographic and other entity tags have been associated with content and indexed, search queries may also be performed using geographic or named entity features. A search UI 126 in SharePoint 2013® may include specific displays that may assist a user in performing a geographic based search as well as support enhanced displays of faceted search results. The search UI 126 may be a custom web part or may also be done by modifying the standard layout of SharePoint 2013® search with standard tools such as HTML, HTML 5, JavaScript and CSS.
[0030] FIG. 2 is a flow chart 200 illustrating the process steps for tagging content for SharePoint 2013® search. The process may begin when the crawler component in SharePoint 2013® performs a crawl for content (step 202 ). In one embodiment the crawl may be a full crawl, wherein in another embodiment the crawl may be an incremental crawl. The crawler component may then feed crawled properties and metadata to the content processing (step 204 ). A determination is made to verify if the crawled content may include geographic or named entities. For example and without limitation a trigger condition may be used. The trigger condition may contain a set of programmatic logic or rules which may determine if content may benefit from geotagging or entity tagging. If the trigger condition evaluates to false crawled content may be associated with managed properties (step 206 ) and passed to the search index component (step 208 ). If the trigger condition evaluates to true the CEWS may send a web service callout (step 210 ) to an entity enrichment service. The entity enrichment service may analyze the content sent in order to determine if the content may be in an image format (scanned documents, pictures, etc.). Content found in an image format may be processed asynchronously by an OCR engine and sent back to be re-crawled by the crawling component as text files (step 212 ). If the content is not in image format, the content may be processed by a geotagging web service or a name entity tagger service (step 214 ). The web service may extract and disambiguate geographic or named entities referred in the content and enrich them with entity metadata. The identified entities and their metadata may be sent back as managed properties to the content processing component and associated with the content (step 216 ). The associated metadata may then be sent to the search index component (step 206 ).
[0031] The foregoing method descriptions and the process flow diagrams are provided merely as illustrative examples and are not intended to require or imply that the steps of the various embodiments must be performed in the order presented. As will be appreciated by one of skill in the art the steps in the foregoing embodiments may be performed in any order. Words such as “then,” “next,” etc. are not intended to limit the order of the steps; these words are simply used to guide the reader through the description of the methods. Although process flow diagrams may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination may correspond to a return of the function to the calling function or the main function.
[0032] The various illustrative logical blocks, modules, circuits, and algorithm steps described in connection with the embodiments disclosed here may be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present invention.
[0033] Embodiments implemented in computer software may be implemented in software, firmware, middleware, microcode, hardware description languages, or any combination thereof. A code segment or machine-executable instructions may represent a procedure, a function, a subprogram, a program, a routine, a subroutine, a module, a software package, a class, or any combination of instructions, data structures, or program statements. A code segment may be coupled to another code segment or a hardware circuit by passing and/or receiving information, data, arguments, parameters, or memory contents. Information, arguments, parameters, data, etc. may be passed, forwarded, or transmitted via any suitable means including memory sharing, message passing, token passing, network transmission, etc.
[0034] The actual software code or specialized control hardware used to implement these systems and methods is not limiting of the invention. Thus, the operation and behavior of the systems and methods were described without reference to the specific software code being understood that software and control hardware can be designed to implement the systems and methods based on the description here.
[0035] When implemented in software, the functions may be stored as one or more instructions or code on a non-transitory computer-readable or processor-readable storage medium. The steps of a method or algorithm disclosed here may be embodied in a processor-executable software module which may reside on a computer-readable or processor-readable storage medium. A non-transitory computer-readable or processor-readable media includes both computer storage media and tangible storage media that facilitate transfer of a computer program from one place to another. A non-transitory processor-readable storage media may be any available media that may be accessed by a computer. By way of example, and not limitation, such non-transitory processor-readable media may comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other tangible storage medium that may be used to store desired program code in the form of instructions or data structures and that may be accessed by a computer or processor. Disk and disc, as used here, include compact disc (CD), laser disc, optical disc, digital versatile disc (DVD), floppy disk, and Blu-ray disc where disks usually reproduce data magnetically, while discs reproduce data optically with lasers. Combinations of the above should also be included within the scope of computer-readable media. Additionally, the operations of a method or algorithm may reside as one or any combination or set of codes and/or instructions on a non-transitory processor-readable medium and/or computer-readable medium, which may be incorporated into a computer program product.
[0036] When implemented in hardware, the functionality may be implemented within circuitry of a wireless signal processing circuit that may be suitable for use in a wireless receiver or mobile device. Such a wireless signal processing circuit may include circuits for accomplishing the signal measuring and calculating steps described in the various embodiments.
[0037] The hardware used to implement the various illustrative logics, logical blocks, modules, and circuits described in connection with the aspects disclosed herein may be implemented or performed with a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general-purpose processor may be a microprocessor, but, in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. Alternatively, some steps or methods may be performed by circuitry that is specific to a given function.
[0038] Any reference to claim elements in the singular, for example, using the articles “a,” “an” or “the,” is not to be construed as limiting the element to the singular.
[0039] The preceding description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined here may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown here but is to be accorded the widest scope consistent with the following claims and the principles and novel features disclosed here.
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Disclosed is a system and method for extending search capabilities of contentment management systems, such as SharePoint 2013®, to enable geographic and name entity based searches. Geographic and named entity searches are enabled by a content enrichment web service. The content enrichment web service calls a geotagging or a named entity tagger web service application to tag crawled managed properties as input and return geographically or entity modified managed properties as output. The system associates one or more geographically and named entity modified managed properties with content and stores this information as metadata in a SharePoint 2013® search index. Thus, the search system allows users to identify a particular geographic entity the user is interested in finding, and to receive search results directly related to that geographic entity on SharePoint 2013®.
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RELATED APPLICATIONS
This application is a continuation-in-part of my prior, co-pending application Ser. No. 814,625 filed July 11, 1977, now abandoned, which was in turn a continuation of Ser. No. 605,388 filed Aug. 18, 1975 and now abandoned.
BACKGROUND OF THE INVENTION
This invention relates generally to bowling balls and more particularly to a novel bowling ball adapted to travel a curvilinear path and having a larger area of maximum hitting force than previously available balls. The invention also provides a method for making the novel and improved bowling ball.
Bowling balls used in competitive sports events must conform to specifications of the American Bowling Congress. The ball cannot weigh more than 16 pounds and must have a circumference of about 27 inches. The ball is provided with appropriately spaced finger holes for reception of the thumb, middle finger and an adjacent finger. These finger holes are drilled in the "top" of the ball. The top weight of the ball must be within three ounces of the bottom weight and the side weights must be within one ounce of each other. The more skillful bowlers roll the ball so that it enters the pin placement at an angle with respect to the longitudinal axis of the bowling lane or alley. This requires that the ball be following a curved path as it strikes the pins and provides for maximum "pin carry". It is known that top weight, which provides a positive off-balance at the finger holes, assists the bowler in rolling a curve or hooked ball. The better bowlers repeatedly roll the first ball of a frame along substantially the same path with adjustments based on changing lane conditions. Theoretically the ball should strike the "pocket" each time at essentially the same angle with respect to the longitudinal axis of the pin placement and with the top weighted point of the ball striking the pins. If the roll is perfectly executed, all ten pins will be knocked down on each roll. However, if there is a departure in form, the ball might not curve at the expected angle or might not rotate so that the pins are struck with the maximum impact.
The conventional bowling ball is provided with a top weight insert generally at the location of the finger holes. This is the point that should strike the pins for maximum effect. It has been proposed in U.S. Pat. No. 3,350,252 to provide this top weight by including in the core of a bowling ball a foam plastic insert spaced radially outwardly from the center of the external shell in the bottom of the ball. The point of top weight of the ball is marked on the surface so that finger holes can be properly located. The point of mass concentration of the ball will theoretically be the same from ball to ball if the location of the insert is the same. The foam insert has a disadvantage that it has an irregular surface of open cells and webbing between the cells. The polymerizable plastic mass used to mold the ball about the insert will enter the cells and produce an irregular interface between insert and ball body which along with the variation in density will result in an irregular distribution of weight. The net result will be that the point of mass concentration will vary from ball to ball. Such variance will be accentuated in lighter weight balls where larger foam inserts are required because of the larger exposed area.
A bowling ball having a solid top weight substantially less than a hemisphere placed in the top half of the ball closely adjacent to the midplane is disclosed in U.S. Pat. No. 3,865,369. The density of the insert is substantially greater than that of the body of the ball which makes it undesirably necessary to use a relatively low density resin for the body.
A bowling ball having a solid wood or metal insert disposed about the geometric center of the ball is disclosed in U.S. Pat. No. 575,128. This ball allegedly rolls noiselessly along the lane. A bowling ball having a shell enclosing a hollow center with the inner wall concentric with the outer surface of the ball is disclosed in U.S. Pat. No. 3,256,018. The shell is formed of a plurality of cast layers of resin. Such balls do not provide for maximum "pin carry" and are not designed to facilitate curving or hooking of the ball.
No matter what configuration or composition, all bowling balls, of which I am aware, are manufactured in a reusable, usually two-piece metallic mold. Such a procedure not only requires a great deal of capital expenditure for mass production purposes but also is susceptable to material waste due to leakage between the mold halves. If great enough, leakage may also result in a scrap ball because voids are formed beneath the surface of the ball. In addition, accelerated curing with microwaves is not feasible with a metallic mold since the microwave energy would be substantially absorbed by the metal itself.
Finally, in balls provided with top weights, usually what can be called the "aspect ratio" of the weight, that is, the ratio of its length to its width, is unity. While providing eccentricity, this concentration of weight can often provide an uneven noncentroidal rolling or "loping" which, if carefully analyzed, could be said to be rolling with periods of acceleration followed by periods of deceleration due to the momentum of the weight. Thus, it is desirable, if providing a top weight, to avoid this uneven rolling. Such noncentroidal rotation can be further complicated if the finger and thumb holes are not properly positioned in the ball. The driller of the ball cannot, by looking at the ball, always determine the precise location or orientation of the top weight. Usually this is accomplished by a balancing procedure which does not always lend itself to consistent results.
SUMMARY OF THE INVENTION
It is thus a primary object of the present invention to provide a bowling ball which will impact the pins with a greater hitting strength despite inconsistencies in the rolling thereof by the bowler.
It is another object of the present invention to provide a bowling ball, as above, with induced eccentricities therein enabling the ball to be more readily rolled in the desired curvilinear path.
It is a further object of the present invention to provide a bowling ball, as above, with induced eccentricity highly concentrated in the track area thereby rolling with greater movement of inertia to provide less deflection on impact with the pins.
It is yet another object of the present invention to provide a bowling pin, as above, with a top weight having an aspect ratio greater than unity and positioned to eliminate uneven rolling of the ball.
It is still another object of the present invention to provide a bowling ball, as above, with a means of identifying the location and orientation of the top weight to aid in the precise placement of the ideal location for the finger and thumb holes.
It is an additional object of the present invention to provide a bowling ball which is manufactured by a unique inexpensive process including the use of a disposable plastic mold.
These and other objects of the present invention, which will become apparent from the description to follow, are accomplished by the means hereinafter described and claimed.
In general, a bowling ball is made in a disposable mold by first placing a member in the mold and then filling the mold with a polymerizable mass. The member has a specific gravity less than the polymerizable mass and is located in the ball such that its centroid will be in the range of from three to six and one-half inches from a point of reference on the surface of the bowling ball. A weight block of specific gravity higher than the mass is then suspended in the mass to a depth in the range of one-half inch to three and one-quarter inches from the point of reference and generally on the same axis as the member. After polymerization of the mass, the mold is ground away and the mass is formed into the finished bowling ball.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section of a mold and polymerizable mass illustrating one embodiment of the invention;
FIG. 2 is a fragmentary plan view taken substantially along line 2--2 of FIG. 1;
FIG. 3 is a bottom view taken substantially along line 3--3 of FIG. 1;
FIG. 4 is an elevation, partially in section, of an alternative embodiment of the bowling ball according to the present invention;
FIG. 5 is a plan view of the supporting member for the hollow insert;
FIG. 6 is an elevation, partially in section, of a still further alternate embodiment of the bowling ball according to the present invention;
FIG. 7 is a cross-section of a mold and polymerizable mass illustrating another embodiment of the present invention; and
FIG. 8 is a somewhat schematic elevation of a drilled bowling ball manufactured according to the embodiment of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of a mold 10 suitable for shaping a polymerizable material 11 into a generally spherical shape somewhat larger than the circumference desired for the bowling ball is illustrated in FIG. 1. Mold 10 is a disposable member molded out of polyethylene, polypropylene, or the like. Mold 10 has spherical walls integral with a cup-shaped protuberant member 12 at the bottom of the mold. A supporting member 13 is locked in the cup-shaped member 12 by means of annular flange 14 embedded in an annular groove 15 in the inner wall of the cup-shaped member 12. As illustrated in FIG. 5, support member 13 does not completely close the opening to cup-shaped member 12 so that any heavy material included in the moldable composition 11 can settle out of the body portion of the ball. The inner surface of member 13 is arcuate shaped to continue the spherical surface of the mold cavity.
A ball 16 having a cavity 17 is disposed in the cavity of mold 10 and held in place by means of a nylon string 18 having a parallelepiped-shaped member 19 on one end and a parallelepiped shaped member 20 on the other end. Ball 16 is eccentrically disposed in the mold cavity and may be on either side of the geometric center of the mold cavity and of the resulting molded ball. A "buttoneer" sold by Dennison Manufacturing Company, Farmingham, Massachusetts, may be used as member 18 for the support of ball 16 in the cavity. The "buttoneer" prevents ball 16 from floating freely in the polymerizable mass 11 and at the same time provides a convenient means for exactly locating the ball 16 in the finished bowling ball by varying the length of string 18 or the like.
A polymerizable mass is then poured into the mold 10 to fill the cavity about ball 16. The mass may be supplied from two tanks, one preferably having resin, filler, pigment and a catalyst and the other preferably having resin, filler, pigment and a promoter, to a mixing head for injection into the mold.
Any suitable synthetic resinous composition may be used such as, for example, the polymerizable compositions disclosed in U.S. Pat. Nos. 3,059,007; 3,353,825; 3,350,252; 3,248,113; 3,256,018 and 3,318,727. The polymerizable composition may be free from filler if the desired weight can be obtained or, as is preferred, it may contain a suitable inorganic particulate filler such as, for example, litharge, talc, barytes, calcium carbonate, silica, kaolin clay, or the like when needed for higher density. Conversely, glass bubbles, hollow silica spheres or any such material having a lesser density may be used as needed for lighter weight balls. A preferred composition is a polyester resin prepared by mixing an ethylenically unsaturated polyester and styrene with an initiator and a suitable filler such as the polyester resin disclosed in U.S. Pat. No. 3,318,727 and the compositions of U.S. Pat. Nos. 3,068,007 and 3,256,018. A coupling agent such as an aminosilane, or any other suitable silane such as a mercapto silane, may be used to impart greater durability with any filler containing SiO 2 functionality such as kaolin clay, silica flour or the like. Aminosilanes are preferred if the synthetic resin is a polyester resin because it is more compatible than the others and provides better cross-linking. A suitable aminosilane is n-β(aminoethyl)-γ-aminopropyltrimethoxysilane sold by Union Carbide as No. A1120. The coupling agent may be mixed with filler prior to its incorporation in the resinous composition or the filler and coupling agent may be added separately to the composition before it solidifies. The use of the coupling agent with the filler in the resinous composition improves the durability and resilience of the resulting bowling ball. Any other suitable coupling agent such as isopropyl triisostearic titanate may be used.
An organic polyisocyanate coupling agent may be used with any filler containing reactive hydrogen determinable by the Zerewitinoff method and reactive with --NCO groups, such as tolylene diisocyanate, diphenyl methane diisocyanate or other suitable polyisocyanate disclosed by Saunders and Frisch Polyurethane: Chemistry and Technology published by Interscience Publishers. For example, such a coupling agent may be used to advantage with a carbon black filler, nitrile rubber or other material.
The aminosilane coupling agent will, of course, inpart increased durability and resilience to a bowling ball whether it has a void or not. Hence, in its broader aspects the invention contemplates a bowling ball free from voids molded from a polymerizable mass containing one of the above fillers having SiO 2 functionality and an aminosilane or other suitable coupling agent which will react chemically with the filler and couple it to the polymerizable mass. Suitable chemically modified fillers are the "NULOK" and "NUCAP" series of kaolin clay fillers containing an aminosilane or mercaptosilane, respectively, for coupling the filler with the polymerizable mass. These materials are available from J. M. Huber Corporation of Edison, New Jersey.
While any suitable polyester may be used for the polymerizable mass, it is preferred to use a flexible polyester prepared from iso-phthalic or ortho-phthalic acid and diethylene glycol, butylene glycol or the like. The hardness of the bowling ball can be varied between a Shore D of 50-100 by selection of the polyester. Blends of rigid and flexible polyesters may be used for this purpose.
With the mold so filled, a cap 21 is then inserted in the opening in the mold and wedged into place by means of an annular ring 22 embedded in an annular groove 23 in the wall of mold 10. Additional polymerizable material may be added through opening 24 to completely fill the mold cavity. The inner surface of cap 21 is arcuate shaped to continue the curved surface of the mold cavity. Ears 25 and 26 having openings 27 and 28 therein are provided for suspending mold 10 by means of hooks 29 and 30 and cords or chains 31 and 32 until the composition in the mold has solidified and cured. Cords 31 and 32 may be tied together for suspension from a single point for the precision centering of the ball 16, as desired, during curing. Curing may be accelerated by heating, if desired, but normally such will not be necessary. In addition, cure systems totally dependent on heat as an initiator, such as cumene hydroperoxide, can be used in conjunction with microwave excitation. The plastic mold permits such microwave usage which may be desirable since it heats the polar polyester resin more evenly throughout than other forms of heating.
Although the member 16 has been shown as spherical, it may have any other conventional shape, such as, cubic, ellipsoidal, hemispherical or the like. A ball with a generally conically shaped member 16 is shown in FIG. 4. Such cavities are advantageous in light weight balls because larger cavities can be used and still leave suffient solid mass for drilling the finger holes without puncturing the cavity. The larger cavities also have the advantage that the density of the resin may be made greater by the addition of a filler to improve the striking force by increasing the moment of inertia.
In the embodiment of a bowling ball illustrated in FIG. 6, a spherical hollow member 16 is disposed in body 34 of the ball with its centroid about 4.06 inches from the top of the ball. The ball has a diameter of 8.58 inches. The outside diameter of the member 16 is 4.14 inches and the density of the polymerizable mass of body 34 is such that the ball weighs 16 pounds. The polymerized mass is cured polyester resin containing kaolin clay and aminosilane coupling agent.
When the curing process is complete the mold may be ground away from the mass on the lathe which turns the ball down to its required circumference. When this is done, member 20 is removed but a portion of string 18 and member 19 remain in the ball. The diameter of string 18 is so small that it is substantially imperceptible on the surface of the bowling ball. Finger holes are cut into the ball in the area having the top weight or in other words where the mass concentration of the ball exists.
The ball so provided, according to any of the aforementioned embodiments, has an increased moment of inertia over a solid ball of a similar size and mass. The formula for the moment of inertia of a sphere is m 2/5r 2 where r is the radius and m is the mass. The moment of inertia for a spherical shell may be calculated from the formula ##EQU1## with m being the mass r 1 the external radius of the sphere and r 2 the internal radius. The amount of inertia for the bowling ball is increased by about 21/2% over that of a uniformly solid bowling ball of 27 inches circumference when the hollow member has an external diameter of 2.68 inches and the density of the material used to cast the ball is such that the ball weight is 16 pounds.
While it has been found, therefore, that a ball with a lighter weight member therein provides a better hitting force, it has also been found that providing the ball with a weight opposed in location to the lighter weight material, affords still greater hitting power in certain situations. In addition, by varying the relative locations of the higher density material and the lower density material, a wide range of combinations of off center weight effects may be obtained.
One such example according to this concept is shown in the embodiment of FIGS. 7 and 8. There a mold 40, quite similar to mold 10, is made of a disposable plastic material such as polyethylene. Mold 40 is generally spherical of a size slightly larger than the approximate 8.5 inch diameter of a conventional bowling ball and includes a protuberance 41 at the bottom thereof. A member 42 of lesser specific gravity than the general mass of the bowling ball, such as polyethylene is selectively positioned within mold 40 by selecting the length of a nylon string 43 such as the buttoneer 18 of the previously described embodiments. String 43 is attached at one end to a resilient disk 44 which may be snapped into protuberance 41. The other end of string 43 is injected into member 42. While member 42 is preferably spherical so that when the mass cures, a uniform shrinkage occurs, it could well be hemispherical or take on any of the numerous shapes previously discussed. It can be hollow but is preferrably an impermeable polyethylene member. As shown in FIG. 7, the preferred member 42 is of approximately a three inch diamter. As such its volume is about 14 cubic inches; however, a member in the range of 0.5 to 200 cubic inches would be acceptable. As will hereinafter be discussed in more detail, it has been found that the centroid of member 42 may be positioned in the range of from three to six and one half inches from a surface of the eventual 8.5 inch bowling ball. As shown in FIG. 7, the reference surface would be the top with member 42 being shown in the approximate middle of the permissible range. The length of string 43 is preset to locate member 42 as desired.
After positioning member 42 in mold 40, a polymerizable mass 45 of specific gravity greater than member 42 is injected into the mold. The composition of the mass may be identical to that of the bowling balls of the previously described embodiments. Member 42 will then float to its desired position being constrained by string 43. A weight block 46 is then suspended in mold 40 to a predetermined depth. Weight block 46 is of a material having a higher specific gravity than mass 45, such as a resin like that of mass 45 mixed with barium sulfate, calcium carbonate or the like, and is suspended by a nylon pin 47 located at the center thereof. Pin 47 is held by a cross-member 48 which rests on an annular shoulder 49 of mold 40 and lies generally on an axis of the bowling ball. Pin 47 may be attached to cross-member 48 in any suitable fashion such as by extending up through a hole in cross-member 48, being bent over, and melted thereon.
The length of pin 47 can be preselected to position weight 46 within the ball as desired. As will hereinafter be discussed in more detail, it has been found that the top of weight 46 may be positioned in the range of from one-half inch to three and one-quarter inches from a surface of the ball. As shown in FIG. 7, this reference surface would be the top with the center of weight 46 being generally on the same axis of the bowling ball and the centroid of member 42.
Weight block 46 could take on a number of configurations. Conventionally these weight blocks are in the shape of a regular symetrical member such as a truncated cone or a cube. In these instances the "aspect ratio" of the member, which for purposes of this example can be defined as the ratio of a member's length to width when viewed in elevation, is unity. Thus, if the weight block were a truncated cone and, the portion thereof of decreasing diameter were suspended downwardly into the bowling ball, in elevation one would view a circle with an aspect ratio of unity. However, as shown in the embodiment of FIGS. 7 and 8, it has been found that a weight block with an aspect ratio of greater than unity provides unique roll characteristics. As best seen in FIG. 8 the rectangular elevational appearance of preferred weight block 46 has an aspect ratio of about 5.0. It has been found that this ratio could vary from a number greater than unity to about 15.0 and be within the spirit of this invention. However, a ratio of five to one in the longitudinal to transverse direction is preferred.
As shown in FIG. 7, from the side, weight block 46 preferably takes on the configuration of a segment of a circle and as previously described, is suspended by pin 47 from cross-member 48 at the center of mass thereof. A second or "dummy" locator pin 50 is also positioned in weight 46 which extends out of the mass 45 but is not connected to cross-member 48. Pin 50 is parallel to pin 47 and positioned along the longitudinal axis of weight 46 such that a line drawn between pins 47 and 50 would be parallel to the edges of weight block 46. As will hereinafter be described, this arrangement aids in the proper drilling of the bowling ball.
Mold 40 is also provided with ears 51 having openings 52 therein so that the mold may be suspended during curing, if desired. As in the previously described embodiments, if the cables which attach to openings 52 are tied together for a single point suspension, both member 42 and weight block 46 will be freely suspended in precise alignment.
With the weight block 46 and member 42 so positioned in the polymerizable mass 45, the mass is allowed to cure either with or without the heat or microwave acceleration, as previously described. After curing the product goes through a rough grind wherein the mold and burrs formed at protuberant member 41 and at the top open end of the mold are removed, thus leaving a generally spherical product. The product then goes through further fine grinding and buffing until the precise diameter for a conventional bowling ball is obtained.
The surface of the bowling ball will be of uniform color depending on the pigmentation selected but the ends of the two pins 47 and 50 will be evident as shown in FIG. 8. This is a guide for the craftsman skilled at drilling the finger and thumb holes in the ball. One advantage of the weight block having an aspect ratio of greater than unity is that the ball can be drilled so that it will roll in the direction of the larger dimension of the block. By observing the orientation of pins 47 and 50, the ball driller can determine how the weight block 46 is oriented and drill thumb hole 53 and finger holes 54 accordingly. The ball of FIG. 8 is shown as having been drilled to give a right handed bowler positive weight, that is, weight accentuating a hooking ball. If negative weight for a right handed bowler were desired, the weight block would be positioned on the other side of the finger and thumb holes. Obviously, reverse locations are true for a left handed bowler.
As previously described, the selectability in locating both the member 42 and weight block 46 render it possible to provide a bowling ball with a wide variety of eccentric weight conditions. For example, under one extreme, if a maximum amount of eccentricity and top weight were desired, the radially outer extent or top of weight block 46 could be located one-half inch from a point of reference on the surface of the ball and the member 42 located with its centriod six and one-half inches from the point of reference and on the same axis as the center of the weight block. At the other extreme, weight block 46 could essentially touch member 42 near the center of the ball to give some, but not extreme, eccentricity.
It should thus be evident that a bowling ball constructed according to the concept described herein accomplishes the objects of the invention and otherwise substantially improves the bowling ball art.
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A bowling ball according to one embodiment of the present invention has a hollow member, or a member of less specific gravity than the mass of the bowling ball, disposed therein with its centroid displaced from the geometric center of the ball. The lighter weight member in the ball permits the use of a dense polymerizable composition for the basic mass of the ball. The ball is molded without the usual shell so that it has a resilient striking surface for maximum impact and pin carry. In another embodiment, a member of a higher specific gravity than that of the polymerizable mass is added generally on the same axis as the lighter weight member to increase the eccentricity of the ball and give it even more driving power upon impact with the pins. The member of higher specific gravity may be provided with pin members extending therefrom to the surface of the ball. These pin members not only determine the depth of the member of higher specific gravity but they also provide a visual indication of the location and orientation of the same.
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FIELD
[0001] This invention relates to a combustion system for use in the combustion of biomass fuels such as wood. The invention may be particularly suitable for use in relation to domestic wood burners, and for convenience only therefore, the invention will be predominantly described in relation to such use.
[0002] However, it is to be understood and appreciated that the invention may also have other applications and/or uses—for example, in relation to open fireplaces, masonry fireplaces, and furnaces. The combustion system may also have industrial applications or uses.
[0003] The prior art and possible applications of the invention, as discussed below, are therefore given by way of example only.
BACKGROUND
[0004] A problem associated with the burning of biomass fuel in general is the production of air pollutants. For example, the burning of biomass fuel (and particularly the inefficient burning of biomass fuel) may produce volatile, toxic, or other undesirable gases. Furthermore, large amounts of smoke and particulate matter may also be released into the atmosphere.
[0005] In this regard open fireplaces are particularly inefficient. That is, open fireplaces usually produce larger amounts of air pollutants, as compared to enclosed fireplaces. Furthermore, an open fireplace generally only provides heat directly in front of the fireplace, with the vast majority of the heat being lost up through the chimney or out through the rear wall of the fireplace.
[0006] The inefficiency of open fire places has been addressed to a certain extent by the use of domestic furnaces. Examples can be found in U.S. Pat. No. 4,559,882 (Dobson) and U.S. Pat. No. 4,630,553 (Goetzman).
[0007] However, whilst the problems of the inefficient burning of biomass fuel for space heating can be addressed somewhat with a furnace, the extra capital cost is not always necessary, practical, or affordable. Furthermore, furnaces tend to be used mainly in very cold climates, but not in temperate climates, and are also usually coupled to some sort of central heating, which is not always desirable.
[0008] Moreover, a further issue with furnaces is that they are usually completely closed off from view, and do not therefore provide the psychological or aesthetic benefits that are derived from lazy flame as a light source. That is, people like to see flames.
[0009] Perhaps a result, “air tight wood burners” or simply “wood burners” have become increasingly more popular over the years, and are now in widespread use. “Wood Stove” is another common term for such appliances, particularly in North America.
[0010] Wood burners generally comprise a metal firebox, into which biomass fuel may be placed and burnt, an adjustable air control or damper, and an exhaust flue. Many, if not most, wood burners also have a glass door through which the fire and/or flames may be viewed.
[0011] The combustion of biomass fuel is a complex process, and includes a range of chemical reactions. As yet, there does not appear to be a wood burner or fireplace designed for space heating that adequately incorporates the various stages of combustion in relation to each other.
[0012] These stages are drying, pyrolysis, combustion and reduction, which if done correctly produce the combustible gases carbon monoxide and hydrogen. The carbon monoxide and hydrogen can then be combusted separately during what is known as secondary combustion to yield only water and carbon dioxide (and heat). However, most wood burners lack the ability to burn or convert such gases (and their precursors such as carbon dioxide and water) due to the wood burner not being able to produce enough heat to do so (conventional wood burners usually reach maximum temperatures of between 600° C.-800° C.).
[0013] Hence, attaining a high enough temperature during secondary combustion to consume all the volatiles distilled during pyrolysis or combustion is difficult because the necessary temperature is often higher than that which can ordinarily be generated. In this regard, the temperature required to adequately consume the vast majority (if not all) of the volatiles and/or particulate matter and smoke would be a minimum of approximately 900° C., and more preferably above 1000° C.
[0014] U.S. Pat. No. 4,672,946 (Craver) describes a wood burner which has a secondary combustion means for burning the particulate matter in the flue gases. However, the temperature reached within the firebox of the Craver device is stated as being only around 540° C. (1000° F.) and the secondary combustion region only reaches up to around 760° C. (1400° F.). Hence, a disadvantage associated with Craver is that the design of the wood burner does not attain high enough temperatures to adequately consume the vast majority of gases or particulate matter. Furthermore, the wood burner described in Craver is not able to be retro-fitted to an existing wood burner or other fireplace.
[0015] In more recent times, many countries or local bodies have introduced regulations to restrict the sale of inefficient and/or polluting wood burners.
[0016] For example, in New Zealand the generally allowable standard for wood burners is a maximum of 1.0 grams of particulate matter released per kilogram of wood burned, accompanied by a minimum efficiency of 65%. However, some regions have gone further than this. For example, the Canterbury Regional Council in New Zealand (which is in the region of a weather-inversion layer) has lowered these levels to 0.6 grams of particulate matter per kilogram of wood burned. The Regulations further restrict the use of wood with a moisture content higher than 25%.
[0017] However, these Regulations are not retrospective, and hence they only have effect in relation to wood burners manufactured and sold after the Regulations came into force. Moreover, to date there have been no innovations which have enabled people to bring their older wood burners up to modern compliance levels (voluntarily or otherwise).
[0018] Two factors which usually have the most detrimental effect regarding the efficiency of, and/or the release of air pollutants from, a wood burner are to do with refueling the wood burner and when shutting down or reducing the air supply to the wood burner.
[0019] Refueling causes quenching, a situation where the introduction of fresh fuel to the fire is not supported by the heat contained within the existing fire to adequately pyrolyse the biomass. As a result, visible smoke and particulate matter are often seen exiting the top of the flue or chimney at this time. This can take a while to subside as enough heat builds up in the fire to commence the correct chemical processes required to efficiently combust the fresh fuel.
[0020] A wood burner user may wish to reduce the air supply to keep the fire burning longer and/or while they are asleep. This is known as “banking”. In doing so, they generally place a full load of biomass fuel in the wood burner and shut down (or minimise) the air supply to prolong the burn time. However, the reduction in available oxygen and the corresponding detrimental effect on combustion results in more air pollutants being produced and released. Because this often results in the amount of air pollutants exceeding the minimum regulated amounts, many modern wood burner designs have denied the user the ability to shut down the air supply.
[0021] The air supply also affects the dynamics of wood burners because a greater draught causes more heat to be generated, but a greater portion of heat is lost up the flue. The higher velocity of gases also results in more particulate matter being exhausted to the atmosphere. Conversely, a lesser draught reduces the amount of particulate matter being drawn from the combustion chamber but also reduces the heat output. However it is possible in these conditions that although less heat is generated, less heat is also lost to the atmosphere as the heat has more time to radiate off before being exhausted.
[0022] Or to put it another way, greater air means greater heat, but lower efficiency, however the greater heat actually results in a cleaner burn which lowers the emissions. With a lesser air supply, the fires get greater efficiency but the lower heat increases emissions. As a result of these dynamics, there is a common saying amongst laboratory engineers which is: “You can build a hot and clean fire, and you can build an efficient fire, but you can't build both in the same fire”. I believe that my combustion system, as described herein, does in fact result in both a hot and clean fire and an efficient fire.
[0023] Another approach taken by wood burner manufacturers to address problems of fire inefficiency or to reduce the release of pollutants is by employing the use of catalytic converters (either by retrofitting to existing wood burners or by incorporating them into new wood burners). However, catalytic converters are generally very expensive, and may be considered complex to operate and/or understand by many people—and this may be prohibitive to both wood burner manufacturers and end consumers. Furthermore, the installation of catalytic converters requires specialist knowledge and significant alterations to be made to the wood burner, and flue, and this can be time consuming, complex and expensive.
[0024] It may therefore be advantageous if there was available a relatively simple and/or improved combustion system, which included primary and secondary combustion zones which were able to result in more efficient combustion of biomass fuels and/or result in a lesser amount of air pollutants being released, as compared to presently available or prior art combustion systems.
[0025] It may also be of advantage if there was available a combustion system which was able to be retrofitted to existing fireplaces, such as wood burners, for example to increase their efficiency and/or to bring them up to modern compliance standards.
OBJECT
[0026] It is an object of the present invention to provide a combustion system which goes some way towards addressing one or more of the above problems or difficulties, or which at the very least provides the public with a useful choice.
DEFINITIONS
[0027] Throughout this specification unless the text requires otherwise, the word ‘comprise’ and variations such as ‘comprising’ or ‘comprises’ will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
[0028] Throughout this specification, the term “biomass” or “biomass fuel” is to be understood to include reference to any type of organic-based fuel which may be used for burning in a fireplace. Examples include (but are not limited to) wood, bark, sawdust, sawdust pellets, brush, straw, logs, coal, and charcoal.
[0029] Throughout this specification, the term “wood burner” is to be understood to refer an enclosed firebox (often metal), and which (usually) has an adjustable air supply, and which is connected to a suitable exhaust flue. Other common names for a wood burner are “solid fuel burner” or “appliance. Moreover, terms such as “wood stove” or “wood burning stove” appear to be the names more commonly used in North America.
[0030] Throughout this specification, the term “fireplace” is to be understood to include any type of structure used for containing or housing a fire. Examples include (but are not limited to) wood burners, open fireplaces, masonry fireplaces and furnaces.
STATEMENTS OF INVENTION
[0031] According to one aspect of the present invention, there is provided a combustion system, said combustion system including:
a) a fireplace, said fireplace including:
i. a fire base, ii. a primary combustion zone for pyrolysising and/or combusting a biomass fuel, iii. a secondary combustion zone for combusting gases and/or particulate matter produced from the pyrolysis and/or combustion of the biomass fuel,
b) an exhaust flue, said exhaust flue including a lower portion, and said lower portion extending to a position near to, or adjacent, said secondary combustion zone and/or said fire base.
[0037] According to another aspect of the present invention, there is provided a combustion system, substantially as described above, wherein said combustion system further includes, or results in, a charcoal/reduction layer forming below the primary combustion zone, and/or between the primary combustion zone and the secondary combustion zone, the arrangement and construction being such that the gases and/or particulate matter produced from the pyrolysis and/or combustion of the biomass fuel in the primary combustion zone have to pass over or through said charcoal/reduction layer prior to entering the secondary combustion zone and/or the lower portion of the exhaust flue.
[0038] According to another aspect of the present invention, there is provided a combustion system, substantially as described above, wherein said combustion system also includes a drying zone for drying the biomass fuel and/or removing water from the biomass fuel prior to the pyrolysis and/or combustion of the fuel.
[0039] According to another aspect of the present invention, there is provided a combustion system, substantially as described above, wherein said combustion system includes a first air supply means for supplying air to the primary combustion zone (or fireplace).
[0040] According to another aspect of the present invention, there is provided a combustion system, substantially as described above, wherein said first air supply means is an air damper.
[0041] According to another aspect of the present invention, there is provided a combustion system, substantially as described above, wherein said combustion system further includes a second air supply means for introducing super heated air into the region of the secondary combustion zone.
[0042] According to another aspect of the present invention, there is provided a combustion system, substantially as described above, wherein said second air supply means includes a secondary flue partially or wholly surrounding the lower portion of the exhaust flue.
[0043] According to an alternative aspect of the present invention, there is provided a combustion system, substantially as described above, wherein said second air supply means includes an air channel which penetrates the exhaust flue and which extends to a position near to, or adjacent, said secondary combustion zone and/or said fire base.
[0044] According to another aspect of the present invention, there is provided a combustion system, substantially as described above, wherein said fire base includes a grate.
[0045] According to another aspect of the present invention, there is provided a combustion system, substantially as described above, wherein said grate includes a plurality of hollow tubes, the arrangement and construction being such that these hollow tubes form part of the second air supply means for introducing super heated air into the region of the secondary combustion zone
[0046] According to another aspect of the present invention, there is provided a combustion system, substantially as described above, wherein the combustion system includes insulation means for insulating the region of the secondary combustion zone.
[0047] According to another aspect of the present invention, there is provided a combustion system, substantially as described above, wherein said insulation means also serves to introduce a degree of air turbulence and/or mixing into the region of the secondary combustion zone.
[0048] According to another aspect of the present invention, there is provided a combustion system, substantially as described above, wherein said insulation means is in the form of a ceramic disc.
[0049] According to another aspect of the present invention, there is provided a combustion system, substantially as described above, wherein said fireplace is a wood burner.
[0050] According to another aspect of the present invention, there is provided a combustion system, substantially as described above, wherein said combustion system is retro-fitted to an existing wood burner.
[0051] According to another aspect of the present invention, there is provided a combustion system, substantially as described above, wherein said fireplace is an open fireplace.
[0052] The combustion system may preferably include a fireplace.
[0053] The fireplace may preferably include a fire base.
[0054] The fire base may be any suitable platform or structure which may form the base of the fireplace or combustion system.
[0055] For example, if the fireplace is a masonry or open fireplace, then the fire base may be the fire pit or grate upon which the biomass fuel is placed for burning.
[0056] Alternatively, if the fireplace is a wood burner, then the firebase may be the floor or bottom of the firebox of the wood burner.
[0057] The fire base may also include a grate which is housed within (or which forms) the floor of the firebox of the wood burner. In such an embodiment, ash may collect below the grate where it may be removed, for example by opening a lower door or tray in the wood burner specifically for this purpose.
[0058] Preferably, the fireplace may include a primary combustion zone for pyrolysising and/or combusting the biomass fuel.
[0059] Preferably, the fireplace may include a secondary combustion zone for combusting gases and/or particulate matter produced from the pyrolysis and/or combustion of the biomass fuel.
[0060] Preferably, the combustion system may include an exhaust flue, with the exhaust flue including a lower portion, and with the lower portion extending to a position near to, or adjacent, the secondary combustion zone and/or the fire base.
[0061] In the case of a wood burner, the exhaust flue may preferably extend through the top of the wood burner and up through the roof or ceiling of the dwelling where the wood burner is housed.
[0062] In another embodiment, the exhaust flue may extend through the rear wall or side wall of the wood burner, and then subsequently pass up through a ceiling of the dwelling, or alternatively pass out through a side wall of the dwelling. In such embodiments, the lower portion of the exhaust flue (which passes into the firebox of the wood burner) may preferable be right-angled so that the secondary combustion zone is still formed underneath the (vertical) open end of the lower portion of the exhaust flue.
[0063] A company which manufactures many types of wood burners which utilise a rear or side flue exit is Jotul Group of Norway.
[0064] Preferably, the combustion system, when in operation, may include, or result in, a charcoal/reduction layer forming below the primary combustion zone, and/or between the primary combustion zone and the secondary combustion zone. In such an embodiment, the arrangement and construction may be such that the gases and/or particulate matter produced from the pyrolysis and/or combustion of the biomass fuel in the primary combustion zone, have to pass over or through the charcoal/reduction layer prior to entering the secondary combustion zone and/or the lower portion of the exhaust flue.
[0065] For example, in an embodiment where the fireplace is a wood burner, it may be appreciated that by extending the flue towards the fire base (or the bottom of the firebox), the combustion gases are required to travel down and across to the mouth of the flue in order to enter the flue. This has the effect of drawing the combustion gases across the charcoal/reduction layer, thus enhancing the further reduction of volatiles and steam to combustible gases such as hydrogen and carbon monoxide. The natural draught (or drawing effect) created by the exhaust flue should be adequate to facilitate this process. Moreover, this means that the lower portion of the exhaust flue therefore helps to create and/or fuel the secondary combustion zone at (or adjacent) its opening.
[0066] Preferably, the combustion system may include a drying zone for drying the biomass fuel and/or removing water from the biomass fuel prior to the pyrolysis and/or combustion of the fuel.
[0067] In the embodiment where the fireplace is a wood burner, the drying zone may be situated above the primary combustion zone. That is, biomass fuel may be introduced above the primary combustion zone in an area that forms, and serves, as a drying zone. Provision for introducing biomass fuel may, for example, be provided via a hinged door at the top or front of the wood burner.
[0068] It is also envisaged that the drying zone may be included within, or comprise part of, the primary combustion zone.
[0069] Preferably, the combustion system may include a first air supply means for supplying air to the primary combustion zone or to the fireplace generally.
[0070] In the case of a masonry or open fireplace, the first air supply means may simply be provided for by the surrounding air.
[0071] In the case of a wood burner, the first air supply means may be provided by an air duct leading into the wood burner. The amount of air that may be permitted to enter the wood burner may be adjustable, for example by the operation of an air damper lever with respect to an air valve.
[0072] Preferably, the combustion system may further include a second air supply means for introducing super heated air into the region of the secondary combustion zone.
[0073] In one embodiment, the second air supply means may be in the form of a secondary flue, partially or wholly surrounding the lower portion of exhaust flue.
[0074] For example, this may be facilitated by placing a piece of larger section or diameter flue around the lower portion of the main exhaust flue, leaving an air gap in between. The air gap created between the secondary flue and the lower portion of the exhaust flue may serve to take air from the top of the firebox (in the case of a wood burner) and channel it down to the secondary combustion zone at the base of the lower portion of the exhaust flue. The air travelling through this air gap may be super heated by the exhausting flue gases within the lower portion of the exhaust flue on one side, and the primary combustion zone on the other side.
[0075] Furthermore, the primary combustion zone may derive benefit by a much increased flame path as the flames are drawn down the air gap from the top of the firebox, thus maintaining a high temperature and increasing the time available to fully burn in.
[0076] In an alternative embodiment of the invention, the second air supply means may include an air channel which penetrates the outside of the exhaust flue and extends downwards towards the bottom of the lower portion of the exhaust flue and/or in the region of the secondary combustion zone.
[0077] In such an embodiment, it may be preferable to create an aperture in the exhaust flue at a point just above the top of the firebox of the wood burner. An air channel may then be inserted through this aperture and downwards to the secondary combustion zone at the lower portion of the main exhaust flue.
[0078] In yet another embodiment, the fire base of a wood burner may be provided with a grate and the grate may include (or be comprised of) a plurality of hollow tubes, the arrangement and construction being such that these hollow tubes form part of the second air supply means for introducing super heated air into the region of the secondary combustion zone.
[0079] It is also envisaged that one or more of the above embodiments for providing for a second air supply means may be present in any one combustion system and/or wood burner.
[0080] Preferably, the combustion system may include insulation means for insulating the region of the secondary combustion zone.
[0081] One purpose of the insulation means may be to maximise temperatures within the secondary combustion zone.
[0082] An example of a suitable insulation means would be a block of a heat resistant and/or insulative material, such as a high thermal resistant ceramic material.
[0083] Preferably, the insulation means may also serve to introduce a degree of air turbulence or mixing into the secondary combustion zone. The introduction of a degree of turbulence into the secondary combustion zone may serve to enhance the levels of combustion and/or temperatures of combustion.
[0084] In the case of a wood burner, the inside of the firebox may also be lined with an insulative material, such as a ceramic material, in order to maximise heat within the primary combustion zone and/or the wood burner. In such an arrangement, the ceramic material may be contoured or shaped so as to minimise any dead air zones within the firebox and/or maximise overall air flows within the firebox.
[0085] It may also be appreciated that the secondary combustion zone is surrounded by, and therefore also insulated by, the primary combustion zone. This enables very high combustion temperatures to be attained, and maintained, in the region of the secondary combustion zone.
[0086] It is envisaged that the invention may be retrofitted to existing fireplaces by making appropriate modifications, or alternatively, the invention may be incorporated into new fireplaces.
PREFERRED EMBODIMENTS
[0087] The description of a preferred form of the invention to be provided herein, with reference to the accompanying drawings, is given purely by way of example and is not to be taken in any way as limiting the scope or extent of the invention.
DRAWINGS
[0088] FIG. 1 : is a perspective front view of a wood burner which incorporates one possible embodiment of the present invention,
[0089] FIG. 2 : is a cut-away side view of the embodiment illustrated in FIG. 1 ,
[0090] FIG. 3 : is a cut-away side perspective view of another possible embodiment of the present invention,
[0091] FIG. 4 : is a perspective front view of yet another possible embodiment of the present invention, and
[0092] FIG. 5 : is a cut-away side view of the embodiment illustrated in FIG. 4 .
DESCRIPTION OF PREFERRED EMBODIMENTS
[0093] Having regard to FIGS. 1 and 2 there is shown a combustion system generally indicated by arrow 1 .
[0094] The combustion system 1 includes a fireplace in the form of a wood burner 2 .
[0095] The wood burner 2 includes a metal firebox 8 and an adjustable air intake control (not shown). The firebox 8 includes a fire base 3 , which effectively forms the floor of the firebox 8 of the wood burner 2 .
[0096] The wood burner 2 also includes a primary combustion zone 4 for pyrolysing and/or combusting wood 6 , and a secondary combustion zone 5 for combusting gases and/or particulate matter produced from the pyrolysis and/or combustion of the wood 6 .
[0097] The wood burner 2 also includes an exhaust flue, generally indicated by arrow 7 .
[0098] The upper part 9 of the exhaust flue 7 extends out of the top 10 of the firebox 8 and ultimately extends up and out through the ceiling and roof of the dwelling in which the wood burner 2 is housed.
[0099] The lower part 11 of the exhaust flue 7 extends into the firebox 8 to a position near to, or adjacent, the secondary combustion zone 5 (or fire base 3 ). This results in the downdraft or side draft of the combustion gases and/or particulate material. That is, the combustion gases and/or particulate material have to work their way downwards from the inside of the firebox 8 in order to be able to enter the open end of the lower part 11 of the exhaust flue 7 . This downdraft (or side draft) is primarily facilitated by the updraft created as hot air (or gases) ultimately travel up the flue 7 on their way to being exhausted through a roof or ceiling (that is, in the direction of arrow 21 ).
[0100] The lower part 11 of the exhaust flue 7 may be retrofitted to existing wood burners 2 .
[0101] For example, the lower part 11 of the exhaust flue 7 may be inserted into the firebox 8 and crimped onto the lower portion of the upper part 9 of the exhaust flue 7 . Alternatively, the lower part 11 of the exhaust flue 7 may be slid into the bottom of the upper part 9 of the exhaust flue 7 .
[0102] An advantage of such an arrangement is that the combustion system 1 may therefore effectively be retrofitted to existing wood burners 2 , thus bringing them up to modern compliance standards.
[0103] Furthermore, the task of retrofitting to existing wood burners 2 , as described above, is a relatively simple, quick and inexpensive operation.
[0104] Alternatively, the lower part 11 of the exhaust flue 7 may be incorporated into new wood burners 2 .
[0105] The combustion system 1 , when in operation, results in a charcoal/reduction layer 12 forming below the primary combustion zone 4 , and between the primary combustion zone 4 and the secondary combustion zone 5 . The arrangement and construction is such that the gases and/or particulate matter produced from the pyrolysis and/or combustion of the wood in the primary combustion zone 4 have to pass over the charcoal/reduction layer 12 prior to entering the secondary combustion zone 5 and/or the exhaust flue 11 .
[0106] The combustion system 1 , when in operation, also results in an ash layer 13 forming on the fire base 3 below the primary combustion zone 4 and charcoal/reduction layer 12 .
[0107] The wood burner 2 also includes a drying zone 14 for drying the wood 6 and/or removing water from the wood 6 prior to the pyrolysis and/or combustion of the wood 6 . The drying zone 14 is situated above (or within) the primary combustion zone 4 . Provision for introducing wood 6 to the wood burner 2 is via a hinged door (not shown) at the front of the firebox 8 .
[0108] The wood burner 2 includes a first air supply means 15 in the form of an adjustable air damper (not shown). The first air supply means 15 serves to provide an air supply to the interior of the firebox 8 , and more particularly to the primary combustion zone 4 .
[0109] The wood burner 2 also includes a second air supply means for introducing super heated air into the region of the secondary combustion zone 5 .
[0110] The second air supply means is provided for by a secondary flue 16 which wholly surrounds the lower part 11 of the exhaust flue 7 . This is facilitated by placing the piece of larger secondary flue 16 (175 mm in diameter) around the lower exhaust flue 11 (150 mm in diameter), leaving an air gap 17 of approximately 25 mm therebetween. The air gap 17 serves to take air from the top of the firebox 8 and channel it down through the air gap 17 to the secondary combustion zone 5 at the base of the lower part 11 of the exhaust flue 7 . The air travelling through this air gap 17 is super heated by the exhausting flue gases within the lower exhaust flue 11 on one side, and the primary combustion zone 4 on the other side.
[0111] Furthermore, the primary combustion zone 4 derives benefit by a much increased flame path as the flames are drawn down the air gap 17 from the top of the firebox 8 , thus maintaining a high temperature and increasing the time available to fully burn in.
[0112] The combustion system 1 includes insulation means for insulating the region of the secondary combustion zone 5 . The insulating means is in the form of a ceramic disc 18 .
[0113] One purpose of the ceramic disc 18 is to maximise temperatures within the region of the secondary combustion zone 5 .
[0114] Another purpose of the ceramic disc 18 is to introduce a degree of air turbulence or mixing into the region of the secondary combustion zone 5 which serves to enhance the levels of combustion and/or increase the temperatures of combustion. That is, the presence of the ceramic disk 18 serves to create an air disturbance in the region of the secondary combustion zone 5 , and the result may be compared to the act of blowing on a fire to increase its intensity.
[0115] It may also be appreciated that the secondary combustion zone 5 is surrounded by, and therefore also insulated by, the primary combustion zone 4 , thus resulting in the maintenance of very high combustion temperatures in the region of the secondary combustion zone 5 .
[0116] The combustion system 1 and/or wood burner 2 may work or be operated as follows:
[0117] Firstly, the firebox 8 of the wood burner 2 may be filled with wood 6 , and perhaps initially filled with smaller pieces of wood such as kindling, sitting atop paper for ignition purposes.
[0118] Once the fire within the firebox 8 has become well established, the wood 6 in the drying zone 14 , situated above (or within) the primary combustion zone 4 , will rapidly dry out, releasing water vapour in the process. This moisture vapour will in fact become a source of fuel when it is later split into hydrogen and carbon monoxide as it passes over the charcoal/reduction layer 12 .
[0119] Once the wood 6 has dried out and entered the primary combustion zone 4 , it will firstly undergo pyrolysis or combustion to produce predominantly charcoal and tar.
[0120] The pyrolysised wood 6 will then undergo combustion to produce predominantly carbon dioxide and water vapour. If enough oxygen is present, the temperature of combustion may also be sufficient to partially consume the charcoal and tar produced from the pyrolysis of the wood 6 , however most existing wood burners would not ordinarily be able to produce sufficient heat to be able to do this.
[0121] An advantage of the combustion system 1 , is that the combustion gases and products of pyrolysis are required to travel down and across to the mouth of the lower flue 11 in order to escape to atmosphere, thus drawing them across the charcoal/reduction layer 12 which greatly enhances the further reduction of the combustion gases, particulate matter and products of pyrolysis to combustible gases. For example, carbon dioxide and water vapour are “reduced” to the more combustible gases of hydrogen and carbon monoxide. The natural draught created by, or adjacent, the lower part 11 of the exhaust flue 7 is adequate to facilitate this process, and one advantage of this process is that it provides for the side draught and/or down draft of the combustion gases and products.
[0122] Furthermore, the resultant combustible gases such as hydrogen and carbon monoxide (as well as any other combustion gases and/or particulate materials and/or products of pyrolysis) then pass through the secondary combustion zone 5 . The secondary combustion zone 5 includes the provision of an air supply of super heated air which passes down the air gap 17 and into the secondary combustion zone 5 (as described previously).
[0123] Tests have shown that sustained temperatures in the region of the secondary combustion zone 5 vary between approximately 1050° C.-−1400° C.—compared to approximately 600° C.-800° C. for a conventional wood burner.
[0124] A sustained temperature in the region of the secondary combustion zone 5 of approximately 1000° C. or above is usually sufficient to combust both hydrogen and carbon monoxide, thus ensuring that none of these otherwise undesirable gases are exhausted to the atmosphere. My invention therefore clearly reaches these temperatures, and this compares favourably with the prior art appliances referred to previously, which do not appear to reach these kind of temperatures.
[0125] Furthermore, tests have shown that the very high temperatures achieved within the secondary combustion zone 5 serve to combust virtually all other gases and/or air pollutants (or smoke) produced by the wood burner 2 .
[0126] This results in less pollutants being exhausted to the atmosphere generally, and also results in less build up of soot and creosote products on the inside of the exhaust flue 7 . For example, testing has shown that these vastly reduced emissions only form very thin white or light grey deposits on the cowl at the top of the flue 7 , whereas previously this whole area had been covered in substantive black deposits. It follows therefore that the flue 7 is much less prone to the build up of soot and creosote products, thus reducing maintenance and also reducing the likelihood of chimney fires. Moreover, the unnecessary build up of soot, creosotes or tars within the flue has the detrimental effect of cooling the flue (which this invention minimises or negates).
[0127] One way of further reducing the exhausting of particulate matter from the wood burner 2 would be by separating the primary combustion zone 4 and the secondary combustion zone 5 , for example with a mesh screen (not shown).
[0128] Alternatively, there could be provided a tapered hearth (not shown) between the primary and secondary combustions zones 4 , 5 —which would serve to concentrate the charcoal/reduction layer 12 at the point where the volatile gases and/or particulate material pass from the primary combustion zone 4 to the secondary combustion zone 5 .
[0129] One of the reasons for the popularity of air-controlled wood burners is that the rate of combustion can be controlled through control of the air intake, or oxygen. However, starving the fire of air results usually results in incomplete combustion and increased pollution. The combustion system 1 uses oxygen, liberated from steam, to help the combustion process, thereby making it less polluting to restrict the air flow into the wood burner 2 .
[0130] Having regard to FIG. 3 , there is shown a cut-away side perspective view of another possible embodiment of the present invention. For convenience, the same numbers are used in FIG. 3 that correspond to the same (or similar) features which are also present in the embodiment described in FIGS. 1 and 2 .
[0131] FIG. 3 illustrates an alternative embodiment whereby the second air supply means includes an air channel 19 which penetrates the outside of the exhaust flue 7 and extends downwards into the secondary combustion zone 5 .
[0132] This is achieved by creating an aperture 20 in the side of the exhaust flue 7 at a point just above the firebox 8 of the wood burner 2 . The air channel 19 may then be inserted through this aperture 20 and extended downwards into, or adjacent, the secondary combustion zone 5 at the bottom of the lower flue 11 . The air travelling through this channel 19 is super heated by the exhausting flue gases within the lower exhaust flue 11 - and the channel 19 therefore serves essentially the same purpose as the secondary flue 16 illustrated in FIG. 2 .
[0133] Having regard to FIGS. 4 and 5 , there is shown another possible embodiment of the present invention. Again, and for convenience only, the same numbers are used in FIGS. 4 and 5 that correspond to the same (or similar) features of the invention which are also present in the embodiments described in FIGS. 1 , 2 and 3 .
[0134] Having regard to FIG. 4 , there is shown a front perspective view of a wood burner 2 . The lower portion 11 of the exhaust flue 7 is centrally located within the firebox 8 , and the fire base 3 is in the form of a grate, the grate being generally indicated by arrow 22 . Below the grate 22 is an ash pit 24 .
[0135] The grate 22 is comprised of a number of open-ended hollow tubes 23 which extend from the sides 25 of the ash pit 24 to the region of the secondary combustion zone 5 (formed just below the periphery of the lower portion 11 of the exhaust flue 7 ).
[0136] There are holes 26 formed in the sides 25 of the ash pit 24 , and these holes 26 may be drilled or pre-formed in the sides 25 . Air is able to flow from the ash pit 24 , through the holes 26 , and along the hollow tubes 23 to the region of the secondary combustion zone 5 . This air flow is indicated by the arrows shown in FIG. 5 .
[0137] This air flow serves as the second air supply means for introducing super heated air into the region of the secondary combustion zone 5 . That is, the air travelling up and along the hollow tubes 23 is super heated by virtue of the heat provided by the charcoal reduction layer 12 , which is above the hollow tubes 23 . Hence, the secondary combustion zone 5 is heated by both the primary combustion zone 4 , the charcoal reduction layer 12 and the super heated air emanating from the ends of the hollow tubes 23 .
[0138] This differs from the embodiment illustrated in FIGS. 1 and 2 in that the super heated air in FIGS. 1 and 2 is provided through the gap 17 between the secondary flue 16 and the lower portion 11 of the exhaust flue 7 . The embodiment illustrated in FIGS. 4 and 5 does away with the secondary flue 16 and instead utilises the air flow through the hollow tubes 23 , as indicated in FIG. 5 , to produce essentially the same result.
[0139] The wood burner of FIGS. 4 and 5 also includes a baffle 27 . The baffle 27 is designed to lengthen the flame path and slow the velocity of the gases and/or particulate matter, whereby there is more time for any gases to be combusted and/or whereby any particulate matter may drop back down to be properly combusted.
VARIATIONS
[0140] While the embodiments described above are currently preferred, it will be appreciated that a wide range of other variations might also be made within the general spirit and scope of the invention and/or as defined by the appended claims.
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This invention relates to a combustion system. The combustion system includes a fireplace which has a fire base, a primary combustion zone for pyrolysising and/or combusting a biomass fuel, and a secondary combustion zone for combusting gases and/or particulate matter produced from the pyrolysis and/or combustion of the biomass fuel. The combustion system also includes an exhaust flue, the exhaust flue extending to a position near to, or adjacent, the secondary combustion zone and/or the fire base. The invention may be particularly suitable for use in relation to wood burners, either by retrofitting to existing wood burners or by incorporating into new wood burners.
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BACKGROUND OF THE INVENTION
The formation of slimes by microorganisms is a problem that is encountered in many aqueous systems. For example, the problem is not only found in natural waters such as lagoons, lakes, ponds, etc., and confined waters as in pools, but also in such industrial systems as cooling water systems, air washer systems and pulp and paper mill systems. All possess conditions which are conducive to the growth and reproduction of slimeforming microorganisms. In both once-through and recirculating cooling systems, for example, which employ large quantities of water as a cooling medium, the formation of slime by microorganisms is an extensive and constant problem.
Airborne organisms are readily entrained in the water from cooling towers and find this warm medium an ideal environment for growth and multiplication. Aerobic and heliotropic organisms flourish on the tower proper while other organisms colonize and grow in such areas as the tower sump and the piping and passages of the cooling system. The slime formation not only aids in the deterioration of the tower structure in the case of wooden towers, but also promotes corrosion when it deposits on metal surfaces. Slime carried through the cooling system plugs and fouls lines, valves, strainers, etc., and deposits on heat exchange surfaces. In the latter case, the impedance of heat transfer can greatly reduce the efficiency of the cooling system.
In pulp and paper mill systems, slime formed by microorganisms is commonly encountered and causes fouling, plugging, or corrosion of the system. The slime also becomes entrained in the paper produced to cause breakouts on the paper machines, which results in work stoppages and the loss of production time. The slime is also responsible for unsightly blemishes in the final product, which result in rejects and wasted output.
The previously discussed problems have resulted in the extensive utilization of biocides in cooling water and pulp and paper mill systems. Materials which have enjoyed widespread use in such applications include chlorine, chlorinated phenols, organo-bromines, and various organo-sulfur compounds. All of these compounds are generally useful for this purpose but each is attended by a variety of impediments. For example, chlorination is limited both by its specific toxicity for slime-forming organisms at economic levels and by the tendency of chlorine to react, which results in the expenditure of the chlorine before its full biocidal function is achieved. Other biocides are attended by odor problems, and hazards with respect to storage, use or handling which limit their utility. To date, no one compound or type of compound has achieved a clearly established predominance with respect to the applications discussed. Likewise, lagoons, ponds, lakes, and even pools, either used for pleasure purposes or used for industrial purposes for the disposal and storage of industrial wastes, become, during the warm weather, besieged by slime due to microorganism growth and reproduction. In the case of industrial storage or disposal of industrial materials, the microorganisms cause additional problems which must be eliminated prior to the materials' use or disposal of the waste.
Naturally, economy is a major consideration with respect to all of these biocides. Such economic considerations attach to both the cost of the biocide and the expense of its application. The cost performance index of any biocide is derived from the basic cost of the material, its effectiveness per unit of weight, the duration of its biocidal or biostatic effect in the system treated, and the ease and frequency of its addition to the system treated. To date, none of the commercially available biocides has exhibited a prolonged biocidal effect. Instead, their effectiveness is rapidly reduced as a result of exposure to physical conditions such as temperature, association with ingredients contained by the system toward which they exhibit an affinity or substantivity, etc., with a resultant restriction or elimination of their biocidal effectiveness, or by dilution.
As a consequence, the use of such biocides involves their continuous or frequent addition to systems to be treated and their addition to multiple points or zones in the systems to be treated. Accordingly, the cost of the biocide and the labor cost of applying it are considerable. In other instances, the difficulty of access to the zone in which slime formation is experienced precludes the effective use of a biocide. For example, if in a particular system there is no access to an area at which slime formation occurs the biocide can only be applied at a point which is upstream in the flow system. However, the physical or chemical conditions, e.g., chemical reactivity, thermal degradation, etc., which exist between the point at which the biocide may be added to the system and the point at which its biocidal effect is desired render the effective use of a biocide impossible.
Similarly, in a system experiencing relatively slow flow, such as a paper mill, if a biocide is added at the beginning of the system, its biocidal effect may be completely dissipated before it has reached all of the points at which this effect is desired or required. As a consequence, the biocide must be added at multiple points, and even then a diminishing biocidal effect will be experienced between one point of addition to the system and the next point downstream at which the biocides may be added. In addition to the increased cost of utilizing and maintaining multiple feed points, gross ineconomies with respect to the cost of the biocide are experienced.
Specifically, at each point of addition, an excess of the biocide is added to the system in order to compensate for that portion of the biocide which will be expended in reacting with other constituents present in the system or experience physical changes which impair its biocidal activity.
SUMMARY OF THE INVENTION
The biocidal compositions of the present invention comprise, as active ingredients, 1) diiodomethyl-p-tolylsulfone (DIMPS) and 2) B-bromo-B-nitrostyrene (BNS). These constituents are commercially available. The synergistic effect obtained by combining DIMPS and BNS has not been previously disclosed.
DETAILED DESCRIPTION OF THE INVENTION
Surprisingly, the present inventors have found that mixtures of DIMPS and BNS are especially efficacious in controlling the growth of fungal microbes, specifically the Trichoderma viride species. This particular species is a common nuisance fungal type found in industrial cooling waters and pulping and paper making systems.
This particular species of mold is a member of the Fungi Imperfecti which reproduce by means of asexual spores or fragmentation of mycelium. It is commonly found on fallen timber and is a widely occurring soil organism. Because of its ubiquitous nature, this mold continually contaminates open cooling systems and pulping and papermaking systems. Contamination can take the form of airborne spores or fungal mats--a mass of agglomerated hyphae bound together with bacterial cells and cemented by gelatinous polysaccharide or proteinaceous material. The slimy mass entraps other detritus, restricts water flow and heat transfer and may serve as a site for corrosion.
These fungi are able to grow in environments hostile to other lifeforms. While they are strict aerobes, Trichoderma produce both hyphae, the vegetative structure, and spores which require minimal metabolic turnover and are able to withstand harsher environmental conditions. Accordingly, by reason of demonstrated efficacy in the growth inhibition of this particular species, one can expect similar growth inhibition attributes when other fungi are encountered. It is also expected that these compositions will exhibit similar growth inhibition attributes when bacterial and algal species are encountered.
In accordance with the present invention, the combined DIMPS and BNS treatment may be added to the desired aqueous system in need of biocidal treatment, in an amount of from about 0.1 to about 200 parts of the combined treatment to one million parts (by weight) of the aqueous medium. Preferably, about 5 to about 50 parts of the combined treatment per one million parts (by weight) of the aqueous medium is added.
The combined treatment is added, for example, to cooling water systems, paper and pulp mill systems, pools, ponds, lagoons, lakes, etc., to control the formation of fungal microorganisms, which may be contained by, or which may become entrained in, the system to be treated. It has been found that the compositions and methods of utilization of the treatment are efficacious in controlling the fungal organism, Trichoderma viride, which may populate these systems. It is thought that the combined treatment composition and method of the present invention will also be efficacious in inhibiting and controlling all types of aerobic microorganisms.
Surprisingly, it has been found that when the ingredients are mixed, in certain instances, the resulting mixtures possess a higher degree of fungicidal activity than that of the individual ingredients comprising the mixture. Accordingly, it is possible to produce a highly efficacious biocide. Because of the enhanced activity of the mixture, the total quantity of the biocidal treatment may be reduced. In addition, the high degree of biocidal effectiveness which is provided by each of the ingredients may be exploited without use of higher concentrations of each.
The following experimental data were developed. It is to be remembered that the following examples are to be regarded solely as being illustrative and not as restricting the scope of the invention.
DESCRIPTION OF PREFERRED EMBODIMENT
DIMPS and BNS were added in varying ratios and over a wide range of concentrations to a liquid nutrient medium which was subsequently inoculated with a standard volume of a suspension of the spores from Trichoderma viride. Growth was measured by determining the amount of radioactivity accumulated by the cells when 14C-glucose was added as the sole source of carbon in the nutrient medium. The effect of the biocide chemicals, alone and in combination, is to reduce the rate and amount of 14C incorporation into the cells during incubation, as compared to controls not treated with the chemicals. Additions of the biocides, alone and in varying combinations and concentrations, were made according to the accepted "checkerboard" technique described by M. T. Kelley and J. M. Matsen, Antimicrobial Aqents and Chemotherapy. 9:440 (1976). Following a two hour incubation, the amount of radioactivity incorporated in the cells was determined by counting (14C liquid scintillation procedures) for all treated and untreated samples. The percent reduction of each treated sample was calculated from the relationship: ##EQU1##
Plotting the % reduction of 14C level against the concentration of each biocide acting alone results in a dose-response curve, from which the biocide dose necessary to achieve any given % reduction can be interpolated.
Synergism was determined by the method of calculation described by F. C. Kull, P. C. Eisman, H. D. Sylwestrowicz and R. L. Mayer, Applied Microbiology 9,538 (1961) using the relationship: ##EQU2## where: Q a =quantity of compound A, acting alone, producing an end point
Q b =quantity of compound B, acting alone, producing an end point
Q A =quantity of compound A in mixture, producing an end point
Q B =quantity of compound B in mixture, producing an end point
The end point used in the calculations is the % reduction caused by each mixture of A and B. Q A and Q B are the individual concentrations in the A/B mixture causing a given % reduction. Q a and Q b are determined by interpolation from the respective dose response curves of A and B as those concentrations of A and B acting alone which produce the same % reduction as each specific mixture produced.
Dose-response curves for each active acting alone were determined by linear regression analysis of the dose-response data. Data were fitted to a curve represented by the equation shown with each data set. After linearizing the data, the con tributions of each biocide component in the biocide mixtures to the inhibition of radioisotope uptake were determined by interpolation with the dose-response curve of the respective biocide. If, for example, quantities of Q A plus Q B are sufficient to give a 50% reduction in 14C content, Q a and Q b are those quantities of A or B acting alone, respectively, found to give 50% reduction in 14C content. A synergism index (SI) is calculated for each combination of A and B.
Where the SI is less than 1, synergism exists. Where the SI=1, additivity exists. Where SI is greater than 1, antagonism exists.
The data in the following tables come from treating Trichoderma viride, a common nuisance fungal type found in industrial cooling waters and in pulping and paper making systems, with varying ratios and concentrations of DIMPS and BNS. Shown for each combination is the % reduction of 14C content (% I), the calculated SI, and the weight ratio of DIMPS and BNS.
TABLE I______________________________________DIMPS vs. BNSppm ppm RatioDIMPS.sup.1 BNS.sup.2 DIMPS:BNS % I SI______________________________________6 0 100:0 943 0 100:0 891.5 0 100:0 750.75 0 100:0 290.38 0 100:0 40.19 0 100:0 00 5 0:100 980 2.5 0:100 900 1.25 0:100 800 0.625 0:100 470 0.313 0:100 170 0.156 0:100 46 5 1.2:1 99 2.703 5 1:1.7 99 2.061.5 5 1:3.3 99 1.740.75 5 1:6.7 99 1.580.38 5 1:13.2 98 1.550.19 5 1:26.3 98 1.516 2.5 2.4:1 98 2.053 2.5 1.2:1 97 1.441.5 2.5 1:1.7 96 1.130.75 2.5 1:3.3 93 1.050.38 2.5 1:6.6 91 1.020.19 2.5 1:13.2 84 1.216 1.25 4.8:1 96 1.793 1.25 2.4:1 95 1.211.5 1.25 1.2:1 92 0.84*0.75 1.25 1:1.7 87 0.75*0.38 1.25 1:3.2 80 0.79*0.19 1.25 1:6.6 78 0.77*6 0.625 9.6:1 94 1.693 0.625 4.8:1 92 1.011.5 0.625 2.4:1 86 0.74*0.75 0.625 1.2:1 72 0.77*0.38 0.625 1:1.6 59 0.90*0.19 0.625 1:3.2 56 0.84*6 0.313 19.2:1 94 1.593 0.313 9.6:1 91 0.92*1.5 0.313 4.8:1 74 0.86*0.75 0.313 2.4:1 49 1.130.38 0.313 1.2:1 32 1.340.19 0.313 1:1.6 24 1.346 0.156 38.5:1 94 1.543 0.156 19.2:1 89 0.92*1.5 0.156 9.6:1 66 0.970.75 0.156 4.8:1 37 1.230.38 0.156 2.4:1 16 1.530.19 0.156 1.2:1 10 1.32______________________________________
TABLE II______________________________________DIMPS vs. BNSppm ppm RatioDIMPS.sup.1 BNS.sup.2 DIMPS:BNS % I SI______________________________________6 0 100:0 943 0 100:0 881.5 0 100:0 700.75 0 100:0 380.38 0 100:0 110.19 0 100:0 40 5 0:100 990 2.5 0:100 950 1.25 0:100 850 0.625 0:100 700 0.313 0:100 340 0.156 0:100 106 5 1.2:1 100 2.853 5 1:1.7 100 2.281.5 5 1:3.3 99 2.060.75 5 1:6.7 99 1.920.38 5 1:13.2 99 1.850.19 5 1:26.3 99 1.816 2.5 2.4:1 99 2.053 2.5 1.2:1 98 1.521.5 2.5 1:1.7 98 1.220.75 2.5 1:3.3 97 1.110.38 2.5 1:6.6 96 1.060.19 2.5 1:13.2 96 1.026 1.25 4.8:1 97 1.723 1.25 2.4:1 96 1.131.5 1.25 1.2:1 95 0.84*0.75 1.25 1:1.7 92 0.75*0.38 1.25 1:3.2 88 0.75*0.19 1.25 1:6.6 85 0.78*6 0.625 9.6:1 96 1.533 0.625 4.8:1 94 0.95*1.5 0.625 2.4:1 90 0.69*0.75 0.625 1.2:1 84 0.61*0.38 0.625 1:1.6 75 0.66*0.19 0.625 1:3.2 73 0.63*6 0.313 19.2:1 95 1.453 0.313 9.6:1 92 0.87*1.5 0.313 4.8:1 83 0.68*0.75 0.313 2.4:1 64 0.82*0.38 0.313 1.2:1 46 1.090.19 0.313 1:1.6 36 1.276 0.156 38.5:1 95 1.393 0.156 19.2:1 90 0.86*1.5 0.156 9.6:1 74 0.79*0.75 0.156 4.8:1 47 1.130.38 0.156 2.4:1 27 1.420.19 0.156 1.2:1 20 1.31______________________________________ Asterisks in the SI column indicate synergistic combinations in accordanc with the Kull method supra, while: .sup.1 indicates a product with 40% actives DIMPS and .sup.2 indicates a product with 100% actives BNS
In Tables I and II, differences seen between the replicates are due to normal experimental variance.
In accordance with Tables I-II supra., unexpected results occurred more frequently within the product ratios of DIMPS to BNS of from about 1:6.6 to 19.2:1. Since the DIMPS product contains about 40% active biocidal component and the BNS product contains about 100% active biocidal component, when based on the active biocidal component, unexpected results appear more frequently within the range of active component of DIMPS:BNS of about 1:16.5 to 7.7:1. At present, it is most preferred that any commercial product embodying the invention comprises a weight ratio of active component of about 1:1DIMPS:BNS.
While this invention has been described with respect to particular embodiments thereof, it is apparent that numerous other forms and modifications of this invention will be obvious to those skilled in the art. The appended claims and this invention generally should be construed to cover all such obvious forms and modifications which are within the true spirit and scope of the present invention.
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A microbial inhibiting composition and method is disclosed. The composition comprises an amount, effective for the intended purpose of diiodomethyl-p-tolylsulfone and B-bromo-B-nitrostyrene. The method comprises administering an amount of this combined treatment to the particular water containing system for which treatment is desired.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/064,829, filed Oct. 21, 1997.
BACKGROUND OF THE INVENTION
The present invention relates to a device and method for studying particles in a fluid.
Microscopic marine particles can dramatically affect, and be affected by, water properties. For example, marine particles have been shown to be indicators of water properties such as pollution, nutrient distribution and water mass boundaries. They have also been shown to control significant properties of water including fluorescence, oxygen and nitrogen content, opacity and light attenuation. Finally, marine particles are living at the very bottom of the food web, and thus can dramatically affect life all the way up the food chain. Thus, it is important to fully understand the properties and distributions of the particles present in water.
Several instruments are available to study individual marine biological particles, including in-situ, on-vessel, and laboratory instruments. However, the currently available instrumentation that is used for marine particle analysis has limitations. Currently, because it is difficult to achieve a sufficient flow rate to enable accurate counting of cells while retaining imaging capability, there has been an ongoing need for instrumentation capable of analyzing and imaging marine particles in the 3-1000 μm range both in the lab and on board a vessel.
SUMMARY OF THE INVENTION
The present invention provides a device for studying particles in a fluid that advantageously allows particles having a broad range of particle size, e.g., in the 3-1000 μm range, to be readily imaged and counted
The device includes optics which provide an excellent depth of field, allowing the use of a "deep " sample chamber and high flow rate to enable the user to image particles in a relatively large sample of flowing fluid accurately and quickly. In preferred embodiments, the device includes software capable of storing and analyzing the images thus obtained, eliminating the need for manual counting and visual inspection of the particles. Moreover, in preferred devices, recording of an image is triggered by fluoresce or scattered light from a particle in the field of view, thus eliminating imaging of portions of fluid which contain no particles.
The device of the invention can be used to image marine particles or other biological particles in a fluid, and is suitable for use in a laboratory or in other environments, for example onboard a vessel.
In one aspect, the invention features a device for studying particles in a fluid that includes a depth of focus enhancer, an optical device including a unique binary optical element which increases the depth of focus of the imaging system.
In another aspect, the invention features a device for studying particles in a fluid that includes a triggering mechanism whereby particle fluorescence or scattered light triggers a signal which results in the imaging of particles passing through the flow chamber.
In another aspect, the invention features devices for studying particles, including computer algorithms that acquire particles images, generate size and scattered light and fluorescence files, and perform interactive scattergram functions. The interactive scattergram functions provide a size/fluorescence light graph ("scattergram") plotting particle data and allow the user to select a region of the scattergam, e.g., with a computer mouse, and display images of particles with properties in the selected region.
The invention also features methods of using the above devices.
Other features and advantages of the invention will be apparent from the description of the preferred embodiments thereon, taken together with drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates a device for studying particles in a fluid according to one embodiment of the invention FIG. 1a is an enlarged perspective view of the flow chamber of the device of FIG. 1.
FIG. 2 is a view of the device of FIG. 1, with portions of the device omittede for clarity, and with a detailed view of the optics in the device.
FIG. 2a is a view of the depth of focus enhancer included in the optics in FIG. 2.
FIGS. 3-3C are a schematic diagram of a circuit that would be suitable for use in triggering the device of FIG. 1.
FIGS. 4-4B are flow charts of the algorithms for software suitable for use in the device of FIG. 1.
FIG. 5 is a schematic diagram showing a photolithographic process that may be used to form the depth of focus enhancer of FIGS. 2a and 2b.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a system 10 for the automated counting and sizing of marine particles. The system 10 includes a low fluorescence flow chamber 15 (i.e., a flow chamber formed of a material that does not readily fluoresce, e.g., microscope glass and low-fluorescence UV curable optical grade epoxy adhesive), including an inlet 20 and an outlet 25. The flow chamber 15 defines a channel 15a (shown in FIG.. 1a) through which a particle-containing fluid flows at a predetermined rate.
A light source 30 is used to generates fluorescence and scatter excitation light which is passed through the imaging optics 35 to the flow chamber 15, resulting in particle fluorescence and/or light scatter. The light source is preferably a mercury arc lamp with 440 nm excitation filter 33, or alternatively a 488 nm laser. Any particle fluorescence emissions from the flow chamber 15 (FIG. 1, 2) that have a wavelength of 535 to 900 nm are monitored with the system emission filters 43 and a high sensitivity photomultiplier tube (PMT) 40. The PMT output is processed by detection electronics 45. Preferably, the detection electronics 45 are provided with user-adjusted gain and threshold settings which determine the amount of fluorescence or scatter required for the system to acknowledge a passing particles.
If a sufficiently fluorescent particle passes through the flow chamber 15 a PMT fluorescence signal is sent to the detection electronics 45, which then generate a trigger signal (See FIG. 3, discussed below). The detection electronics 45 also preferably include a mechanism whereby the user may alternatively select a setting which automatically generates a trigger signal every second. The trigger signal causes a very high intensity LED flash 50 to backlight the flow chamber 15 and image the passing particles. The very high intensity LED flash 50 is preferably a 670 nm LED which is flashed under the flow chamber for 200 μsec (or less) to capture an instantaneous image of the particles in flow on a video camera 60, which is positioned above the flow chamber 15. The trigger signal also causes a framegabber 55 and video camera 60 to image the flow chamber 15 while the LED flash 50 is occurring, allowing the framegrabber 55 to acquire this image immediately. The computer 65 may then measure the particle and store the data for later analysis.
The detection electronics 45 provide an amplified version of the PMT fluorescence signal to the analog-to-digital converter of computer 65. The software of computer 65 monitors the amplified version of the PMT fluorescence signal before, during and after the fluorescent events determine the peak fluorescence of each triggering particle. As will be discussed in detail below, with reference to FIG. 4, when a fluorescent particle is detected, the software scans the resulting image, separating the different particle The image of each particles is extracted from the image of the flow chamber 15 an inserted in a file. A special file is used to store the information on each particle, including the file location of the particle image, the particle size, fluorescence and time of particle passage.
Imaging Optics
FIG. 2 is a schematic view of the epi-fluorescence and imaging optics 35 (shown as a "black box " in FIG. 1). The imaging optics 35 include, but are not limited to, a 0.12 numerical aperture 4× microscope objective 75 to image the particle flow onto the video camera 60, focus fluorescence excitation light from the light source 30 onto the flow chamber 15 and focus the resulting particle fluorescence or scattered light onto the system PMT 40. A dichroic mirror 80 prevents the light from the light source 30 from reflecting back from the flow chamber 15 into the video camera 60. A partial mirror 85 splits the light from the light source 30, directing some of the light (preferably about 50%) to the video camera 60 and the remainder of the light to the PMT 40. A dichroic mirror may be used in place of the partial mirror 85.
The length and width of channel 15a of flow chamber 15 are selected to exactly match the field of view of the imaging optics 35 (1 mm across and 1 mm deep). This keeps all of the particles flowing through the flow chamber in focus, removing the need for a focussing sheath flow, and thereby enabling accurate counting of cells while retaining imaging capability. A depth of focus enhancer 70 is used with the objective 75 to increase the system depth of focus. Preferably, the depth of focus enhancer is designed to increase the depth of focus to match the channel depth. The depth of focus enhancer 70 allows the use of a thick flow chamber 15 with a high flow rate (e.g., up to 10 ml per minute) while maintaining very high image resolution without the depth of focus enhancer 70, the desired depth of focus would be difficult to attain without decreasing the system numerical aperture by a factor which would degrade the resolution and decrease the light throughput of the system, making it difficult to detect particle fluorescence.
Depth of Focus Enhancer
FIG. 2a is an enlarged view of the depth of focus enhancer 70 included in the optics in FIG. 2. The depth of focus enhancer is an optical element that imparts a prescribed phase delay onto an incident wave-front through materials of varying thicknesses and possibly with different indices of refraction. The optical components which impart the phase delay are normally made of ground and polished glass. The shape of the optical element is shown in FIG. 2a. Preferably, the element is configured to impart a phase delay on incident light such that the microscope objective has a continuum of foci rather than a single focus. This may be accomplished by an element which imparts spherical aberration to the lens.
The depth of focus enhancer 70 is preferably a "binary optical element", an optical element fabricated by etching the desired phase delay into a glass substrate by a series of photolithographic exposure and etch steps. The rest is that a quantized version of the desired waveform is etched into the glass.
A binary optical element is fabricated by a series of etches where material in the substrate glass is etched a prescribed depth or not etched at all. If, as is generally the case, the etch is depth halved for each successive etch cycle, the result is that for n etch cycles, there will be 2 n possible different levels in the substrate. Generally n is between 1 and 5. The resulting pattern in the substrate is a quantized version of the desired pattern much like the output of a digital to analog converter, with a quantization level of MAX/2 n where MAX is the maximum value of the waveform.
Usually, the waveform to be synthesized in the binary element substrate is on the order of several wavelengths. For example, a typical binary optical element realization of a lens is generated with as many as 100 wavelengths of curvature. Since the number of etch cycles is generally within the range of from 1 to 5, binary optical elements are generally crated by taking advantage of the fact that an arbitrary delay is optically identical to that delay minus a delay of Mλ, where M is any integer and λ is the optical wavelength of design. This wrapping property allows the designer to compress the lens design by subtracting the largest possible value of Mλ from the wave to be approximated, crating a resulting waveform which ranges from 0 to λ. If the designer then converts this compressed form to a quantized waveform, the binary element is an effective approximation of the desired waveform with a maximum effective error of 2 -n λ.
Once the wrapping process has been applied to the desired waveform, it is possible to generate the photolithography masks for the binary optic element. This is accomplished with a successive approximation technique where successive powers of two are subtracted from the desired waveform. Considering that any waveform W that is between 0 and λ may be approximated by ##EQU1## where ω k =1 or 0, the n etching of the etching of the binary optical element may be generated by successively subtracting power of two from the original waveform. Putting this mathematically, if we let
ρ i =i th radial sample
Q k =K th mask, k=1, . . . n
we can describe the series of n masks as ##EQU2## The graph below illustrates the desired waveform and fabricated waveform for a four-level fabrication process with folding over and a step size of λ/4. ##STR1##
Photolithography is used to transfer the binary optical waveform onto the substrate. The glass substrate is prepared for this process by carefully cleaning it of contaminants by a wash with acetone and methanol. It is then rinsed with de-ionized water and dried with a jet of dry nitrogen. The process is repeated until the substrate is absolutely clean. Next, a thin layer of photoresist (e.g., 1.3 microns of positive resist, Microposit 1813, Shipley, Inc., Marlborough, Mass.) is spun onto the substrate. The substrate is then placed in a bake oven for half an hour to harden the photoresist for the exposure and develop processes. The resist is then exposed to ultraviolet light through the photolithography mask, placed in close contact with the substrate (See FIG. 5). Next, the photoresist is developed, leaving resist where the mask was opaque (a positive process). The substrate is then placed in an acid etch where the resist protects the underlying area from being etched. The etched depth must be carefully controlled to impart the appropriate phase delay at each location. In general, the delay W glass caused by a step of glass of height Δ air is
W.sub.glass =Δ(n.sub.glass -n.sub.air)
where
n glass =glass substrate index of refraction
n air =1.0(index of refraction of air)
Using this and the act that mask n is used to create a delay of 2 -n λ, the appropriate depth to etch is ##EQU3##
This etch depth can be imparted to the substrate by characterizing the etch rate for a given etching process and then carefully controlling the etching time. A suitable solution is 5% HF in NH 4 F. This was found to etch the soda-lime glass slide at 180 nm/min with agitation.
Finally, after the etch, the photoresist is removed with an acetone wash and the substrate is rinsed with de-ionized water. The end product of this processing is a substrate with the mask pattern etched in glass. The substrate may then be sent through further resist-mask-etch cycles to transfer more levels to the phase profile.
The predominant aberration required for depth of focus enhancement is primary spherical, which can be completely described by a fourth-order polynomial. With this in mind, we designed two binary optical elements based on a fourth order polynomial: a two-level element and a four-level element. In general, the fourth order polynomial is of the form:
OPD.sub.Approx =γρ.sup.2 +βρ.sup.4
which means the phase function associated with this is:
Φ.sub.approx =k(γρ.sup.2 +βρ.sup.4)
If we take the first derivative of this, we find that the spatial frequency of the phase is: ##EQU4##
The size of the phase feature for Φ approx is the multiplicative inverse of the spatial frequency. Also for a given binary corrector, the phase steps are given by ##EQU5##
Multiplying the phase steps by the size of the phase features and scaling the result to the radius of the objective aperture stop, a, we fine that the minimum feature size of the binary element is: ##EQU6## Once the parameters γ and β were computed to generate a useful depth of focus, we found that the misfocus parameter, γ, could be slightly adjusted to achieve a feature size no smaller than 200 μm for the two-level element, which simplified fabrication The four-level corrector minimum feature size was no smaller than 100 μm. Graph (a), below, shows the effective phase profiles of two and four level depth of focus-enhancing elements. Preferably, the four-level enhancer is used. ##STR2## Detection Electronics
FIG. 3 is a schematic diagram of a circuit that would be suitable for use in triggering the device of FIG. 1. The system light detector signal is amplified by the variable gain circuit comprised of operational amplifier U1. The user may manually adjust the gain of the circuit with the with the potentiometer attached to the terminals at J5. The amplified signal is present for computer analysis at the output labeled "Analog Out." Comparator U2 compares the amplified signal to a threshold set by the potentiometer R4. If t he signal exceeds the threshold, the output of U2 pin 2 goes to logic 1. This value causes the trigger LED to illuminate, alerting the user to the presence of a triggering signal. The trigger also clears flip-flop U6-A pin via U3 and capacitor C9.
Sync stripper U4 provides vertical synchronization signals from the system video camera. These are used to generate synchronized flow chamber LED flashes and computer trigger signals (trigger out). When a vertical synchronization signal arrives from the video camera, the U4 VSO signal sets U6-A pin 1. The transition of U6-A pin 1 forces the transistor Q2 output low via capacitor C13. As C13 charges, Q2 ceases to pull down trigger out
The high-low transition of trigger out activates the variable delay output of U7. After a time determined by R18 and R16 and C15, U7's output rises, charging capacitor C14 and temporarily pulling dow pin 7 of J8 which is used to drive the high intensity LED for flow chamber backlighting. Transistor Q3 may be driven by external signals to pull down this same pin 7 under computer and to provide continuous backlighting.
This circuitry assures that a light detector signal (fluoresce or scatter) which may occur at any time results in signals which trigger the computer and LED flash only after the next video vertical synchronization signal. This results in clear images on the video camera and hence, at the computer.
The auto-trigger circuit comprised of U8 and U9 divides the video frame even/odd signal by 10, and if selected by the user switch J9 or computer control line J8, provides a video-synchronized trigger out and LED flash which may be used to randomly sample the flow stream, and also results in clear images.
Imaging and Analysis Software
FIG. 4 is a flow chart of the algorithm for the in-flow particle imaging and analysis system software used by computer 65 to store and analyze images. When a trigger is generated (i.e., a fluorescent or light scattering particle is detected), the software scans the resulting image, separating the different particle sub-images in it. The area of each particle is measured by summing the number of pixels in each particle image below a software selected threshold and multiplying the result by the equivalent physical area of a pixel. This computed area of the particle is stored in a spreadsheet-compatible file along with other properties of the particle, e.g., its measured peak fluorescence, time of particle passage, and the location of the particle in the image. The sub-image of each particle is copied from the chamber image and saved with other sub-images in a collage file. Several of these collage files may be generated for each system experiment. A special system file is generated, containing the collage file location of each particle sub-image, particle size, fluorescence and time of particle passage.
The system software has two data review modes: (1) image collage and (2) interactive scattergram. In the image collage mode, the user may review a series of sub-images in a collage file using the computer mouse to select desired sub-images. Reviewing these files allows the user to identify particle types, count particles, or study other features.
In interactive scattergram mode, data is presented to the user as a dot-plot; e.g., a graph of particle size vs. particle fluorescence or light scatter. As shown by the algorithm in FIG. 4a, if the user selects a region of the scattergram with the computer mouse, images of particles having the characteristics plotted in that region are displayed on the computer screen this allows the user to study particle populations and to examine images of particles with specific sizes or fluorescence, such as cells of a specific type. Because a spreadsheet compatible file is generated for each experiment, the user may also review the data with a spreadsheet program. This information allows the user to readily generate cell counts and fluorescence or scatter and size distribution histograms for each sample. This file also contains the location of each particle in the original image which is used to remove redundant data from particles that have become attached to the flow chamber.
Other embodiments are within the scope of the invention.
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The present invention provides a device for studying particles in a fluid that advantageously allows particles having a broad range of particle size, e.g., in the 3-1000 μm range, to be readily imaged and counted.
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This application is a U.S. National Phase under 35 U.S.C. §371 of International Application No. PCT/IB2012/052353, filed May 11, 2012, which claims priority under 35 U.S.C. §§119 and 365 to Swedish Application No. 1150436-2, filed May 13, 2011.
FIELD OF INVENTION
The present invention relates to a process for purifying, such as salt/ion depletion and/or free sugar depletion, preferably by using dewatering, a slurry comprising cellulose, such as microfibrillated cellulose, by subjecting the slurry to an electric field.
BACKGROUND
Microfibrillated cellulose (MFC), which also is known as nanocellulose, is a material typically made from wood cellulose fibers. It can also be made from microbial sources, agricultural fibers, dissolved cellulose or CMC etc. In microfibrillated cellulose the individual microfibrils have been partly or totally detached from each other.
Microfibrillated cellulose has a very high water binding capacity and it is thus very difficult to reduce the water content of a slurry comprising microfibrillated cellulose and accordingly it is thus difficult to purify. High water content of a slurry comprising microfibrillated cellulose also prevents usage of MFC in many different application where MFC with high solids would be required.
Today there exist several different methods to remove water from a slurry comprising cellulose, such as microfibrillated cellulose. It is for example possible to use different drying techniques. Examples of different drying techniques are; freeze drying, spray drying and supercritical drying. These techniques are however quite energy demanding and thus not so cost efficient to use in large scale processes. Also, hornification, or superhornification, of the microfibrillated cellulose fibers often tends to occur when water is removed with different drying techniques. Hornification is when irreversible bonds between the fibers are formed. When hornification has occurred it is not possible for the fibers to expand and swell in water and the original water bonding capacity of the fibers is thus lost. The hornification may be prevented by addition of chemicals which physically prevent or modify the fibers in such way that the formation of bonds between cellulose fibers are limited or prevented. CA1208631A describes a process to re-disperse dried microfibrillated cellulose by addition of additives that will prevent the fibrils from bonding to each other and thus also prevents hornification of the fibers.
Further there is disclosed by Luchache et al. in Annals of the University of Craiova, Electric Engineering series, No. 32, 2008; ISSN 1842-4805 dewatering of pulp and paper waste sludge.
Mechanical treatments in order to remove water from a slurry comprising cellulose, such as microfibrillated cellulose can also be used. However, they are normally not very successful due to the small fiber size and size distribution of the microfibrillated cellulose. Moreover, filtration of a slurry comprising cellulose, such as microfibrillated cellulose is difficult due to the dense web formed by the slurry. Furthermore, the bonds between the microfibrillated cellulose fibers are also quite strong and this will also make mechanical dewatering less efficient.
The inefficiency or limitations in drying in e.g. pressurized dewatering will further give problems with the removal of ions of cellulose constituents. Since a filter cake is formed during dewatering, a higher resistance to dewatering is obtained. At the same time, it is more difficult to remove e.g. ions or other dissolved species since these might be accumulated in the filter cake. Therefore, the obtained dewatered filter cake of MFC might in fact contain the initial amount of ions or even substantial higher amount of ions.
When using a normal drying method, the ions and residual chemicals will remain in the concentrated fiber suspensions and finally in the dried MFC or cellulose sample.
There is thus a need for an improved process for purifying, such as salt/ion depletion and/or free sugar depletion, of a slurry comprising cellulose, such as microfibrillated cellulose without causing hornification, or superhornification.
SUMMARY OF INVENTION
The present invention solves one or more of the above problems, by providing according to a first aspect a process for purifying such as salt/ion depletion and/or free sugar depletion, preferably using dewatering, of a slurry comprising cellulose, such as microfibrillated cellulose wherein the process comprises the following steps:
providing a slurry comprising cellulose and liquid, subjecting the slurry to an electric field inducing the liquid of the slurry to flow, separating the liquid from the cellulose thus obtaining a liquid depleted slurry, adding a washing liquid, such as an organic solvent, to the liquid depleted slurry subjecting the liquid depleted slurry to an electric field inducing the washing liquid of the slurry to flow and separating the washing liquid from the cellulose, thus obtaining a purified cellulose.
The present invention also provides according to a second aspect cellulose, such as microfibrillated cellulose, purified according to the first aspect.
The present invention also provides according to a third aspect, cellulose, such as microfibrillated cellulose, obtainable by the process according to the first aspect.
The present invention also provides according to a fourth aspect use of the cellulose, such as microfibrillated cellulose, according to the second or the third aspect in a strength additive, a thickener, a viscosity modifier, a rheology modifier, a cleaning powder, a washing powder, a detergent, a foam composition, a barrier, a film, a food product, a pharmaceutical composition, a cosmetic product, a paper or board product, a coating, a hygiene/absorbent product, an emulsion/dispersing agent, a drilling mud, a composite material, in water purification, in a filter, in a solar cell, in a battery, in an electronic circuit (which may be flexible, printed or coated), or to enhance the reactivity of cellulose in the manufacture of regenerated cellulose or cellulose derivatives.
The object of the present invention is thus to provide a process for purifying, such as salt/ion depletion and/or free sugar depletion, preferably by using the dewatering, a slurry comprising cellulose, such as microfibrillated cellulose, in an improved way.
Another object of the present invention is to provide dewatered cellulose, such as microfibrillated cellulose with improved properties.
These object, as well as other objects and advantages, is achieved by the process according to the first aspect which also is reflected in claim 1 . It has been shown that the use of an electric field will strongly improve purifying such as salt/ion depletion and/or free sugar (carbohydrate) depletion, preferably by using dewatering, of a slurry comprising cellulose, such as microfibrillated cellulose.
The purifying, such as salt/ion depletion and/or free sugar depletion, may preferably be done using dewatering by using electro-osmosis (or capillary electrophoresis). This dewatering may also additionally also involve stimulation of other external sources such as mechanical or optical or magnetic field. One example is an ultrasound treatment. The purifying, may also be followed by any one or a combination thereof of the below methods to further dry the material:
1) Drying methods by evaporation
2) Freeze drying because of increased solids
3) Adding de-hornification additives can also be used in drying of dewatered material
4) dewatered material may also partially be dried further to obtain material which behaves like solid particles and thus more easily used in commercial applications while still easily mixed and dispersed to other components (individual fibers are essentially maintained) or easily used as such.
It is preferred that an electric field with a voltage of 10-100 V is used. Increasing the voltage typically increases the water extraction rate. The optimal value is when the current intensity of the generated electric field and the voltage gradient are at maximum allowable levels.
Pressure and/or heat may also be applied to the slurry in order to further improve the purifying, such as salt/ion depletion and/or free sugar depletion, of the slurry, preferably when using dewatering. The pressure may be applied after the electric field has been applied and the dewatering of the slurry has been started. This is due to that it may be preferred to increase the dry content of the slurry before pressure is applied. Another possibility is to have weak dewatering in E-field simultaneously as mechanical pressure is applied. However, it depends of course on the dry content of the slurry being treated.
The pressure applied is preferably a mechanical pressure, such as compression by the use of for example a roll nip or felts.
The dry content of the slurry comprising cellulose, such as microfibrillated cellulose, before purifying, such as salt/ion depletion and/or free sugar depletion, preferably by using dewatering is preferably about 1-10% by weight. After the treatment according to the process it is preferred that the dry content of the purified, such as salt/ion depleted and/or free sugar depleted, preferably by using dewatering, slurry comprising cellulose, such as microfibrillated cellulose, is about 5-50% by weight.
The temperature of the slurry during purifying, preferably involving dewatering, is preferably above 30° C. and preferably below 100° C.
The slurry may also comprise nanoparticles (such as absorbents), salt and/or surfactants which are stimulated by the electric field and improves the liquid flow. In this way the purifying, salt/ion depletion and/or free sugar depletion, preferably involving dewatering, of the slurry is increased. Further, aromas may be depleted.
The present invention also relates to cellulose, such as microfibrillated cellulose, being purified, such as salt/ion depleted and/or free sugar depleted, preferably by using dewatering according to the process described above. It has been shown that by purifying, such as salt/ion depletion and/or free sugar depletion, preferably by using dewatering, a slurry comprising cellulose, such as microfibrillated cellulose by the aid of an electric field no or very limited hornification of the microfibrillated cellulosic fibers will occur.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a process for purifying, such as salt/ion depletion and/or free sugar depletion, preferably by using dewatering a slurry comprising cellulose, such as microfibrillated cellulose. Due to the characteristics of microfibrillated cellulose fibers, e.g. its size, size distribution and fiber bonds, it is normally very difficult to purify, such as salt/ion deplete and/or free sugar deplete, a slurry comprising microfibrillated cellulose by using dewatering.
It is intended throughout the present description that the expression “cellulose” embraces any type of cellulose, such as cellulose fibres (cellulose material). The cellulose may also be a microfibrillated cellulose (MFC). The cellulose may be bleached or unbleached. The cellulose may also be crystalline cellulose, MCC (microcrystallinic cellulose; has high purity need due to its potential use in pharmaceutical compositions or other medical uses), BNC, NCC (nanocrystallinic cellulose; may be used in electrical applications and has magnetical properties), CNC, CMC (carboxymethylated cellulose) or synthetic polymer fibers and fibers made from dissolving pulp. The cellulose may be present in the form of a pulp, which may be chemical pulp, mechanical pulp, thermomechanical pulp or chemi(thermo)mechanical pulp (CMP or CTMP). Said chemical pulp is preferably a sulphite pulp or a kraft pulp.
The pulp may consist of pulp from hardwood, softwood or both types. The pulp may e.g. contain a mixture of pine and spruce or a mixture of birch and spruce. The chemical pulps that may be used in the present invention include all types of chemical wood-based pulps, such as bleached, half-bleached and unbleached sulphite, kraft and soda pulps, and mixtures of these. The pulp may be of dissolved type. The pulp may also comprise textile fibers. The pulp may also come from agriculture (e.g. potato, bamboo or carrot).
It is intended throughout the present description that the expression “free sugar” embraces not only sugars in monomeric forms but also smaller polymers. It embraces also free carbohydrates.
It has been shown that by subjecting a slurry comprising cellulose, such as microfibrillated cellulose fibers to an electric field the purification such as salt/ion depletion and/or free sugar depletion, preferably by using dewatering can strongly be improved. One theory of why it works so well, is that the electric field induces the liquids of the slurry to flow and thus pulls the water molecules away from the microfibrillated cellulose fibers instead of pushing the microfibrillated fibers as a mechanical treatment will do. Pulling the water molecules will make it possible to also remove water molecules being absorbed by the microfibrillated fibers in a very efficient way. It is thus very easy to purify the cellulose fibers of the slurry.
It has been shown that by purifying, such as salt/ion depletion and/or free sugar depletion, preferably by using dewatering, a slurry comprising cellulose, such as microfibrillated cellulose, by subjecting the slurry to an electric field, no substantial hornification of the microfibrillated fibers will occur. It is thus possible for the microfibrillated cellulose obtained according to the process of the first aspect to swell when the microfibrillated cellulose is in contact with water again. This is of great importance when the microfibrillated cellulose for example is used as a strength additive, a thickener or as a viscosity modifier. Furthermore, the bonding ability of the dewatered microfibrillated cellulose is also very good, i.e. no substantial decrease in bonding ability is seen.
When it comes to salt/ion depletion this effect may be due to the fact that the voltage gradient induces a migration of the different ions with the filtrate. This leads to a decrease in the specific conductivity of the product and a decrease in the conductivity of the sample.
Preferred embodiments of the first aspect of the invention are apparent from the dependent claims and the subject matter thereof is further set out below.
The dewatering is preferably done by the use of electro-osmosis. Electro-osmotic flow is often abbreviated EOF which is synonymous with electro-osmosis or electro-endosmosis. FFF is also one further electro-osmosis process. Electro-osmosis is the motion of liquid, such as water, induced by an applied potential or electric field across a porous material, capillary tube, membrane, microchannel, or any other fluid conduit. The voltage generated by the electric field is preferably between 10-100 V.
The liquid containing ion/salt and or free sugars of the slurry are separated from the cellulose, such as microfibrillated cellulose, by removing the liquid. It can preferably be done by different filtering techniques.
The slurry comprises cellulose, such as microfibrillated cellulose, and a liquid. The liquid may be water, a solvent and mixtures of different solvents and/or liquids. The solvent may be an alcohol, such as isopropanol, polyethylene glycol, glycol or ethanol. It can also be an acid or base. Solvents, such as isopropanol, can change the surface tension of the slurry and this will promote dewatering. The solvent may also be a solvent having at least one ketone group, and this may preferably be acetone. It is also possible that the liquid is an ionic liquid. The slurry may also comprise nanoparticles, polymers, pigments, salts and/or surfactants which are stimulated by the electric field and will improve the liquid migration and movement, i.e. the flow, in the electric field and thus also the dewatering.
According to a further preferred embodiment of the present invention the washing liquid is water and/or an organic solvent. The organic solvent is preferably acetone. In case drying is desirable as a follow-up of the process according to the first aspect as set out earlier, water (most preferred distilled water) is preferred as washing liquid in case of the cellulose being MFC, NCC, NFC or other cellulose derivative in a more efficient way (solvents should there be avoided) to avoid hornification.
The slurry may also as set out above comprise fibers of regular length. It is also possible that the slurry comprises fillers, such as nanoclays, polymeric based absorbents, PCC, kaolin or calcium carbonate. The amounts of microfibrillated cellulose in the slurry may be between 20-90% by weight, the amount of regular sized fibers such as kraft, hardwood and/or softwood fibers may be 10-80% by weight. If larger amounts of fillers and longer fibers are present in the slurry it is possible to achieve a slurry with very high dry content by using the dewatering process according to the invention. A dry content of up to 90% by weight is possible to achieve since the present of long fibers and/or fillers will make it easier to dewater the slurry.
It is however, preferred to use a slurry comprising high amounts of microfibrillated cellulose. A slurry comprising microfibrillated cellulose in an amount of 80-100% by weight, or 80-90% by weight, is often preferred. In many cases it is preferred that the slurry comprises 100% of microfibrillated cellulose, i.e. no fibers of longer size is present. The amount of microfibrillated cellulose depends on the end use of the microfibrillated cellulose.
It may also be advantageous to subject the slurry to increased pressure in combination with the electric field. It has been shown that the combination of electric field and pressure will strongly improve the purification, preferably by using dewatering, of a slurry comprising cellulose, such as microfibrillated cellulose. It is preferred to apply the pressure after the dewatering with the electric field has started, i.e. when the solid content of the slurry has increased, preferably to about 4% by weight. If the solid content of the slurry is too low when the pressure is applied, the microfibrillated cellulose is pressed through the openings of the dewatering device together with the water and no purification (such as salt/ion depletion and/or free sugar depletion) of the microfibrillated cellulose will occur. When the solid content of the slurry is increased, the viscosity is also increased and it is possible to apply pressure to the slurry and be able to increase the dewatering of the slurry.
The pressure is preferably a mechanical pressure being applied in any possible way. It possible to use, for example a roll nip, belt or felts for applying the mechanical pressure to the slurry during dewatering. It is also possible to combine the treatment with the electric field with other kind of treatments in order to increase the dewatering. Examples of other treatments besides increasing the pressure are acoustic and vacuum based systems.
The dry content of the slurry comprising cellulose, such as microfibrillated cellulose, before purifying, such as salt/ion depletion and/or free sugar depletion, preferably by using dewatering, is about 1-50% by weight. It may also have about 1-30% by weight or about 1-10% by weight.
After the treatment according to the process of the first aspect it is preferred that the dry content of the dewatered slurry comprising cellulose, such as microfibrillated cellulose, is about 5-50% by weight, more preferably above 20% by weight. It is thus possible to receive a slurry comprising microfibrillated cellulose with very high dry content in a very energy efficient way. Even though the dry content is increased the properties of the microfibrillated cellulose after dilution of water is maintained, e.g. the water swelling properties and strength.
The temperature of the slurry may be below 30° C. before dewatering and increased during the dewatering process but kept at a temperature below 100° C. However, lower temperatures, for example room temperatures are also possible. The temperature should preferably be kept below boiling point. Increased temperature may improve the dewatering. This is due to that that the viscosity of water is decreased.
The present invention also relates to cellulose, such as microfibrillated cellulose, being purified according to the process of the first aspect above. It has been shown that by purifying, such as salt/ion deplete and/or free sugar deplete, preferably by using dewatering, a slurry comprising cellulose, such as microfibrillated cellulose, by the aid of an electric field, no or very limited hornification of the microfibrillated cellulosic fibers will occur. It is thus possible to produce a microfibrillated cellulose with improved properties in a fast and very energy efficient way compared to the use of for example drying techniques.
A microfibrillated cellulose fiber is normally very thin (˜20 nm) and the length is often between 100 nm to 10 μm. However, the microfibrils may also be longer, for example between 10-200 μm, but lengths even 2000 μm can be found due to wide length distribution. Fibers that has been fibrillated and which have microfibrils on the surface and microfibrils that are separated and located in a water phase of a slurry are included in the definition MFC. Furthermore, whiskers are also included in the definition MFC.
The microfibrillated cellulose is typically made from wood cellulose fibers, it is possible to use both hardwood and softwood fibers. It can also be made from microbial sources, agricultural fibers, such as wheat straw pulp or other non-wood fiber sources. It can also be produced by bacteria or made from CMC.
Using this electric field set out in the first aspect of the invention, in addition also reduces the number of bacteria as their cell walls will blow up. The process of the first aspect, as it removes ions, also removes ions and water also from microbes. This means that this ion removal and water removal will kill/antimicrobial effect.
According to a further preferred embodiment of the present invention the process according to the first aspect of the invention may be followed by one or more modification steps, such as a counter-ion change as set out below.
According to a further preferred embodiment of the present invention the cellulose according to the second and the third aspect may further be processed by using ion exchange e.g. as disclosed in WO2009126106 which discloses a method for modifying cellulose fibers. It would be possible to change cellulose to different counter-ion forms to get e.g. CMC adsorbed/absorbed into fibres. Thus it would e.g. be possible to have a sodium counter ion modification to enhance MFC production. It would also be possible to e.g. go from Ca-form to Na-form and vice versa.
According to a further preferred embodiment of the present invention counter-ion change, which preferably follows after the process steps of the first aspect, may be performed through a process comprising the following steps:
1) washing ions away from the pulp with electro osmosis (until the filtrate conductivity is low enough)—optionally followed by addition of liquid, preferably distilled water, 2) washing the “clean” pulp with a sodium carbonate such as NaHCO3 and a basic agent, such as NaOH (to increase the pH to about 9)—preferably this may be done by adding NaHCO3 and NaOH into the washing liquid of the electro-osmosis apparatus 3) washing the pulp with distilled water in the electro-osmosis apparatus to remove excess Na-ions.
Changing of the counter-ions as set out above could be desirable in several applications;
to make pulp more homogenous for chemical reactions, for enabling different chemical reactions, for improved reactivity of the pulp, for improved drying or for improved re-dispergativity of the one's dried pulp.
In barrier applications, which may be multi-layered, as set out in the fourth aspect of the present invention the use of the cellulose according to the second and third aspect may be especially desirable in packaging of electronic equipment, or when making solar cells or batteries from cellulose, due to purity.
The purified cellulose according to the second and third aspect can be present as low metal pulps. As such they may be useful for low conductivity paper (due to di-electrical properties), enzyme treatments of pulps or as pulp for chemical modifications.
The purified cellulose according to the second and third aspect in the form of microfibrillated cellulose may be especially useful in the following applications/uses:
barriers due to improved film forming properties washing powders due to improved Ca 2+ removal (absorbs/adsorps) or in other similar applications where hard water is a problem cleaning drinking water as it is possible to achieve improved heavy metal removal from drinking waters (this is still a large problem in some areas of word) by oxidation and different additives one can improve metal absorption properties metal absorbents which are biodegradable
Preferred features of each aspect of the invention are as for each of the other aspects mutatis mutandis. The prior art documents mentioned herein are incorporated to the fullest extent permitted by law. The invention is further described in the following examples, together with the appended figures, the only purpose of which is to illustrate the invention and are in no way intended to limit the scope of the invention in any way.
FIGURES
FIG. 1 discloses the dewatering setup scheme (left) and cathode plate with holes.
FIG. 2 discloses dependencies of current and mass of collected water on time at constant applied voltage 20 V.
FIG. 3 discloses dewatering of low conductivity MFC.
FIG. 4 discloses time dependencies of the water mass collected during dewatering of low conductivity MFC at different voltages are presented.
EXAMPLES
1. Experimental Set-Up
For investigation of MFC dispersion dewatering an experimental setup was assembled, scheme of which is on FIG. 1 . It consists of a plastic pipe with internal diameter 46 mm, fitted into a stainless steel funnel. At the lower end of the pipe there is a plate with holes, also made of stainless steel, which serves as the lower electrode, usually cathode. A paper filter is placed on the plate, the MFC dispersion is loaded onto the filter. On top or the MFC column there is one more paper filter, after this the upper electrode (anode) is placed.
The best results were achieved with platinum electrode—no process changes due to the electrode corrosion or contamination were observed.
The setup of FIG. 1 constituted a cell with MFC investigated; DC voltage was applied into it from the current source. The water, emerging from the funnel was assembled into beaker, which was situated on top of a balance; the mass of the water extracted from MFC was registered during experiments. The experiments usually were carried out in two modes: with a voltage U constant or with current i constant.
Dependencies of current and mass of collected water on time at constant applied voltage 20 V is disclosed in FIG. 2 . An increase of pressure causes an increase both of current and increment of collected water.
Surprisingly it was thus found that electro-osmosis dewatering may be used if;
in the beginning (more or less) only electro-osmosis is used due to dewatering the viscosity will increase enough—that mechanical pressure may be applied (as reflected in FIG. 2 )
FIG. 3 discloses dewatering of low conductivity MFC.
FIG. 4 discloses time dependencies of the water mass collected during dewatering of low conductivity MFC at different voltages are presented. The voltage increase causes an increase of dewatering speed (initial slope) and process saturation value.
Example 2
Reference MFC (initial MFC)—dry content (IR) 1.7%
Salt/Metal contents based on dry matter;
Al 9.5 mg/g
Fe 16 mg/g
Ca 1200 mg/kg
Cu 5.5 mg/kg
K 310 mg/kg
Mg 210 mg/kg
Mn 1.1 mg/kg
Na 1400 mg/kg
Ni 1.6 mg/kg
Pb 1.1 mg/kg
Si 76 mg/kg
Zn 5.9 mg/kg
Dewatering Procedure 1—Only Removing Water;
A paper filter was places on cathode then MFC and then a second paper filter. After this the anode was laid on the top of this. The pressure (of weight of anode) was 750 kPa. After short time (2 min) an additional weight was added (pressure to 2400 Pa). The voltage during dewatering was 100V and time 640 s.
Procedure was repeated 3 times and pressure was increased (last time 4.6*10^5 Pa).
Dewatered MFC (electro-osmosis MFC)—results are given below:
Salt/Metal contents based on dry matter 30.5%
Al 8.5 mg/kg
Fe 11 mg/kg
Ca 30 mg/kg
Cu 0.69 mg/kg
K 85 mg/kg
Mg 5.7 mg/kg
Mn 0.24 mg/kg
Na 12 mg/kg
Ni 0.68 mg/kg
Pb <0.4 mg/kg
Si 13 mg/kg
Zn 1.5 mg/kg
Example 3
Reference MFC (initial MFC)—dry content (IR) 1.7%
Salt/Metal contents based on dry matter;
Al 9.5 mg/g
Fe 16 mg/g
Ca 1200 mg/kg
Cu 5.5 mg/kg
K 310 mg/kg
Mg 210 mg/kg
Mn 1.1 mg/kg
Na 1400 mg/kg
Ni 1.6 mg/kg
Pb 1.1 mg/kg
Si 76 mg/kg
Zn 5.9 mg/kg
Dewatering Procedure 2—Removing Water and Washing with Acetone
MFC was dewatered 5 min (as in procedure 1 above i.e. Example 2). After this the current was switched off and acetone was added (about the same amount as water was removed in previous step). After this dewatering was started and continued about 10 min.
Dewatered MFC (electro-osmosis MFC with acetone)—results given below:
Salt/Metal contents based on dry matter 23.5%
Al 4.6 mg/kg
Fe 10 mg/kg
Ca 10 mg/kg
Cu 0.68 mg/kg
K 40 mg/kg
Mg 7.1 mg/kg
Mn 0.13 mg/kg
Na 14 mg/kg
Ni 0.50 mg/kg
Pb <0.4 mg/kg
Si 13 mg/kg
Zn 1.5 mg/kg
Example 4
Temperature Test
Using the same set up as out above, temperature tests were performed.
Temperature 90-95° C.—dewatering in 60 s=about 16 g water
Temperature 21° C.—dewatering in 60 s=about 13.5 g water
Accordingly it was beneficial to use higher temperature to improve dewatering. Thus the energy needed for dewatering is much lower at elevated temperatures.
Example 5
A further trial was done where even more ions (especially Ca 2+ ions) were removed.
In the start the total amount was 20 g of wet MFC.
1) about 11 g of water was removed with electro-osmosis
a. metal content of the water
i. Ca 14 mg/l ii. K 2.7 mg/l iii. Na 26 mg/l iv. Si 1.3 mg/1
2) about 10 g of distilled water was added
3) about 10 g of water was removed
a. metal content of the water
i. Ca 8 mg/l ii. K 0.56 mg/l iii. Na 0.78 mg/l iv. Si 0.22 mg/1
4) about 10 g of distilled water was added
5) about 9 g of water was removed
a. metal content of the water
i. Ca 7.4 mg/l ii. K 0.56 mg/l iii. Na 0 mg/l (below detection limit) iv. Si 0.076 mg/l
6) distilled water (as reference)
a. metal content of the water
i. Ca 0.079 mg/l ii. K 0 (below detection limit) iii. Na 0 (below detection limit) iv. Si 0 (below detection limit)
In view of the above detailed description of the present invention, other modifications and variations will become apparent to those skilled in the art. However, it should be apparent that such other modifications and variations may be effected without departing from the spirit and scope of the invention.
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The present invention relates to a process for purifying a slurry comprising cellulose, such as microfibrillated cellulose, wherein the process comprises the following steps: —providing a slurry comprising cellulose and liquid, —subjecting the slurry to an electric field inducing the liquid of the slurry to flow, —separating the liquid from the cellulose thus obtaining a liquid depleted slurry, —adding a washing liquid, such as an organic solvent, to the liquid depleted slurry—subjecting the liquid depleted slurry to an electric field inducing the washing liquid of the slurry to flow and—separating the washing liquid from the cellulose, thus obtaining a purified cellulose. The invention also relates to cellulose such as microfibrillated cellulose obtainable from said process.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to a method for supporting and hydrodynamically centering a rotating workpiece during machining on a workpiece machine/grinding machine, and relates to a steady for performing said method.
[0002] Usually centering steadies are used for supporting rotating workpieces during grinding. This support is necessary in order to prevent the workpiece from sagging from the effect of the forces of the grinding wheel that are acting in the transverse direction. For this, support bodies are used that contact the workpiece at a plurality of locations and center it with respect to the axis of rotation. The support is generally provided in a self-centering manner by means of three support elements arranged on the circumference of the bearing to be supported. Such steadies are known, for example, from DE-OS 1 577 369.
[0003] The support elements for such steadies are normally coated with CBN (cubic centered boron nitride) or PCD (polycrystalline diamond) at the contact points, to reduce wear and visible running tracks. Since the steadies contact the workpiece at the support elements, a so-called running track necessarily occurs at the support point. The running track is based on a smoothing of the surface roughness at points of contact and is optically visible. This change in the surface quality can potentially have an unfavorable influence on the lubricating film in the bearing. In addition, the supporting portion changes in this area of the bearing. Although any change in the dimensions of the bearing point in the area of the running track is frequently only minor, such a change is frequently no longer acceptable given constantly increasing technical demands on the bearing points. The finish grinding of the bearing point that is therefore necessary after using the steady leads to an undesired increase in grinding time and thus in unit costs.
[0004] Moreover, a steady that supports the bearing at three locations suffers from the disadvantage that a short-wave non-circularity that has occurred on the bearing point during machining is also formed on the bearing point and in at least some cases cannot be compensated. These two effects cannot be entirely prevented with the known steadies.
[0005] Another variant of steadies are so-called hydrostatic steadies, such as are described in DE-OS 1 627 998 and EP 1 298 335 B1 (German translation: DE 602 10 187 T2). With these steadies, the bearing point is supported by a hydrostatic bearing in which a plurality of hydrostatic pockets distributed around the interior circumference of the bearing are actuated using a fluid that is under pressure. This produces a hydrostatic pressure on the bearing point of the shaft, and this pressure supports and centers the shaft. The fluid pressure is adjusted using a regulating device. A particular disadvantage of this type of steady is that the bearing point cannot be machined while being supported because it is entirely surrounded by the steady. This variant also requires a special design for the support shell, with support pockets and relief grooves, which leads to complex and expensive production.
[0006] According to DE 102 32 394 B4 from Erwin Junker Maschinenfabrik GmbH (Applicant), for supporting a rotating workpiece, at least one cushioned body that can be actuated using a pressure fluid is positioned against the workpiece from the side disposed opposite the grinding wheel.
[0007] The positioning force can be influenced pneumatically or hydraulically. In certain embodiments a fluid can be added between the cushioned body and the workpiece as a pressure means and lubricant. One disadvantage of this type of support is the single-sided support of the workpiece and the complex design.
[0008] The underlying object of the invention is to provide a method for supporting a rotating workpiece during machining, which method avoids the disadvantages of the prior art, and to propose a cost-effective steady that is suitable for performing the method.
SUMMARY OF THE INVENTION
[0009] This object is attained using a method having the features cited in claim 1 and using a steady in accordance with either of claim 10 or 11 . Additional embodiments of the method are provided in claims 2 through 9 and additional embodiments of the steady are provided in claims 12 through 16 .
[0010] In accordance with an embodiment of a method according to the invention, the axial region of the workpiece that is to be supported is subjected to pressure that acts radially, that is, on the longitudinal axis of the workpiece and thus on the axis of rotation, and the magnitude of which is controlled between a minimum value and a maximum value as a function of the current rotational speed. Specifically this means that the bearing point of the rotating workpiece, for example, a gear shaft, crankshaft, or camshaft, the bearing point being used for providing for support by means of a steady, is actuated in the steady with a contact pressure that can be controlled. The fluid that is used for producing the contact pressure can be, for instance, the cooling oil or lubrication oil used for grinding. This fluid is preferably supplied to the annular gap via a transverse bore (i.e., a bore that is laterally offset with respect to the axis of the steady), the aperture of which opens into the annular gap between steady and bearing point, and forms a hydrodynamic bearing there. This bearing, which is under pressure at the machining rotational speed, supports the workpiece on all sides in the region of the steady. This prevents direct contact between the steady and the surface of the bearing so that no running track can occur. In addition, it has also surprisingly been demonstrated that pressure-dependent, dynamic centering of the workpiece occurs in the region of the bearing point.
[0011] When the method is performed, the pressure of the fluid that is supplied to the annular gap via the opening in the transverse bore is controlled between a minimum value, when the workpiece is started up, and a maximum value. In accordance with the invention, the maximum value occurs when the machining rotational speed is attained, and is essentially maintained at this level during machining It is within the framework of the invention that when the workpiece is ground at a variable machining rotational speed, the fluid pressure follows the current machining rotational speed. However, it is also possible to keep the pressure constant in this case. What is crucial is that the corresponding pressure range covered is essentially higher than the fluid pressure when start-up begins.
[0012] The minimum value of the pressure results from the requirement for a closed lubricating film in the annular gap between the steady and the bearing point of the workpiece. This means that the minimum value should be greater than 0. However, a value of zero should also be included as the minimum value for the pressure. What is crucial during operation is that the fluid pressure builds up quickly at start-up. This lubricating film must be ensured as soon as possible upon the workpiece starting up from being at rest, because otherwise undesired direct contact occurs between the metal parts. However, the pressure must not be too high at the beginning, because this would act on the bearing point in a non-symmetrical manner, which would also lead to contact between the aforesaid parts. In addition, fluid pressure that is too high on the bearing point inhibits the start-up of the workpiece because it acts like a brake since the workpiece at the affected bearing point can then have contact with the bearing shell in the bearing shell at the side of the bearing shell opposite the supply bore.
[0013] During this start-up process in which the shaft attains an increasing rotational speed, the fluid pressure is increased according to the current rotational speed. In the framework of the invention, this can occur continuously or at appropriately selected stages. According to one aspect of the invention, the increase in pressure is controlled linearly as the rotational speed of the driven workpiece increases. In one modification, a non-linear, progressive increase in the fluid pressure with the speed may also be advantageous. This is implemented, for instance, in a manner such that at the beginning of the start-up process there is a relatively slow increase in the fluid pressure, while at a higher rotational speed, i.e., near machining rotational speed, there is a relatively sharp increase in the fluid pressure. Controlling the fluid pressure in this manner permits especially rapid start-up, at the beginning of accelation of the workpiece, while the high pressure that is required for dynamically centering the workpiece during machining is essentially not brought entirely to bear until near the end of the start-up. In certain cases it can be useful to let the increase in pressure occur especially rapidly at first, for instance, when an especially rapid and reliable use of the dynamic bearing of the workpiece is desired due to the material properties of the workpiece.
[0014] The maximum value of the fluid pressure can be determined using tests. Inter alia, this maximum value is a function of the rotational speed of the workpiece during machining and of the fluid used for producing pressure. Tests have demonstrated that an increase in the fluid pressure in the annular gap leads to a pressure-dependent improvement in the centering of the workpiece with respect to its axis of rotation. Concentricities in the range of a few μm can be attained at pressures for instance in a range between 5 and 150 bar. The concentricity increases at a given rotational speed as pressure increases. In the framework of the invention, “maximum value” shall be construed to be the maximum pressure that is required for each machining status, at which pressure the grinding work for the workpiece then occurs at the machining rotational speed.
[0015] Using the inventive procedure results in the advantages that the rotational speed of the shaft to be ground ramps up rapidly and smoothly from idle to machining rotational speed, and that during grinding there is very precise centering and support for the shaft at the bearing point. These advantages do not exist for the prior art cited in the foregoing, because the prior art is merely concerned with the behavior of the steadies at machining rotational speed and do not consider the start-up process. In addition, the effect of the very precise centering of the shaft that is rotating at high rotational speed using an optimum, high fluid pressure at the bearing point is not mentioned. However, high fluid pressure, per se, would lead to problems during start-up. Only the invention has realized that, for optimum machining of shafts with a short machining time, it is advantageous to control the fluid pressure in the steady as a function of the current rotational speed of the workpiece.
[0016] A control device that responds to the current rotational speed of the workpiece and controls or regulates the fluid pressure accordingly is provided to control the fluid pressure in accordance with the invention. It makes practical sense to use a CNC control for the grinding machine for this purpose, since this CNC is already present. The control acts on valves that make it possible to adjust the fluid pressure in the annular gap, for example, by changing the flow. It is possible to adjust the pressure by regulating the flow amount with nothing further required, because fluid is always exiting via the annular gap, which is open laterally.
[0017] In the design of the invention, the control includes at least one sensor that detects the current fluid pressure and compares it to a pre-specified, rotational speed-dependent value. For this purpose, the control device preferably has an electronic computer that is programmed appropriately and that has input devices, processors, memory, and other necessary devices.
[0018] The fluid pressure is preferably controlled such that it also follows a variation in the rotational speed of the workpiece that is due to the machining of the workpiece during individual or a plurality of rotations. Thus, the term “maximum value of the fluid pressure” should not be considered as an absolutely sharply defined value Rather, it can have a certain bandwidth that is however slight relative to the highest value. What is crucial is that the fluid pressure during machining is significantly higher than when the workpiece starts up and that it is maintained in the high pressure range during machining.
[0019] A further embodiment of the invention relates to a structural form of steady that differs from the steady in accordance with another described embodiment herein, and that is similar to that in DE 102 32 394 B4 from Applicant. The steady according to the embodiment of the invention has at least one bearing region that can be pressed against the workpiece and that can be actuated with a fluid pressure. The steady according to the embodiment also has means for supplying a fluid that is acting as a lubricant between the workpiece and the bearing region. In this case, “bearing region” means a part of a steady that surrounds the workpiece to be supported only in a limited segment of its circumference. Such steadies can have one or a plurality of bearing regions. In accordance with DE 102 32 394 B4, the bearing regions are embodied as cushioned bodies, made of an elastic solid material or an elastic outer skin filled with an elastic pressure medium, that are preferably placed against the roller to be ground in the circumferential region opposite the grinding wheel. With this structural form of the inventive steady, both the contact pressure of the bearing region and the fluid pressure of the fluid that is used as a lubricant and cooling means, essentially independent of the contact pressure in the bearing region, are pre-specified. In accordance with the invention, the fluid pressure is controlled as a function of the rotational speed, as has already been described with respect to steadies in accordance with the other embodiment of the invention. The fluid pressure when the workpiece starts up from idle is initially low and increases as the rotational speed increases until it reaches its maximum value at machining rotational speed. The minimum value of the fluid pressure must not be lower than the contact pressure in the bearing region, however, because otherwise there would be no lubrication. The contact pressure in the bearing region per se remains essentially constant, and can be pre-specified by the control, for example, via pneumatic or hydraulic means.
[0020] In accordance with yet another embodiment, the at least one bearing region is provided with a supply line, the workpiece-side opening of which permits fluid to enter between the bearing region and the workpiece. If a plurality of bearing regions are provided, in accordance with a further embodiment, they should preferably be arranged concentric with the workpiece to be supported and coaxial with its axis of rotation.
[0021] The method in accordance with the invention, and the associated steadies, are employed for machining shaft-like parts. Workpieces can be, for example, gear shafts, camshafts, or crankshafts. The embodiments illustrated in the following can be used for supporting all possible shafts. The details are determined by the technical aspects of and grinding technology for each specific case.
[0022] The steadies according to the invention can also be used in a grinding machine, the grinding station of which is improved with regard to loading and unloading the workpieces. This structural variant is equipped with a rotary indexing table that carries two support apparatuses. The support apparatuses alternate traveling into the machining position. Thus, the next workpiece can be ready for the next clamping in a matter of seconds, and there is no need to wait additional workpiece exchange time. The workpiece is loaded and unloaded on the side of the rotary indexing table that faces away from the grinding wheel while the other workpiece is being machined.
[0023] For finish-machined bearing points for shaft parts, camshafts, crankshafts, etc., divided bearing blocks can be used for steadies. With such bearing blocks, it is possible to receive the shaft parts in exactly the same manner when grinding the contours, cams, connecting rod bearings, etc. Moreover, no visible running tracks remain on the shaft at the support point for the steady.
[0024] Using this approach, not only is it possible to precisely reproduce the recent employment conditions for the shaft-like workpieces, but the best dimensional, shape, and position tolerances are also attained during machining.
[0025] With respect to the different diameters of the bearing points to be supported, the bearing shells/bearing blocks must be adapted to the support diameter, this preferably occurs using suitable, workpiece-independent exchangeable parts when retrofitting the workpiece machine.
[0026] The methods for supporting and dynamically centering a rotating workpiece and the steady in accordance with the invention are described in the following using the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a schematic top view of a grinding machine in which the method for supporting the workpiece and the inventive steady according to the invention can be employed;
[0028] FIG. 2 is a simplified lateral section through a support apparatus having a divided steady with pivotable jaws for supporting shaft-like parts in accordance with the invention;
[0029] FIG. 3 is a simplified lateral section through a support apparatus having an integrated steady in accordance with the invention;
[0030] FIG. 4 is a simplified lateral section through a support apparatus having a steady embodied as a bearing block in accordance with the invention;
[0031] FIG. 5 is a schematic top view of a support apparatus having a plurality of support points in accordance with the invention for receiving a plurality of bearing points for a crankshaft; and
[0032] FIG. 6 is a schematic partial view of a divided steady in accordance with FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0033] FIG. 1 is a schematic top view of a grinding machine 1 in which the method according to the invention is used and the shaft-like workpiece 12 is received in the steady 10 for performing this method. The grinding machine 1 has a machine bed 2 on which a grinding station 3 is arranged. On the machine bed 2 , this grinding station 3 has a compound slide rest 6 that includes the two CNC-controlled traverse axes. The Z axis 21 runs parallel to the workpiece longitudinal axis 20 and the X axis 22 is oriented perpendicular to the Z axis 21 , and thus to the workpiece longitudinal axis 20 .
[0034] In accordance with FIG. 1 , a grinding headstock 13 with feed slides that can be moved, CNC controlled toward the X axis 22 , and that can be positioned toward the workpiece in the direction of the X axis 22 , is attached to the compound slide rest 6 . The grinding headstock 13 receives at least one grinding spindle 14 that, in its front area, receives at least one grinding wheel 15 . The grinding wheel 15 and the grinding spindle 14 have a common center axis that is oriented axis-parallel to the center axis of the workpiece 12 during non-circular grinding. Arranged on the machine bed 2 in the front region, is a grinding table 5 that receives the support apparatus 8 for the shaft (workpiece 12 ) to be processed and that has inventive steadies 10 embodied, for example, as bearing blocks 18 . The grinding table 5 also bears the workpiece headstock 7 with a chuck, the jaws of which are borne floating so that they are balanced perpendicular to the workpiece longitudinal axis 20 , and so that they drive the workpiece about the C axis 23 (axis of rotation) stiffly and with no clearance radially.
[0035] There is also a cover 17 for the guide tracks of the Z axis 21 of the grinding station 3 , and at least one dressing apparatus 16 for the grinding wheels 15 on the grinding table 5 . A housing that surrounds the grinding machine 1 and other assemblies that are necessary for operating the grinding machine 1 are also present and familiar to one skilled in the art. They are not depicted in FIG. 1 for the sake of better clarity.
[0036] FIG. 2 is a schematic partial cut-away depiction of an exemplary embodiment of an inventive steady 10 in a support apparatus 8 . The support apparatus 8 has a base body 9 on which the steady/steadies 10 are arranged and that can be securely mounted to the grinding table 5 by means of screws 38 and clamping claws 39 . The steady 10 is divided in two at the dividing point 25 , with two jaws 11 that are mounted on the base body 9 of the support apparatus 8 by means of associated pivot axes 33 . Reference number 11 ′ refers to the position of the jaws 11 when they are pivoted outward. For supporting shaft-like workpieces 12 , during grinding the jaws 11 are pivoted in about the pivot axis 33 , and this is preferably done by means of hydraulic drives (not shown here). The jaws 11 then completely surround the bearing point 42 to be supported of the workpiece 12 that can rotate about its longitudinal axis in the bore 30 formed by the two jaws 11 of the steady 10 .
[0037] One of the jaws 11 of the inventive steady 10 is provided with a transverse bore 34 that opens via the opening 35 into the central bore 30 of the steady 10 . The inventive pressure fluid can be conducted into the annular gap 62 formed between the workpiece 12 and the wall of the bore 30 through the opening 35 via additional bores 37 (not shown in FIG. 2 ) in the base body 9 and/or via other supply lines 36 (see FIG. 6 ). The dividing point 25 between the jaws 11 is machined with particular care and is constructed such that no gap through which the pressure fluid can enter or exit the dividing point 25 is formed when the jaws 11 are in the closed position. To this end, it is provided that at the dividing point 25 the two jaws 11 have planar, metal contact that, in conjunction with the contact pressure exerted on the jaws 11 by means of the preferably hydraulic adjusting forces, leads to the dividing point 25 being leak-proof.
[0038] The version described with reference to FIG. 2 is employed when, for instance, an assembled camshaft is produced, the bearing points 42 of which, after the cam is placed on the pipe, still have to be machined at the bearing points 42 . The divided embodiment of the steadies 10 or bearing blocks 18 is also necessary when machining cast camshafts, because in this case, the bearing blocks 11 cannot be placed for the assembly until after the bearing points 42 have been completely machined.
[0039] FIG. 3 depicts the clamping principle for the support apparatus 8 having another structure for the inventive steady 10 . In this case, the steady 10 , which is embodied as an undivided bearing block 18 , is received in the support apparatus 8 at the same level 19 as the assembly level for the later installation. The bearing block is embodied with lateral extensions or tabs 24 that, provided with appropriate bores, can also facilitate later assembly. The bearing block 18 is fixed on the base body 9 of the support apparatus 8 using two tension levers 32 that can be pivoted hydraulically about the pivot axes 33 . They are used at the location of the fastening screws that will be employed later when the workpiece 12 is installed in the interior of the motor. Provided on the base body 9 for precisely positioning the bearing blocks on the base body 9 of the support apparatus 8 are positioning means, in this case depicted as an example as a stop 31 . Naturally, other positioning means may be used as well, such as centering sleeves or pins. The bearing of the tension levers 32 and their hydraulic activation are depicted only in a simplified manner here. Thus reference number 32 ′ indicates the outwardly pivoted positions of the tension levers 32 . The support apparatus 8 is attached to the grinding table 5 via the base body 9 , for which purpose screws 38 and clamping claws 39 are provided.
[0040] As can be seen in FIG. 3 , the bearing block 11 has a bore 30 for receiving the corresponding bearing point 42 of the workpiece 12 to be ground. It also has a transverse bore 34 that is arranged off center with respect to the bore 30 , and the opening of which 35 opens into the bore 30 . This transverse bore 34 is aligned with an additional bore 37 in the base body 9 of the support apparatus 8 , which itself is connected to a supply line 36 . Thus, a lubricant can be conducted from the supply line 36 into the bore 31 via an opening 35 in the transverse bore 34 .
[0041] FIG. 4 depicts another undivided steady 10 in accordance with the invention that is embodied as a bearing block 18 like that in accordance with FIG. 3 . This bearing block 18 is mounted to the base body 9 of the support apparatus 8 by means of screws 26 . When being used, the bearing block 18 is pushed axially onto the supporting bearing point 42 or the bearing point 42 is inserted into the bore 30 of the bearing block 18 .
[0042] FIG. 5 is a schematic depiction of the entire length of crankshaft 40 with steadies 10 embodied as bearing blocks 18 , as support points in accordance with the invention. Since the crankshaft has five bearing points 42 , there are also five clamping points for the bearing blocks 18 across the length of the support apparatus 8 . Using these, the crankshaft 40 is supported for machining, for instance, for machining the connecting rod 43 , across its entire length at its bearing points 42 . The stiffness that is necessary for high precision grinding provides the support at the bearing points because the grinding forces are absorbed at the bearing points. Thus, during grinding all that is necessary is to floatingly clamp the end of the crankshaft 40 using the chuck for the workpiece headstock 7 , and its drive in the C axis 23 , which is CNC-controlled.
[0043] FIG. 6 depicts a divided steady 10 having two jaws 11 , as they have already been described using FIG. 2 , as a detail with segment 61 of the crankshaft 40 in the area of the bearing point 42 . The steady 10 is provided with the bore 30 for receiving the bearing point 42 . The diameter of the bore 30 is, for example, 25 mm and is finished with a diameter tolerance of approx. 15 μm. The transverse bore 34 opens into the bore 30 at the opening 35 . The transverse bore 34 supplies the lubricant when the inventive method is being performed. In this case, as well, care should be taken that the dividing point 25 between the two jaws 11 of the steady 10 is absolutely leak-proof with respect to the lubricant that enters and acts as the pressure fluid. Direct metal-to-metal contact by the two jaws 33 at the dividing point 25 has proved itself for this purpose, the corresponding contact surfaces having to be machined with adequate precision. High precision is naturally also required for producing the two half shells that are embodied in the jaws 11 , and that form the opening 30 for receiving the bearing point 42 of the workpiece 12 when the jaws 11 are inwardly pivoted, as depicted in FIG. 6 .
[0044] When performing the method according to the invention, during the grinding cycle, lubricant is supplied to the support point 42 through the opening 35 of the transverse bore of the bearing block 18 acting as support 10 . This lubricant enters into the annular gap 62 formed between the wall of the bore 30 and the bearing point 42 of the workpiece 12 and thus lubricates these components. Because it is under pressure, this lubricant escapes as lost oil through the annular gap 62 into the interior of the grinding machine 1 . Therefore the same lubricant that is used as a cooling lubricant when grinding, is used for lubricating the bearing point. However, this grinding oil is specially filtered so that no grinding residues travel into the bearing point 42 of the workpiece 12 .
[0045] The oil loss through the annular gap 62 also seals the bearing point 42 so that soiling particles do not penetrate into the bearing point 42 from outside. The bearing point 42 that is received in the bore 30 is approx. 40 to 60 μm smaller in diameter than the bore diameter. This results in a lubricant gap, corresponding to the annular gap 62 , approx. 20 to 30 m in thickness, in which a hydrodynamic bearing is embodied during operation. This hydrodynamic bearing requires a minimum rotational speed for the rotating shaft/bearing point 42 for building up the lubricating film and in accordance with the invention is well below the grinding rotational speed when grinding the cam shape or the connecting rod. This grinding speed is generally in the range of approx. 50 to 500 min −1 .
[0046] In order to obtain good results when grinding workpieces, such as, for example, gear shafts, crankshafts, and camshafts, the method in accordance with the invention is performed as follows: When the shaft to be ground is started up from idle, the pressure of the lubricating oil supplied via the opening 35 to the bearing point 42 is set lower, and then as the workpiece 12 speeds up to the target rotational speed for grinding, the pressure is increased continuously. The pressure of the lubricating oil is increased as a function of the current rotational speed of the workpiece 12 until the target rotational speed, and thus the target pressure for grinding, have been attained. Pressure is controlled via special valves that are actuated via the CNC control.
[0047] This manner of proceeding is based on the knowledge in accordance with the invention that the radial stiffness of the bearing point increases when the supply pressure of the lubricating oil is increased. When the lubrication pressure is adjusted optimally at the target rotational speed for grinding, it is possible to attain trueness of the run for the bearing point 42 of 1 to 2 μm. Surprisingly, experiments have demonstrated that the inventive method is especially suitable for grinding gear shafts, crankshafts, and camshafts when the pressure in the hydrodynamic lubricating point/bearing point 42 is adapted to the rotational speed for grinding the workpiece 12 . The optimum pressures are in the range of approx. 5 to 150 bar, depending on the rotational speed.
[0048] Excessive lubricating oil pressure and lubricating oil pressure that is too low do not provide satisfactory results. The lubricating film can tear when the lubricating oil pressure in the bearing point 42 is too low. When the lubricating oil pressure is set too high, the shaft is pressed against the side of the bore 30 that opposes the opening 35 . In both cases the bearing would be damaged and it would not be possible to attain satisfactory grinding results.
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In a method for the hydrodynamic support and centering of a rotating workpiece during grinding and a steady rest usable for this purpose the bearing to be supported is impinged upon by a contact pressure which changes in accordance with rotational speed from a minimum pressure when the shaft is started from a standstill, to a maximum value during the processing rotational speed. The steady rest has an opening of a transversebore in a central bore receiving a supply line by which a lubricant can be supplied as hydraulic fluid to the bearing. The method is particularly suitable for the processing of camshafts and crankshafts.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of PCT International Application No. PCT/KR2010/005759 filed Aug. 27, 2010, the contents of which are incorporated herein by reference in their entirety.
TECHNICAL FIELD
The following disclosure relates to a compound for promoting the secretion of human antimicrobial peptides, and more particularly, to a new compound for inducing direct or indirect expression of human β-defensin-2 and -3 and LL-37, which are human antimicrobial peptides, a method for preparing the same, and a composition comprising the same as an active ingredient.
BACKGROUND
Antimicrobial peptides are natural antimicrobial materials involved in innate immunity mechanisms in vivo, and low-molecular weight peptide materials that retain antimicrobial activities against various microorganisms including bacteria, fungi, and viruses and induce local biophylaxis and systemic immune response. The antimicrobial peptide generally has an amphipathic structure, and according to antimicrobial mechanism thereof, a cation part thereof binds to an anionic phospholipid included in a cell membrane of the microorganism to break the cell membrane of the microorganism.
Defensins are one of the antimicrobial peptides that have been most studied, and are largely classified into α-defensin and β-defensin depending on structural characteristics thereof. β-defensin is a peptide material that is expressed in mucous epithelium such as skin, lungs, organs, kidneys, reproductive organs, etc. Until now, 6 sorts of human β-defensins, human β-defensin-1 (hBD-1), human β-defensin-2 (hBD-2), human β-defensin-3 (hBD-3), human β-defensin-4 (hBD-4), human β-defensin-5 (hBD-5), and human β-defensin-6 (hBD-6) have been separated and identified. In particular, while hBD-1 is uniformly expressed in epidemic cells, hBD-2 is increasingly expressed at an infected region or a physically damaged region and has been known to play an important role in controlling a systemic immune response and an inflammatory response. In addition, it has been recently reported that hBD-3 is very highly expressed at skin lesion regions of psoriasis patients. In recent years, it has been recently known that β-defensins are involved in not only local phylaxis but also acquired immunity resulting from chemotactic migration of dendritic cells, T lymphocytes, monocytes, etc.
Cathelicidins have extensive antimicrobial activities and various immunomodulatory functions. LL-37, one of the human cathelicidin degradation products, has a α-helix structure, and has extensive antimicrobial activities and inflammation modulatory functions in vivo. In other words, LL-37 exhibits direct antimicrobial activities against bacteria, fungi, viruses, etc., and chemotaxis for neutrophil, mononuclear cells, and T cells, and induces proliferation of endotheliocyte. In particular, LL-37 existing in the skin does prompt defense at the time of penetration of foreign antigens, and thus has antigen inhibitory functions (Braff M H, Bardan A, Nizet V, et al. Cutaneous defense mechanisms by antimicrobial peptides. J Invest Dermatol (2005) 125, 9).
When physical damage or infection occurs in the skin, defensin and LL-37, which are antimicrobial peptides, are secreted to induce antimicrobial activity and a systemic immune response, and particularly induce differentiation and proliferation of epidermal keratinocytes, to thereby be involved in wound healing (Niyonsaba F, Ushio H, Nakano N, et al. Antimicrobial peptides human β-defensins promote epidermal keratinocyte migration, proliferation and production of proinflammatory cytokines and chemokines. J Invest Dermatol (2007) 127, 594). Also, study results have been recently reported that expression of β-defensin-2, LL-37, etc., which are antimicrobial peptides, decreased in the skin of patients with atopic dermatitis, which is a cause of high sensitivity to staphylococcus (Ong P Y, et al. Endogenous Antimicrobial Peptides and Skin Infections in Atopic Dermatitis. The England Journal of Medicine (2002) 347, 1151-1160).
Therefore, the antimicrobial peptides play important roles in primary defense and treatment against foreign sources of infection. In particular, the antimicrobial peptides is expression-induced in the skin, thereby primarily inhibiting infection of the skin and blocking penetration of foreign sources of infection by promoting the recovery of the damaged region, and thus, play important roles in protection of skin and maintenance of skin health.
The related art reported materials promoting the secretion of antimicrobial peptides in vivo. Korean Patent Laid-Open Publication No. 10-2006-0076775 discloses that various organic acids promote β-defensin secretion and International Patent Laid-Open Publication No. WO 0168085 discloses that amino acid, isoleucine, promotes defensin secretion. However, there are limitations in that some materials have unfavorable effects and other materials induce simultaneous secretion of inflammatory cytokines as well as antimicrobial peptides. For this reason, there have been demands for compounds having superior activity of promoting secretion of antimicrobial peptide and not inducing secretion of inflammatory cytokines.
The present inventors synthesized various materials in order to produce new materials for promoting antimicrobial peptides for a long time, and conducted experiments for activities thereof. As a result, the present inventors synthesized new compounds having excellent effects in promoting the secretion of human β-defensins and LL-37 in vivo, and completed the present invention.
SUMMARY
An embodiment of the present invention is directed to providing a new compound for promoting secretion of human antimicrobial peptide in vivo.
Another embodiment of the present invention is directed to providing a method for preparing the new compound for promoting secretion of human antimicrobial peptides in vivo.
Still another embodiment of the present invention is directed to providing a composition including the new compound for promoting secretion of human antimicrobial peptides in vivo as an active ingredient.
In one general aspect, there is provided a new compound for promoting secretion of human antimicrovial peptides in vivio represented by Chemical Formula (I) below:
(wherein in Chemical Formula (I), R 1 is C1˜C17 straight chain or branched alkyl, phenyl, or benzyl; and R 2 is hydrogen, methyl, or ethyl).
The compound of Chemical Formula (I) may have an effect of promoting secretion of human antimicrobial peptides, specifically, β-defensin and/or LL-37. Here, a more preferable compound may be a compound where R 1 is C5 straight chain alkyl and R 2 is methyl in the chemical formula (I) above, and may be represented by Chemical Formula (Ia) below.
In another general aspect, there is provided a method for preparing a new compound for promoting secretion antimicrobial peptide in vivo, including:
(A) dissolving a compound of Chemical Formula (II) or hydrochloride thereof in an organic solvent in the presence of organic base; and
(B) adding a compound of Chemical Formula (III) thereto at a reaction temperature of 0° C.˜5° C., followed by stirring.
Compound of Chemical Formula (II)
[wherein in Chemical Formula (II), R 2 is hydrogen, methyl, or ethyl]
Compound of Chemical Formula (III)
[wherein in Chemical Formula (III), R 1 is C1˜C17 straight chain or branched alkyl, phenyl, or benzyl]
In still another general aspect, there is provided a composition for promoting secretion of antimicrobial peptides in vivo, the composition including the new compound of Chemical Formula (I) as an active ingredient.
Here, as the active ingredient, the compound of Chemical Formula (I) or Chemical Formula (Ia) may be contained at 0.001˜90 wt %, and more preferably 0.001˜50 wt %, in the composition.
Here, the formulation type of the composition may not be particularly limited as long as it is applicable for the human body including mucous membranes, such as, skin, respiratory tract, oral cavity, nasal cavity, or the like, as a local administration agent, and the composition may be prepared in a liquid phase, an emulsion phase, a suspension phase, a cream phase, an ointment phase, a gel phase, a jelly phase, or a spray phase.
Here, the formulation type of the composition may not be particularly limited as long as it is applicable for the human body as a systemic administration, and the composition may be prepared as an oral administration, an injection, or the like.
ADVANTAGEOUS EFFECTS
As set forth above, since the human antimicrobial peptides, defensin and LL-37, have prompt antimicrobial activities and are secreted in various tissues and organs of the body, including skin, the new compound of the present invention for promoting secretion of defensin and LL-37 and the composition including the same were administered for external use or for internal use, thereby exhibiting effective antimicrobial activities on various regions of the body while overcoming restricted administration paths, generation of antibiotic bacteria, safety problems, and the like, of the existing antimicrobial agents.
The material for promoting secretion of human defensin and LL-37 in vivo of the present invention can induce the promotion of secretion of β-defensin-2 and LL-37 in vivo at the applied region thereof, and thus enhance antimicrobial activities and immune functions, thereby improving bio-defense response. Therefore, the material for promoting secretion of antimicrobial peptides of the present invention is effective in prediction and treatment of syndromes resulting from infection by foreign antigens, such as bacteria, fungi, and viruses. In particular, the present invention induces an increase in antimicrobial peptides at a lesion region of atopic dermatitis where the antimicrobial peptides are reduced, and thus can obtain effective advantages in suppressing infection of the skin.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing expression degrees of human antimicrobial peptides, hBD-2 and LL-37 in vivo, by a compound of the present invention;
FIG. 2 is a graph showing skin barrier recovery capability in the mouse coated with the compound of the present invention;
FIG. 3 is a graph showing anti-inflammatory efficacy of the compound of the present invention in an animal model with atopic dermatitis;
FIG. 4 is an image showing expression degrees of mouse antimicrobial peptide, CRAMP, which has a similar structure to human antimicrobial peptide, LL-37, in the corneum of the skin, when the compound of the present invention is coated on an atopic animal model;
FIG. 5 is an image showing proliferation degrees of cells in the epidemic layer when the compound of the present invention is coated on an atopic animal model;
FIG. 6 is a graph showing mast cells when the compound of the present invention is coated on an atopic animal model; and
FIG. 7 is a graph showing cytotoxicity of the compound of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS
Hereinafter, a new compound for promoting secretion of human antimicrobial peptides in vivo according to the present invention will be described in detail.
A new compound for promoting secretion of human antimicrobial peptides in vivo has a structure of Chemical Formula (I) below:
(wherein in Chemical Formula (I), R 1 is C1˜C17 straight chain or branched alkyl, phenyl, or benzyl; and R 2 is hydrogen, methyl, or ethyl).
In the present invention, a compound where R 1 is C5 straight chain alkyl and R 2 is methyl in the chemical formula above, is more preferable, and represented by Chemical Formula (Ia) below:
The compound of Chemical Formula (I) is prepared by the following method.
The compound of Chemical Formula (I) may be prepared by including: dissolving a compound of Chemical Formula (II) or hydrochloride thereof in an organic solvent in the presence of organic base; adding a compound of Chemical Formula (III) thereto at a reaction temperature of 0°˜5° C., followed by stirring; and extracting, drying, and filtering the reacted material.
Compound of Chemical Formula (II)
[Wherein in Chemical Formula (II), R 2 is hydrogen, methyl, or ethyl.]
Compound of Chemical Formula (III)
[Wherein in Chemical Formula (II), R 1 is C 1 -C 17 straight chain or branched alkyl, phenyl, or benzyl.]
In the above reaction, the organic base is preferably selected from the group consisting of triethyl amine, diethyl amine, trimethyl amine, and dimethyl amine, and more preferable is trimethyl amine. In addition, the organic solvent used in the reaction is preferably selected from the group consisting of dichloro methane, N,N-dimethyl formamide, chloroform, acetonitrile, and acetone, and more preferable is dichloromethane. In the reaction, the step (B) is preferably carried out by stirring for 3˜4 hours at 0° C.
The compound of Chemical Formula (Ia) as a representative compound of the compound of Chemical Formula (I) may be prepared as shown in the Reaction Scheme below.
Dichloro methane (DCM) is added to (L)-tyrosine methyl ester HCl salt, and triethyl amine (TEA) is added thereto, thereby dissolving HCl salt. The reactor is temperature-lowered to 0° C. by using an ice bath, and hexanoyl chloride is slowly added, following by stirring for 3˜4 hours. Water is added to the reacted material, followed by extraction with ethyl acetate. Drying over sodium sulfate followed by filtering is carried out. The solvent is removed from the filtrate by rotary evaporation, followed by solidification with hexane and ethyl acetate, thereby obtaining a white solid [Compound of Chemical Formula (Ia)].
As the experiment results confirming whether the thus synthesized compound of Chemical Formula (Ia) simulates secretion of β-defensin and cathelicidin, it can be seen that the compound of the present invention promotes secretion of β-defensin-2 and LL-37 in human cells that are cultured.
In addition, it can be confirmed that, by using the compound of Chemical Formula (Ia), expression of antimicrobial peptides is increased in the skin and anti-inflammatory efficacy and skin barrier function are improved as the result of application to an animal model with atopic dermatitis, and skin barrier recovery is significantly promoted as the result of experiments using an animal model with acute skin barrier disruption.
EXAMPLES
Hereinafter, the present invention will be described through the following examples and experimental examples, but the present invention is not limited to these examples.
Example 1
Preparation of (S)-Methyl 2-(hexanamido)-3-(4-hydroxyphenyl)propanoate
200 ml of dichloro methane (DCM) was added to (L)-tyrosine methyl ester HCl salt (23.16 g, 0.1 mol), and 28 ml of triethyl amine (TEA, 0.2 mol) was added thereto, thereby dissolving HCl salt. The reactor was temperature-lowered to 0° C. by using an ice bath, and hexanoyl chloride (13.8 ml, 0.1 mol) was slowly added, following by stirring for 3-4 hours. 200 ml of water was added to the reacted material, followed by extraction with 400 ml of ethyl acetate. Drying over sodium sulfate followed by filtering was carried out. The solvent was removed from the filtrate by rotary evaporation, followed by solidification with hexane and ethyl acetate, thereby obtaining a white solid (27.1 g, 92.5% yield) [hereinafter, referred to as Compound 1a].
mp: 96° C.
NMR (400 MHz CDCl 3 ) 1 H: 0.873 (3H, t, CH 3 CH 2 ), 1.261 (4H, m, CH 3 CH 2 CH 2 ), 1.584 (2H, m, CH 2 CH 2 CH 2 CH 2 CO), 2.175 (2H, t, CH 2 CH 2 CO), 2.955-3.118 (2H, dd, dd, CHCH 2 Ph), 3.742 (3H, s, OCH 3 ), 4.883 (1H, m, CH 2 CH(NH)CO), 5.922 (1H, d, NH), 6.720 (2H, d, CHC(OH)CH), 6.933 (2H, d, CH(CH 2 )CCH)
Example 2
Preparation of (S)-Methyl 3-(4-hydroxyphenyl)-2-(octanamido)propanoate
200 ml of dichloro methane (DCM) was added to (L)-tyrosine methyl ester HCl salt (23.16 g, 0.1 mol), and 28 ml of triethyl amine (TEA, 0.2 mol) was added thereto, thereby dissolving HCl salt. The reactor was temperature-lowered to 0° C. by using an ice bath, and 16.6 ml of octanoyl chloride (0.1 mol) was slowly added, following by stirring for 3-4 hours. 200 ml of water was added to the reacted material, followed by extraction with 400 ml of ethyl acetate. Drying over sodium sulfate followed by filtering was carried out. The solvent was removed from the filtrate by rotary evaporation, followed by separation by column chromatograph using hexane and ethyl acetate (Hex:EA=2:1), thereby obtaining a white solid (30.1 g, 93.3% yield).
mp: 76° C.
NMR (400 MHz CDCl 3 ) 1 H: 0.881 (3H, t, CH 3 CH 2 ), 1.262 (8H, m, CH 3 CH 2 CH 2 CH 2 CH 2 ), 1.581 (2H, m, CH 2 CH 2 CH 2 CO), 2.177 (2H, t, CH 2 CH 2 CO), 2.960-3.111 (2H, dd, dd, CHCH 2 Ph), 3.740 (3H, s, OCH 3 ), 4.888 (1H, m, CH 2 CH(NH)CO), 5.926 (1H, d, NH), 6.725 (2H, d, CHC(OH)CH), 6.931 (2H, d, CH(CH 2 )CCH)
Example 3
Preparation of (S)-Methyl 2-(dodecanamido)-3-(4-hydroxyphenyl)propanoate
300 ml of dichloro methane (DCM) was added to (L)-tyrosine methyl ester HCl salt (23.16 g, 0.1 mol) and 28 ml of triethyl amine (TEA, 0.2 mol) was added thereto, thereby dissolving HCl salt. The reactor was temperature-lowered to 0° C. by using an ice bath, and 21.88 g of dodecanoyl chloride (0.1 mol) was slowly added, following by stirring for 3˜4 hours. 200 ml of water was added to the reacted material, followed by extraction with 500 ml of ethyl acetate. Drying over sodium sulfate followed by filtering was carried out. The solvent was removed from the filtrate by rotary evaporation, followed by separation by column chromatograph using hexane and ethyl acetate (Hex:EA=2:1), thereby obtaining a white solid (34.2 g, 90.5% yield).
mp: 89° C.
NMR (400 MHz CDCl 3 ) 1 H: 0.881 (3H, t, CH 3 CH 2 ), 1.262 (16H, m, (CH 2 ) 8 ), 1.581 (2H, m, CH 2 CH 2 CH 2 CO), 2.177 (2H, t, CH 2 CH 2 CO), 2.960˜3.111 (2H, dd, dd, CHCH 2 Ph), 3.740 (3H, s, OCH 3 ), 4.888 (1H, m, CH 2 CH(NH)CO), 5.926 (1H, d, NH), 6.725 (2H, d, CHC(OH)CH), 6.931 (2H, d, CH(CH 2 )CCH)
Example 4
Preparation of (S)-Methyl 3-(4-hydroxyphenyl)-2-(palmitamido)propanoate
300 ml of dichloro methane (DCM) was added to (L)-tyrosine methyl ester HCl salt (23.16 g, 0.1 mol), and 28 ml of triethyl amine (TEA, 0.2 mol) was added thereto, thereby dissolving HCl salt. The reactor was temperature-lowered to 0° C. by using an ice bath, and 27.49 g of palmitoyl chloride (0.1 mol) was slowly added, following by stirring for 3˜4 hours. 200 ml of water was added to the reacted material, followed by extraction with 500 ml of ethyl acetate. Drying over sodium sulfate followed by filtering was carried out. The solvent was removed from the filtrate by rotary evaporation, followed by solidification with hexane and ethyl acetate, thereby obtaining a white solid (39.4 g, 90.8% yield).
mp: 100° C.
NMR (400 MHz CDCl 3 ) 1 H: 0.881 (3H, t, CH 3 CH 2 ), 1.262 (24H, m, CH 3 (CH 2 ) 12 ), 1.581 (2H, m, CH 2 CH 2 CH 2 CO), 2.177 (2H, t, CH 2 CH 2 CO), 2.960˜3.111 (2H, dd, dd, CHCH 2 Ph), 3.740 (3H, s, OCH 3 ), 4.888 (1H, m, CH 2 CH(NH)CO), 5.926 (1H, d, NH), 6.725 (2H, d, CHC(OH)CH), 6.931 (2H, d, CH(CH 2 )CCH)
Example 5
Preparation of (S)-Methyl 3-(4-hydroxyphenyl)-2-(phenylacetamido)propanoate
200 ml of dichloro methane (DCM) was added to (L)-tyrosine methyl ester HCl salt (23.16 g, 0.1 mol), and 28 ml of triethyl amine (TEA, 0.2 mol) was added thereto, thereby dissolving HCl salt. The reactor was temperature-lowered to 0° C. by using an ice bath, and 15.46 g of phenylacetyl chloride (0.1 mol) was slowly added, following by stirring for 3˜4 hours. 200 ml of water was added to the reacted material, followed by extraction with 400 ml of ethyl acetate. Drying over sodium sulfate followed by filtering was carried out. The solvent was removed from the filtrate by rotary evaporation, followed by solidification with hexane and ethyl acetate, thereby obtaining a white solid (27.7 g, 88.1% yield).
mp: 101° C.
NMR (400 MHz CDCl 3 ) 1 H: 2.852-3.032 (2H, dd, dd, CHCH 2 Ph), 3.554 (2H, s, PhCH 2 CO) 3.709 (3H, s, OCH 3 ), 4.837 (1H, m, CH 2 CH(NH)CO), 5.917 (1H, d, NH), 6.628 (2H, d, CHC(OH)CH), 6.724 (2H, d, CH(CH 2 )CCH), 7.155-7.348 (5H, m, PhCH 2 )
Example 6
Production of Cream Formulation
A cream formulation having the following composition was produced by a general method for forming cream.
TABLE 1
Weight
Function
Ingredient
(%)
Aqueous
Antiseptic
Methyl paraben
0.2
Phase
Polymer
xanthan gum
0.1
Moisturizer
Glycerine
8.0
Purified Water
Water
74.0
Oil Phase
Fatty Acid
Stearic acid
2.0
Higher Alcohol
Cetanol
2.0
Wax
Bees wax
2.0
Surfactant
POE(15) GMS
2.5
Surfactant
POE(10) GMS
1.0
Surfactant
GMS
1.5
Oil
Macademia nut oil
3.0
Oil
Squalane
3.0
Antiseptic
Propyl paraben
0.1
Active
Synthesized Material of
0.5
ingredient
Example 1 (Compound 1a)
Additive
Spice
Fragrance
0.1
It was confirmed that cream produced from Example 6 had excellent storage stability and feeling of use.
In order to assess promotion of antimicrobial peptide secretion by using Compound 1a of Example 1, in vitro experiments were conducted.
Test Example 1
Promotion of Secretion of β-Defensin and LL-37
A medium containing 1% penicillin/streptomycin but not serum was used to culture human keratinocyte (HaCaT). The human keratinocyte was cultured in a 5% CO 2 incubator at 37° C. The cells were seeded in each well of a 6-well plate at 3×10 5 cells/well, and then cultured for 48 hours. 1.7 mM calcium chloride and the new material synthesized from Example 1 were added thereto, and the cells were allowed to culture for 24 hours.
For assessment, at least one untreated control and at least one positive control were used together. 2.5 ng/mL of lipopolysaccharides (LPS), which is known to promote expression of hBD-2 and LL-37, was used as the positive control, and was allowed to react. After the reaction was completed, a supernatant was collected, and then the cells were washed with phosphate buffer saline (PBS) and collected by using a trypsin-EDTA solution, and stored in a tube. 1 ml of a triazole reagent was added to extract mRNA. After reaction for 15 seconds at room temperature, 200 μl of chloroform was added. Centrifugal separation at 13,000 rpm was carried out for 10 minutes. The supernatant was transferred into another tube, and then 5000 of isopropanol was added thereto, followed by centrifugal separation at 13,000 rpm for 10 minutes. The precipitated RNA wash washed by using 70% ethanol. After washing was carried out two times, RNA was dissolved by using distilled water at the time of the third washing. The diluted RNA was analyzed at a wavelength between 260 nm and 280 nm, and quantitated.
The thus obtained RNA was subjected to RT-PCR procedure to obtain PCR results. For the RT-PCR, 2 μl of MgCl 2 , 1 μl of RT buffer, 1 μl of dNTP mix, 0.25 μl of Rnase inhibitor, 0.5 μl of RTase, 0.5 μl of oligo dT, 3.75 μl of distilled water, and 2 μg of RNA were placed in the tube, and then were allowed to react. The RT-PCR conditions were 45° C. for 1 hour and 95° C. for 5 minutes. PCR was carried out for qualitative analysis on GAPDH, hBD-2 and -3, and LL-37. The used primers were obtained from the following documents (Kim J E, Kim B J, Jeong M S, et al, Expression and Modulation of LL-37 in Normal Human Keratinocytes HaCaT Cells and Inflammatory Skin Diseases. J Korean Med Sci (2005) 20, 649; Pernet I, Reymermier C, Guezennec A, et al, Calcium triggers beta-defensin (hBD-2 and hBD-3) and chemokine macrophage inflammatory protein-3 alpha (MIP-3alpha/CCL20) expression in monolayers of activated human keratinocytes. Exp Dermatol (2003) 12, 755).
The used primers are as follows.
GAPDH sense:
(SEQ ID NO: 1)
5′-GGG CAT GAA CCA TGA GAA GT-3′
GAPDH antisense:
(SEQ ID NO: 2)
5′-GTC TTC TGG GTG GCA GTG AT-3′
hBD-2 sense:
(SEQ ID NO: 3)
5′-CCA GCC ATC AGC CAT GAG GGT-3′
hBD-2 antisense:
(SEQ ID NO: 4)
5′-GGA GCC CTT TCT GAA TCC GCA-3′
hBD-3 sense:
(SEQ ID NO: 5)
5′-TTC CAG GTC ATG GAG GAA TC-3′
hBD-3 antisense:
(SEQ ID NO: 6)
5′-GAG CAC TTG CCG ATC TGT TC-3′
TNF-α sense:
(SEQ ID NO: 7)
5′-GAG AAG GGT GAC CGA CTC AG-3′
TNF-α antisense:
(SEQ ID NO: 8)
5′-ATG TTC GTC CTC CTC ACA GG-3′
LL-37 sense:
(SEQ ID NO: 9)
5′-TCG GAT GCT AAC CTC TAC CG-3′
LL-37 antisense:
(SEQ ID NO: 10)
5′-GGG TAC AAG ATT CCG CAA AA-3′
12.5 μl of PCR premix, 2 μl of primer sense (10 uM), 2 μl of primer antisense (10 uM), 1.5 μl of cDNA, and 7 μl of distilled water were inputted, and then PCR was carried out. PCR conditions of hBD-2 and -3 were 30 cycles of 94° C. for 30 seconds, 59° C. for 30 seconds, and 72° C. for 30 seconds, and then 72° C. for 10 minutes. PCR conditions of LL-37 were 30 cycles of 94° C. for 30 seconds, 60° C., for 30 seconds, and 72° C. for 30 seconds, and then 72° C. for 10 minutes. After amplification, the final products were mixed together, the final solution was loaded on an agaros gel containing a nucleic acid insertion visible under UV (such as, ethidium bromide), which is gelled at 1.5%. The sample was migrated and then read out under UV in a dark room, and digitally photographed. Photos of the gel were analyzed by image processing software which quantifies the band intensities. As basal levels of defensin and LL-37 expression (untreated control) were not detectable, antimicrobial peptide expression was detectable by using intensity ratios of the hBD-2/GAPDH, hBD-3/GAPDH, and LL-37/GAPDH bands in the positive control and sample-treated groups. Real-time PCR was carried out in order to more clarify these results. 5 μl of Sybergreen, 2 μl of primer sense (10 uM), 2 μl of primer antisense (10 uM), 1 μl of cDNA, and 1 μl of distilled water were inputted, and then the real-time PCR was carried out.
The results are shown in FIG. 1 . As can be seen in FIG. 1 , it can be seen that the compound of the present invention promotes the secretion of human β-defensin-2 and LL-37 from cultured human-derived cells.
Test Example 2
Recovery of Skin Barrier Damage
Skin barriers of nude mice were acutely damaged, and then effects of the new material represented in Example on recovery of acute skin barriers were assessed. D-Squame was used to induce skin barrier damage to left and right back regions of 6-8 week aged nude mice. Here, all the experimental groups were maintained to have no difference in trans epidermal water loss (TEWL) through measurement of the trans epidermal water loss (TEWL), and then vehicle (PEG:EtOH=7:3) and the new material represented in the example were coated thereon. The trans epidermal water loss (TEWL) was measured at the time of 0 h, 3 h, 6 h, and 24 h to confirm recovery of the skin barrier, and skin biopsies were conducted at the respective time, to thereby implement histological examination and other examinations.
The results are shown in FIG. 2 . It can be confirmed from the results of FIG. 2 that the new compound of the present invention show significant results on the recovery of skin barrier damage.
Test Example 3
Efficacy Assessment on Animal Model with Atopic Dermatitis
An animal model with atopic dermatitis was constructed by coating the abdomens of 6-8 week aged nude mice with 5% oxazolone solution one time for percutaneous sensitization; after week, with 0.1% oxazolone solution every other day, six times, and 1% oxazolone solution every other day, four times. It has been reported that in the case of the animal model with atopic dermatitis using oxazolone, antimicrobial peptides were reduced in the skin (Man M-Q, Hatano Y, Lee S H, et al. Characterization of a hepten-induced, murine model with multiple features of atopic dermatitis: structural, immunologic, and biochemical changes following single versus multiple oxazolone challenges. J Invest Dermatol (2008) 128, 79-86). The skin of the animal model with atopic dermatitis constructed as above was coated with vehicle (PEG:EtOH=7:3) and Compound 1a of Example 1 diluted with the vehicle at a concentration of 0.1% once in the morning and in the afternoon for a total of four days. On the last day, thickness of the skin was measured. Corticosteroid based drug, Dexamethasone, which is an effective anti-inflammatory agent, was used as a positive control.
The obtained results are shown in FIG. 3 . These results confirmed that the new material synthesized according to the example had an inflammatory effect in the animal model with atopic dermatitis.
The new compound synthesized according to Example 1 was coated for four days, and then skin tissue biopsy was conducted to form a paraffin block. The tissue was allowed to adhere on the slide by using a paraffin cutter. After 500 μl of a peroxides blocking reagent was loaded, the reaction was carried out for 30 minutes. Washing with PBS solvent was carried out three times at a time interval of 5 minutes. After 500 μl of a peroxide blocking reagent was loaded, the reaction was carried out for 15 minutes. The first goat anti-mouse CRAMP was allowed to react at 25° C. for 30 minutes. The reaction using donkey anti-goat IgG-HRP as an antibody was carried out at 25° C. for 30 minutes. The reaction using DAB as a color forming agent was carried out for 10 minutes. After the reaction was completed, expression of CRAMP in the corneum of the skin was measured through a microscope. The obtained results were tabulated in Table 4. A), B), C), and D) of FIG. 4 show Normal, Negative control, 0.01% Dexamethasone, and 0.1% Compound 1a, respectively.
Another slide was used to measure proliferating cell nuclear antigen (PCNA). After 500 μl of a peroxides blocking reagent was loaded, the reaction was carried out for 30 minutes. Washing with PBS solvent was carried out three times at a time interval of 5 minutes. After 500 μl of a peroxides blocking reagent was loaded, the reaction was carried out for 15 minutes. The first rabbit anti-mouse PCNA was allowed to react out at 25° C. for 30 minutes. The reaction using donkey anti-rabbit IgG-HRP as an antibody was carried out at 25° C. for 30 minutes. The reaction using DAB as a color forming agent was carried out for 10 minutes. After the reaction was completed, proliferation of skin cells in the epidermis layer of the skin was measured through a microscope. The obtained results are shown in FIG. 5 .
Another slide was used to measure mast cells. After paraffin was removed from the slide, the reaction in the potassium permanganate solution was carried out for 2 minutes. The slide was washed by using distilled water. The reaction in the potassium metabisulphite solution was carried out for 1 minute. The slide was washed by using distilled water for 3 minutes. The reaction in the acidified toluidine blue solution was carried out for 5 minutes. The slide was washed by using distilled water. After the reaction was completed, mast cells of the skin were measured through a microscope. The obtained results are shown in FIG. 6 .
It can be seen from the above test results that the new compound of the present invention has superior inflammatory efficacy and significantly promotes improvement and recovery of skin barrier.
Test Example 4
Cytotoxicity
A medium containing 1% penicillin/streptomycin but not serum was used to culture human keratinocyte (HaCaT). The human keratinocyte was cultured in a 5% CO2 incubator at 37° C. The cells were seeded in each well of a 96-well plate at 2.5×10 4 cells/well, and then cultured for 48 hours. The cells were further cultured for 24 hours by using a medium without serum. On the next day, the new material synthesized by the example was added at different concentrations thereof, and then the reaction was carried out for 24 hours. After four hours after the color forming reagent was put, apoptosis was measured at an absorbance of 590 nm. The obtained results are shown in FIG. 7 .
It can be seen from the above test results that the new compound of the present invention has also no problems in view of stability.
INDUSTRIAL APPLICABILITY
The present invention is directed to an industrially applicable novel compound capable of inducing direct or indirect expression of human β-defensin-2 and -3 and LL-37, which are human antimicrobial peptides, a method for preparing the same, and a composition comprising the same as an active ingredient.
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Disclosed is a compound having an acceleration effect on the secretion of human β-defensin, LL-37, which is a human-derived anti-microbial peptide, a method for preparing same, and a composition for accelerating the secretion of anti-microbial peptide having same as an active ingredient, and the compound and the composition using same of the present invention enhance the anti-microbial effect and the immunity control effect that the anti-microbial peptide has in the body by accelerating the secretion of the anti-microbial peptide in the body.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application is related to the application titled "Mail Alert System" filed Jun. 29, 1996 by the same inventor, bearing the Ser. No. 08/673,350.
FIELD OF THE INVENTION
The invention is in the field of processing systems for real-time data streams of transaction records, and pertains in particular to a system for processing such data streams according to specific criteria, and reporting results of such processing.
BACKGROUND OF THE INVENTION
Scholars and historians have traditionally given names to different periods based on dominant characteristics of the time. The time we live in is often called the information age. Development of more and more sophisticated communication systems together with larger and more complex institutions has made it so. Businesses of all sorts and private individuals too, rely heavily on timely information to make decisions on an ongoing basis. Timely information is truly a most important commodity.
Much, if not most information is incremental rather than continuous, and systems for assimilating, analyzing, and reporting such information must allow for this characteristic. Such information occurs and is reported in small bites. Transaction information and transaction analysis is a good example, and of this sort of information, stock sales reports are typical, and will be used as an example in the present patent application.
In the case of stock reports, such as the transactions of the New York Stock Exchange, good and timely information can easily make a difference between success and failure in stock trading. The same is true in transaction analysis in many other areas of human endeavor. In stock trading as an example, individuals making private decisions and people making decisions for large organizations, have to have certain information for their decisions, and success may well depend on quickly noting specific events or trends in transactions. If an event or trend is missed altogether or only noticed with serious delay, the result can be catastrophic.
It is quite common today among companies and individuals as well to use computer technology to track and analyze such information, and many systems for doing this sort of analysis has been developed. Some, in the case of individuals, are designed to operate on personal computers, such as laptop and desktop PCs. In the case of bigger organizations systems may operate on large and more powerful computers. Regardless of the ability of the computer equipment, however, there are still drawbacks, based primarily on the fact that the data stream in many cases is simply enormous. In the case of stock transactions for example, people make decisions based on such as instant prices, price trends, volume of sales, volume trends, high and low sales in a fixed period, and the like. Different analysts, of course, use differing criteria. To appreciate the scope of the problem, one need only check the volume of transactions for a single trading day on the New York Stock Exchange. On Jul. 16, 1996, for example, the sales volume on the New York Stock Exchange was 422,903,290 shares in the 8-hour trading day. This is more than 14,684 shares traded per second. Shares, of course, are not traded one-share-at-a-time, but typically in blocks of 100 shares. So the number of transactions (blocks) in this particular case is over 100 transactions per second. To make meaningful analysis on the basis of such a massive transaction data stream is a prodigious process.
What is clearly needed is an analysis system that can quickly and efficiently track and analyze such a massive data stream, using equipment of a reasonable size, power, and cost, and provide summary information analyzed according to diverse sets of criteria to subscribers.
SUMMARY OF THE INVENTION
In a preferred embodiment of the present invention a method for analyzing a data stream of transaction records is provided, comprising steps of: (a) prestoring criteria for significance; (b) applying time slices to the data stream to create successive finite feed records consisting of those transaction records occurring in each time slice; (c) comparing the records in each finite feed record with the criteria for significance, (d) preparing therefrom significant records of just those transaction records matching the criteria for significance; and (e) providing the successive significant records for further procedure. In some embodiments each feed record analyzed and each significant record produced is discarded after use.
In a preferred embodiment a new time slice is generated for each data cycle based on the volume of records received during a prior time slice.
In some embodiments the further procedure comprises comparing each significant feed record produced with prestored customer interest tables, and producing therefrom an alert table. The alert table is used to guide transmission of alerts to subscribers, and alerts are deleted from the alert table after transmission to a subscriber. The system is adaptable to all sorts of transactional data streams, and is very useful for such as stock quote data streams.
The system in various embodiments provides a way to analyze a transactional data stream and to produce processed information for alerting users and guiding users in decisions based on the data contained in a data stream. The system has an advantage in speed of analysis, operating in near real time, and requires smaller, less powerful, and hence less expensive computer equipment for analysis than is typically required for analysis on a comparative scale by conventional techniques using conventional equipment platforms.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a pseudo code listing of operating code for a TradeAlert™ transaction analysis system according to a preferred embodiment of the present invention.
FIG. 2 is a diagrammatical illustration depicting a typical topology in the embodiment of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is a new method and apparatus comprising a data-processing system that provides for processing of massive amounts of data in finite time slices, providing as a result processed information in substantially realtime without necessity for extremely powerful and thus expensive computing hardware. By realtime results is meant that processed information is presented to a user of the system from a massive transactional data stream very nearly as the data stream is received, with a delay too small to be noticable by a user. Data thus processed may be directly read and used by a user, and then, if appropriate, be input to other systems for further processing.
In the present invention near realtime results are achieved by a unique process fully described below, wherein information batches over finite time slices are taken from a transactional data stream, processed according to pre-stored criteria, then presented as results to a user or users, which in many embodiments may be paying subscriber's to a processing system. In this specification the inventor has termed the system in a general sense a Real Time Transaction Alert System, used as a descriptive title for this specification. In a particular embodiment the system is named the TradeAlert™
FIG. 1 is a pseudo code listing of operating code for the TradeAlert™ transaction analysis system according to a preferred embodiment of the present invention, and
FIG. 2 is a diagrammatical illustration depicting a typical topology in the embodiment of FIG. 1. These two figures are referred to extensively below in describing exemplary embodiments of the present invention.
Refer first to FIG. 2, which shows an exemplary topology wherein the data stream to be analyzed is from a stock trading organization such as the New York Stock Exchange. Data is generated at the Market 210, then sent via data link 211 to ground station 212. The data stream then continues via uplink 213, satellite 200 and downlink 214 to receiver dish 215, which then feeds into TradeAlert™ server 220 via data link 216. In TradeAlert server 220 the signal on link 216 carrying the relevant data stream, in this case transactions of the stock exchange, is demodulated (with internal satellite modem e.g.) and the data is fed into a feed 130 (see FIG. 1) of the processing system described herein. After processing described in detail below with primary reference to FIG. 1. The results can be distributed in one or more of several ways, as shown for example by pager 221, via Fax 223, or via Internet or other similar local area network and/or wide area network in any combination to workstations, such as stations 222, 224 and 225 or wireless organizers such as organizer 226.
It will be apparent to those with skill in the art that any of the elements shown and the organization of the elements may vary in a number of ways, and also that plural elements may in some instances be used without departing from the spirit and scope of the invention. For example, in a system with multiple subscribers, which will be typical, there will be multiple result feeds, at least one to each subscriber. There are many elemental substitutions that may be made as well. For example, the satellite link may be a leased phone line and/or Internet or other type of network connection. The same comments apply to the notification side any type of electronic messaging may be used, in addition or instead of those shown to transmit the alert notices and any other result data, such as synthesized phone calls on multiple phones, Teletext notification in areas with Teletext service, digital phone messaging where available, and so forth.
Referring now primarily to FIG. 1, lines 100-116 provide descriptive definitions, which are used below in description of the system. In this listing of definitions, Objects are listed in bold type, objects being those elements of the invention upon which actions are performed or which are the result of actions performed. Objects may in many cases be abstract in character. Actions performed by the TradeAlert™ system are listed in Italics. Much of the definition portion of the pseudo-code of FIG. 1 is reproduced below with further aliteration.
Line 107 indicates that incoming high-speed Feeds are processed by the TradeAlert™ system. There may be, depending on the size and sophistication of the equipment and the control routines in various embodiments of the invention, multiple data Feeds, and the Feeds may provide transactional records of one or more of many different types. For purposes of illustration herein a Feed is a stock transaction data stream.
Line 108 indicates that a Feed is considered to be empty when there has been no data received since a previous lookup, and that an incoming Feed is structured in Feed Records. Feed Records are read from a Feed data stream. A Feed Record then, is a finite record which may contain multiple Feed Issues. In the example of stock transactions, Feed Issues are individual stock transaction records, and a Feed Record is an atom of information in a Feed indicating a group of transactions. As indicated above in the Background section, in the case of the New York Stock Exchange, these records could come at a rate of greater than 100 Feed Records per second. In other cases the data feed rate could be greater or lesser.
Line 109 defines a Feed Table as a buffer for handling feed records received in a finite time slice. The TradeAlert™ system looks at a Feed and creates Feed Tables at specific intervals, referred to herein also as time slices. The time slice is a variable in a preferred embodiment, and is calculated by the system The value of the time slice determines, based on assumptions about the rate of a Feed, about how many Feed Records will be in a Feed Table.
Line 110 defines a Significant Feed Table as a buffer containing all Feed Records in a Feed Table that are unique for Feed Issues and for Interest Criteria. Interest Criteria are indications of customer interest in Interest Records in Customer Interest Tables (Line 111). In the system, interests of customers are pre-recorded as Interest Records in Customer Interest Tables, which are used in processing data by the system.
Line 113 defines an Alert as an atom of information provided to a customer. Alerts are generated in an Alert Table by matching records in a current Significant Feed Table with records in a Customer Interest Table. Once Alerts are sent to a customer (user) they are deleted from the Alert Table.
As noted in line 120, tasks are concurrent and ongoing. That is, once a Feed Table is created, the system does not wait for all other processes relevant to that Feed Table to be carried out before another is created.
Procedures of the TradeAlert™ system are described in FIG. 1 after line 120. There are, in the embodiment described, three concurrent procedures. These have been labeled in FIG. 1 as (a) Receive Feed Records (b) Query and (c ) Send Alerts.
In the following descriptions of the tasks and characteristics of the tasks, these definitions are used:
T=duration of a time slice
N=number of customer records in the system, which is the number of customers served
m=data feed rate in records per unit of time
M=number of feed records received in a time slice T, which is a function of T & m
S=size of the Significant Table
I=number of unique issues in the feed
Coeff1=Coefficient
Receive Feed Records is the process of operating on the incoming Feed and producing Feed Tables. Each Feed Table is a result of grouping Feed Records received over a finite time slice T. The task is a continuing task (forever), and each Feed Table produced has a size M depending on the variable m. There may be assumed an upper limit for m, as the physical parameters of the system (bandwidth, nature of links) will support only a certain maximum rate.
In a preferred embodiment, the time slice is determined for each processing cycle dependent on the data feed. For example, given a value for a first finite time slice t1, a finite number of records will be captured from the data stream and processed. The value for the next time slice t2 is determined from the first time slice t1, as t2=f(t1), where f is preferrably a continuous function increasing in t. The idea here is, as the data feed varies in volume, the time slice also varies, with a longer time slice for heavier feed.
Task Query operates on Feed Tables produced by task Receive Feed Records to produce Significant Feed Tables and Alert Tables. In Query successive Feed Tables are scanned for significant data only; the significant data being that data matching Feed Issues and Interest criteria in Customer Interest Records.
It is in task Query that a significant advantage over conventional data stream processing lies. Many fewer records, namely the significant records only, have to be matched against each and every customer profile, and thus processing time is greatly reduced. For an example, in a time slice of t1, data for ten-thousand records (10 kT) may be received. Assume for this example that all of the customers are interested only in IBM stock. The Feed Record produced from this time slice, having a total of 10 kT, may include only 500 records for the stock IBM (chosen as example of an active issue). Out of these 500 records, customer criteria may indicate only the highest, lowest, least margin and most margin may need be selected, as well as the total volume. So the 500 records would be concentrated into perhaps 5 records, which greatly simplifies the matching for customer requests. The Query task in this case produces a Significant Feed Table of 5 records out of ten thousand in the Feed Table.
Producing the Significant Feed Table in task Query is a first step. In a second step, individual customer interests are consulted from Customer Interest Records and an Alert Table is produced for use by task Send Alerts.
Task Alerts is the procedure of processing the Alert Tables produced in Step 2 of Task Query, and forwarding the actual alert signals to customers, which are then deleted from the Alert Table. The methods and mechanics of sending alerts has been discussed above.
In various embodiments of the present invention, existing elements of control routines and the like may be incorporated as elements of the invention. There are, for example, existing database programs that may be incorporated for performing some of the operations in the various tasks. It will be apparent to those with skill in the art that for a Sendalert™ system to operate successfully, it must be capable of processing a given incoming data stream without undue delay (to operate in substantially real time), as advertised. For this to be so, certain criteria have to be met. Part of the requirement may be met by knowledge of the nature of an incoming data stream and of the tools used to create it. For example, for most data feeds artificially generated, it can be assumed that operations on a database originate the data feed. This will dictate a choice of a database at the SendAlert™ system can be made so that the speed of the incoming feed will be supported.
Here some further considerations:
F1, F2, Q1 & Q2 in angle brackets < > (lines 131, 132, 136 and 137) in FIG. 1 are variables describing the average estimated times for the appropriate steps to complete
<F1> is dependent on the parameters of the incoming feed (speed, distribution, etc.).
<F2> is dependent on the speed of the database and of the hardware available.
<Q1> is dependent on the size of FeedTable at the time of execution--M
It can be assumed:
<Q1>˜Coeff1*M, with Coeff1<1
(selection is cheaper than insertion in most databases)
It can be assumed that the size of the SignificantTable is limited up by the number of unique issues supported by the feed (same order of magnitude).
S˜I (see example of IBM above)
<Q2> is dependent on the size of the Customer Interest Table (˜N)
<Q2>˜N*I
A value for the time slice can be dictated by the Query task as being:
T=<Q1>+<Q2>=(Coeff1*M+I*N)*β
It can be assumed that M is a linear function of T (because of speed limit on feed), so:
T=β*(m*T+I*N)
This equation in T has one unique finite solution.
Based on the above, it can be stated that a system using the above algorithm will be able to provide the service with a delay of a finite time slice T.
For any instance of the system, the time slice T can be reduced by hardware and software (database) upgrades.
Consideration in differential equations will show that in conditions of a variable feed with a finite speed, such a system would oscillate with a finite decreasing amplitude and would never get into an unstable state.
It will be apparent to those with skill in the art that there are many alternatives to the embodiments described above that might be incorporated without departing from the spirit and scope of the invention. Many of these alternatives have already been mentioned. It is common, for example, for different programmers to utilize widely varied code sequences to accomplish the same results. There are similarly many alternatives in the computer and communication hardware described that might be incorporated without departing from the spirit and scope of the invention. Length of time slice can vary from one embodiment to another. Adaptivity to specific data feeds may be accomplished as well by altering the code routines used to practice the invention. There are many other alternatives that may be used, so the invention is limited only by the scope of the following claims.
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A computerized analyzer for a transactional data stream prepares feed records from the data stream, the feed records comprising all transaction records received in a finite time slice. A new feed record is prepared for each passing time slice, and, in a preferred embodiment, new time slices are generated during operation based on record volume received during a previous time slice. The feed records are condensed to significant feed records by selecting only those transaction records in each feed record that are significant according to prestored criteria including subscriber interest records. Once a significant feed record is prepared, it is compared with subscriber interest records to produce an alert table. An alert transmitter transmits alerts to subscribers following the alert table. Alerts are deleted from the alert table as they are sent to subscribers. The system is suited to many types of transactional data streams, and suited for such as stock quote data streams.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of the legally related U.S. application Ser. No. 11/570,734, filed Jun. 17, 2007; which claims the benefits of the legally related 371 of PCT/US05/13334, filed Apr. 19, 2005; which claims the benefits of the legally related U.S. Provisional Patent Application Ser. No. 60/580,556, filed Jun. 17, 2004, which is fully incorporated herein by reference.
BACKGROUND
[0002] The present invention relates to polymers that are useful in paper additives.
[0003] “Sizing,” as applied to paper, refers to a fibrous substrate's ability to resist wetting or penetration of a liquid into a paper sheet. Aqueous dispersions of alkenylsuccinic anhydride (ASA) cellulose-reactive sizing agent have been widely used in the paper and board making industry for many years, for sizing a wide variety of grades which include printing and writing grades and bleached and unbleached board grades. Cellulose-reactive alkenylsuccinic anhydride emulsions impart hydrophobic properties to the paper and board products.
[0004] Chemicals used to achieve sizing properties are known as either internal sizes or surface sizes. Internal sizes can be either rosin-based or synthetic sizes such as alkenylsuccinic anhydride, or other materials. Internal sizes are added to the paper pulp prior to sheet formation. Surface sizes are sizing agents that are added after the paper sheet has formed, most generally at the size press, although spraying applications may also be used.
[0005] A synthetic sizing agent such as alkenylsuccinic anhydride sizing agent is ordinarily applied by dispersing it in a cationic or amphoteric hydrophilic substance such as a starch or a polymer. The starch or polymer-dispersed alkenylsuccinic anhydride sizing emulsions have been added to the pulp slurry before the formation of a paper web. This type of addition of alkenylsuccinic anhydride sizing emulsions to the paper making system is commonly called wet-end addition or internal addition of alkenylsuccinic anhydride.
[0006] Papermakers would benefit from a cationic or amphoteric polymer that is different from known polymers and, preferably, that also enhances the sizing efficiency of paper products. Unfortunately, known methods and compositions have prevented papermakers from achieving this goal. Known compositions and methods require an unduly large amount of materials to size paper products. Papermakers are under pressure to improve sizing efficiency and, as such, there is an ongoing need to develop products and methods that improve sizing efficiency.
[0007] For the foregoing reasons, there is a need to develop a paper additive that improves the sizing efficiency of paper products.
SUMMARY
[0008] The invention relates to a cationic polymer useful as a papermaking additive, which is obtained by copolymerizing:
[0009] (1) a vinyl monomer of the formula:
[0000] CH 2 ═CR 1 —COA(CH 2 ) n N + R 2 R 2 R 3 X − (I)
[0000] or (CH 2 ═CHCH 2 ) 2 N + (R 2 ) 2 X − (Ia)
[0010] wherein R 1 is a hydrogen atom or a methyl group, A is an oxygen atom or NH group, n is 2 or 3, R 2 and R 3 are each a methyl group or an ethyl group and X is a chlorine atom, a bromine atom, or X − is a methyl sulfate ion; and
[0011] (2) a vinyl monomer of the formula:
[0000] CH 2 ═CR 4 —CONH 2 (II)
[0012] wherein R 4 is a hydrogen atom or a methyl group; and
[0013] (3) a vinyl monomer of the formula:
[0000] CH 2 ═CR 5 COO(CH 2 ) n OH (III) or
[0000] CH 2 ═CR 6 COO(CH 2 ) m CH(OH)CH 2 OH (IIIa)
[0014] wherein R 5 and R 6 is a hydrogen atom or a methyl group, n is 1-4, inclusive and m is 1 or 2.
[0015] In another embodiment, the invention relates to an amphoteric polymer useful as a papermaking additive, which is obtained by copolymerizing (1) a vinyl monomer of the formula:
[0000] CH 2 ═CR 1 —COA(CH 2 ) n N + R 2 R 2 R 3 X − (I)
[0000] or (CH 2 ═CHCH 2 ) 2 N + (R 2 ) 2 X − (Ia)
[0016] wherein R 1 is a hydrogen atom or a methyl group, A is an oxygen atom or NH group, n is 2 or 3, R 2 and R 3 are each a methyl group or an ethyl group and X is a chlorine atom, a bromine atom, or X − is a methyl sulfate ion; and
[0017] (2) a vinyl monomer of the formula:
[0000] CH 2 ═CR 4 —CONH 2 (II)
[0018] wherein R 4 is a hydrogen atom or a methyl group, and
[0019] (3) a vinyl monomer of the formula:
[0000] CH 2 ═CR 5 COO(CH 2 ) n OH (III)
[0000] or CH 2 ═CR 6 COO(CH 2 ) m CHOHCH 2 OH (IIIa)
[0020] wherein R 5 and R 6 is a hydrogen atom or a methyl group and n is 1 or 4 and m is 1 or 2; and
[0021] (4) an anionic vinyl monomer of the formula:
[0000] CH 2 ═CR 7 COOR 8 (IV)
[0000] wherein R 7 is a hydrogen atom or a methyl group, and R 8 is a hydrogen atom, an alkali metal, ammonium group.
[0022] In another embodiment, the invention relates to a method for making the cationic polymer or a method for making the amphoteric polymer.
[0023] In another embodiment, the invention relates to a method comprising (a) providing paper stock; (b) adding to the paper stock a composition comprising: (i) synthetic sizing agent, and (ii) the above described cationic polymer or amphoteric polymer, and (c) forming a web from said paper stock, such that the web exhibits an improved sizing efficiency as compared to a web made without the cationic polymer.
[0024] These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description and appended claims.
DESCRIPTION
[0025] The invention is based on the remarkable discovery that by using a certain cationic polymer or amphoteric polymer, it is now possible to enhance the sizing efficiency of a paper product.
[0026] Other than in the operating examples or where otherwise indicated, all numbers or expressions referring to quantities of ingredients, reaction conditions, etc., used in the specification and claims are to be understood as modified in all instances by the term “about.” Various numerical ranges are disclosed in this patent application. Because these ranges are continuous, they include every value between the minimum and maximum values. Unless expressly indicated otherwise, the various numerical ranges specified in this application are approximations.
[0027] The term “paper”, as used herein, is meant to include fibrous substrates that include not only paper as the term is commonly used but all types of cellulose-based products in sheet and web form, including, for example, board and paperboard. The sizing compositions may be added to any stock containing cellulosic fibres, optionally in combination with mineral fillers, and usually the content of cellulosic fibres is at least 50% by weight, based on dry stock. Examples of mineral fillers of conventional types include kaolin, china clay, titanium dioxide, gypsum, talc and natural and synthetic calcium carbonates such as chalk, ground marble and precipitated calcium carbonate.
[0028] A cationic polymer of the invention is obtained by copolymerizing
[0029] (1) a vinyl monomer of the formula:
[0000] CH 2 ═CR 1 —COA(CH 2 ) n N + R 2 R 2 R 3 X − (I)
[0000] or (CH 2 ═CHCH 2 ) 2 N + (R 2 ) 2 X − (Ia)
[0030] wherein R 1 is a hydrogen atom or a methyl group, A is an oxygen atom or NH group, n is 2 or 3, R 2 and R 3 are each a methyl group or an ethyl group and X is a chlorine atom, a bromine atom, or X − is a methyl sulfate ion; and
[0031] (2) a vinyl monomer of the formula:
[0000] CH 2 ═CR 4 —CONH 2 (II)
[0032] wherein R 4 is a hydrogen atom or a methyl group; and
[0033] (3) a vinyl monomer of the formula:
[0000] CH 2 ═CR 5 COO(CH 2 ) n OH (III) or
[0000] CH 2 ═CR 6 COO(CH 2 ) m CHOHCH 2 OH (IIIa)
[0034] wherein R 5 and R 6 is a hydrogen atom or a methyl group, n is 1-4, inclusive and m is 1 or 2.
[0035] The synthetic sizing agent may be any sizing agent that can imparts desired sizing properties. Preferred sizing agents include alkenyl succinic anhydride (ASA) and alkyl ketene dimer (AKD), and alkeno ketene dimer, alkyl isocyanates, and alkyl anhydrides.
[0036] The vinyl monomer (I) may be a quaternary ammonium group-containing vinyl monomer produced by quaternizing a dialkylaminoalkyl ester of acrylic acid or methacrylic acid with an alkyl halide or alkyl sulfate. Specific examples of the vinyl monomer (I) include quaternized products resulting from dimethylaminoethyl acrylate, diethylaminoethyl acrylate, dimethylaminoethyl methacrylate, diethylaminoethyl methacrylate, etc. As the quaternizing agent, there may be exemplified methyl chloride, methyl bromide, methyl iodide, ethyl bromide, etc.
[0037] The vinyl monomer (Ia) may include diallyldimethylammonium chloride.
[0038] The vinyl monomer (II) includes acrylamide and methacrylamide. These monomers are effective in increasing the molecular weight of the resulting polymer due to its high polymerizability. They are also effective in improving the water solubility of the produced polymer.
[0039] The vinyl monomer (III) may include hydroxymethyl (meth)acrylate, 2-hydroxyethyl (meth)acrylate, hydroxyprolyl (meth)acrylate and hydroxybutyl (meth)acrylate.
[0040] The vinyl monomer (IIIa) may include 2,3-dihydroxypropyl (meth)acrylate and 3,4-dihydroxybutyl (meth)acrylate.
[0041] The cationic charge of the cationic polymer ranges from at least 1 to 99 mole %.
[0042] In one embodiment, the cationic polymer has a 2-hydroxyethyl methacrylate ranging from 1 to 30 mole percent. In another embodiment, the cationic polymer has a 2-hydroxyethyl methacrylate ranging from 2 to 20 mole percent. In another embodiment, the cationic polymer has a 2-hydroxyethyl methacrylate ranging from 5 to 10 mole percent.
[0043] Although not required, the cationic polymer can be crosslinked or branched.
[0044] The amphoteric polymer of the invention is generally obtained by copolymerizing:
[0045] (1) a vinyl monomer of the formula:
[0000] CH 2 ═CR 1 —COA(CH 2 ) n N + R 2 R 2 R 3 X − (I)
[0000] or (CH 2 ═CHCH 2 ) 2 N + (R 2 ) 2 X −
[0046] wherein R 1 is a hydrogen atom or a methyl group, A is an oxygen atom or NH group, n is 2 or 3, R 2 and R 3 are each a methyl group or an ethyl group and X is a chlorine atom, a bromine atom, or X − is a methyl sulfate ion; and
[0047] (2) a vinyl monomer of the formula:
[0000] CH 2 ═CR 4 —CONH 2 (II)
[0048] wherein R 4 is a hydrogen atom or a methyl group, and
[0049] (3) a vinyl monomer of the formula:
[0000] CH 2 ═CR 6 COO(CH 2 ) n OH (III)
[0000] or CH 2 ═CR 6 COO(CH 2 ) m CHOHCH 2 OH (IIIa)
[0050] wherein R 5 and R 6 is a hydrogen atom or a methyl group and n is 1 or 4 and m is 1 or 2; and
[0051] (4) an anionic vinyl monomer of the formula:
[0000] CH 2 ═CR 7 COOR 8 (IV)
[0052] wherein R 7 is a hydrogen atom or a methyl group, and R 8 is a hydrogen atom, an alkali metal, ammonium group.
[0053] The anionic vinyl monomer (IV) may include acrylic acid or methacrylic acid.
[0054] The amphoteric polymer preferably has an anionic charge ranging from 0 to 40 mole percent.
[0055] The molecular weight of the cationic polymer or amphoteric polymer varies, depending on the needs at hand. In one embodiment, the cationic polymer or amphoteric polymer has a molecular weight ranging from 10,000 to 3,000,000 daltons average molecular weight. In another embodiment, the cationic polymer or amphoteric polymer has a molecular weight ranging from 100,000 to 2,000,000 daltons average molecular weight. In another embodiment, the cationic polymer or amphoteric polymer has a molecular weight ranging from 100,000 to 1,000,000 daltons average molecular weight. Molecular weights stated herein are weight average.
[0056] The proportion of the vinyl monomers to be copolymerized may be varied depending on the desired properties of the resulting polymer, the kinds of monomers used, the polymerization mode to be adopted, etc. But, the molar proportion of the vinyl monomers (I), (II), (III) and (IV) is usually about 1 to 99:1 to 99:1 to 30:0 to 40, or about 1 to 10:1 to 85:2 to 10:0 to 5
[0057] The copolymerization of the vinyl monomers may be carried out in an aqueous medium in the presence of a catalyst by a per se conventional procedure such as solution polymerization, emulsion polymerization or precipitation polymerization.
[0058] In case of solution polymerization, there may be employed as the reaction medium water, a lower alcohol or their mixture, among which the use of water is particularly preferred. The total concentration of the vinyl monomers in the aqueous medium may be from about 5 to 80% by weight. Depending on the total concentration or composition of the vinyl monomers, the polymer is produced in a form ranging from a fluidizable liquid to a non-fluidizable solid. When the product is a liquid, it may be used as such. When the product is a solid, it may be crushed, if necessary, followed by drying to give a powdery material.
[0059] In use, the invention provides valuable methods. In one embodiment, the invention relates to a method that includes the steps of (a) providing paper stock; (b) adding to the paper stock a composition comprising: (i) synthetic sizing agent, and (ii) a cationic polymer useful as a paper additive obtained by copolymerizing:
[0060] (1) a vinyl monomer of the formula:
[0000] CH 2 ═CR 1 —COA(CH 2 ) n N + R 2 R 2 R 3 X − (I)
[0000] or (CH 2 ═CHCH 2 ) 2 N + (R 2 ) 2 X −
wherein R 1 is a hydrogen atom or a methyl group, A is an oxygen atom or NH group, n is 2 or 3, R 2 and R 3 are each a methyl group or an ethyl group and X is a chlorine atom, a bromine atom, or X − is a methyl sulfate ion; and
[0062] (2) a vinyl monomer of the formula:
[0000] CH 2 ═CR 4 —CONH 2 (II)
wherein R 4 is a hydrogen atom or a methyl group, and
[0064] (3) a vinyl monomer of the formula:
[0000] CH 2 ═CR 5 COO(CH 2 ) n OH (III)
[0000] or CH 2 ═CR 6 COO(CH 2 ) m CHOHCH 2 OH
wherein R 5 and R 6 is a hydrogen atom or a methyl group and n is 1-4, inclusive and m is 1 or 2. (iii) water or starch solution, and
[0066] (c) forming a web from said paper stock, such that the web exhibits an improved sizing efficiency as compared to a web made without the cationic polymer.
[0067] When the amphoteric polymer of the invention is used, the invention provides a method that includes the steps of (a) providing paper stock; (b) adding to the paper stock a composition comprising: (i) a synthetic sizing agent, and (ii) the amphoteric polymer useful as a paper additive, which is obtained by copolymerizing
[0068] (1) a vinyl monomer of the formula:
[0000] CH 2 ═CR 1 —COA(CH2) n N + R 2 R 2 R 3 X − (I)
[0000] Or (CH 2 ═CHCH 2 ) 2 N + (R 2 ) 2 X −
[0069] wherein R 1 is a hydrogen atom or a methyl group, A is an oxygen atom or NH group, n is 2 or 3, R 2 and R 3 are each a methyl group or an ethyl group and X is a chlorine atom, a bromine atom, or X − is a methyl sulfate ion; and
[0070] (2) a vinyl monomer of the formula:
[0000] CH 2 ═CR 4 —CONH 2 (II)
[0071] wherein R 4 is a hydrogen atom or a methyl group, and
[0072] (3) a vinyl monomer of the formula:
[0000] CH 2 ═CR 5 COO(CH 2 ) n OH (III)
[0000] or CH 2 ═CR 6 COO(CH 2 ) m CHOHCH 2 OH (IIIa)
[0073] wherein R 5 and R 6 is a hydrogen atom or a methyl group and n is 1 or 4 and m is 1 or 2.
[0074] (4) an anionic vinyl monomer of the formula:
[0000] CH 2 ═CR 7 COOR 8 (IV)
[0075] wherein R 7 is a hydrogen atom or a methyl group, and R 8 is a hydrogen atom, an alkali metal, ammonium group;
[0076] (iii) water or starch solution, and
[0077] (c) forming a web from said paper stock,
[0000] such that the web exhibits an improved sizing efficiency as compared
to a web made without the amphoteric polymer.
[0078] When a polymer of the invention is added to the surface of paper, the invention provides a method that involves the steps of (a) providing paper stock; (b) forming a web from said paper stock, (c) adding to the web a composition cationic polymer or the amphoteric polymer. Such a polymer is added to the surface of a fibrous substrate by any suitable means, e.g., by size press application, spraying and/or water box application.
[0079] In the embodiment in which the surface of paper is treated, anionic or non-ionic polymers may also be used. In this embodiment, non-ionic polymers are obtained by copolymerizing vinyl monomers of formulae (II) and (III) and/or (IIIa). Anionic polymers can obtained by copolymerizing monomers of formula (II), and (III), and/or (IIIa), and (IV).
[0080] The synthetic sizing agent can be applied in various amounts. For instance, the synthetic sizing agent is generally applied at a dosage ranging from 0.1 kg/metric ton to 10 kg/metric ton, or 0.5 to 5, or from 1 to 4. In one embodiment, the synthetic sizing agent:polymer is added to the paper stock at weight ratios that enable the resulting web to exhibit an improved sizing efficiency as compared to a web made without the cationic polymer. In one embodiment, the synthetic sizing agent:polymer is added at a weight ratio ranging from 1:0.05 to 1:1. In another embodiment, the synthetic sizing agent:polymer is added at a weight ratio ranging from 1:0.1 to 1:0.5. In another embodiment, the synthetic sizing agent:polymer is added at a weight ratio ranging from 1:0.1 to 1:0.2.
[0081] The synthetic sizing agent can also be added in various forms. In one embodiment, the synthetic sizing agent is emulsified with a polymer. In another embodiment, the sizing agent is emulsified with water and surfactants. In another embodiment, the sizing agent is emulsified in starch.
[0082] In one embodiment, for instance, the synthetic sizing agent is added as a sizing emulsion containing a surfactant and the emulsion is prepared under low shear conditions, e.g. those shearing conditions are created by a device selected from the group of centrifugal pumps, static in-line mixers, peristaltic pumps, magnetic stirring bar in a beaker, overhead stirrer, and combinations thereof. In another embodiment, the synthetic sizing agent is added as a sizing emulsion containing surfactant and the emulsion is prepared under high shear conditions.
[0083] Examples of suitable surfactants include but are not limited to alkyl and aryl primary, secondary and tertiary amines and their corresponding quaternary salts, sulfosuccinates, fatty acids, ethoxylated fatty acids, fatty alcohols, ethoxylated fatty alcohols, fatty esters, ethoxylated fatty esters, ethoxylated triglycerides, sulfonated amides, sulfonated amines, ethoxylated polymers, propoxylated polymers or ethoxylated/propoxylated copolymers, polyethylene glycols, phosphate esters, phosphonated fatty acid ethoxylates, phosphonated fatty alcohol ethoxylates, and alkyl and aryl sulfonates and sulfates. Examples of preferred suitable surfactants include but are not limited to amides; ethoxylated polymers, propoxylated polymers or ethoxylated/propoxylated copolymers; fatty alcohols, ethoxylated fatty alcohols, fatty esters, carboxylated alcohol or alkylphenol ethoxylates; carboxylic acids; fatty acids; diphenyl sulfonate derivatives; ethoxylated alcohols; ethoxylated fatty alcohols; ethoxylated alkylphenols; ethoxylated amines; ethoxylated amides; ethoxylated aryl phenols; ethoxylated fatty acids; ethoxylated triglycerides; ethoxylated fatty esters; ethoxylated glycol esters; polyethylene glycols; fatty acid esters; glycerol esters; glycol esters; certain lanolin-based derivatives; monoglycerides, diglycerides and derivatives; olefin sulfonates; phosphate esters; phosphorus organic derivatives; phosphonated fatty acid ethoxylates, phosphonated fatty alcohol ethoxylates; polyethylene glycols; polymeric polysaccharides; propoxylated and ethoxylated fatty acids; alkyl and aryl sulfates and sulfonates; ethoxylated alkylphenols; sulfosuccinamates; sulfosuccinates.
[0084] In one embodiment, the surfactant component includes an amine selected from the group consisting of trialkyl amine of the formula (I):
[0000]
[0000] dimethyl sulfate quaternary salt of trialkyl amine of the formula (I), benzyl chloride quaternary salt of trialkyl amine of the formula (I), and diethyl sulfate quaternary salt of trialkyl amine of the formula (I), in which R1 is methyl or ethyl, R2 is methyl or ethyl, and R3 is alkyl having 14 to 24 carbon atoms. In another embodiment, the surfactant excludes this amine.
[0085] The surfactant levels can range from about 0.1 weight % up to about 20 weight % based on the alkenylsuccinic anhydride component.
[0086] The order in which the synthetic sizing agent is added can vary. In one embodiment, the synthetic sizing agent is added in conjunction with the cationic polymer.
[0087] The sizing efficiency improvement provided by the method can be determined by various methods. For instance, the sizing efficiency: resistance of water to paper increase measurements can be determined by the ink penetration test or the Cobb test.
[0088] The sizing efficiency improvement can range from 10 to 200 percent more, as compared to when the paper is prepared without the polymer.
[0089] The paper made with a method of the invention has favorable qualities. In one embodiment, the paper has a ink penetration ranging from 50 to 1500 seconds. In another embodiment, the paper has a cobb value ranging from 15 to 200 grams/m2
[0090] The invention is further described in the following illustrative examples in which all parts and percentages are by weight unless otherwise indicated.
EXAMPLES
Example 1
Comparative
[0091] A low molecular weight 90/10 mole % acrylamide/[2-(methyl-acryloyloxy)ethyl]trimethylammonium chloride copolymer (AMD/Q6) was prepared by a free radical co-polymerization. The polymerization process was carried out by simultaneous, continuous addition of ammonium persulfate and monomer solutions to a reaction vessel that contained deionized water and chelating agent buffered with malic acid. The monomer solution was prepared by mixing 45.62 parts of 52.96% acrylamide solution, 10.45 parts of 75% Q6 solution, 2.4 parts of 2% sodium hypophosphite solution, and 53.93 parts of deionized water. The pH of the monomer solution was adjusted from 4.14 to 3.78 with a 20% solution of malic acid. The monomer solution was sparged with nitrogen for an hour before addition. The reactor vessel solution was prepared by addition of 278.46 parts of deionized water and 0.27 parts of 40% pentasodium diethylenepentaacetate. The pH of the reactor vessel solution was adjusted from 10.63 to 3.76 with 0.57 parts of 20% malic acid solution. The latter solution was sparged with nitrogen for an hour.
[0092] The initiator solution was prepared by addition of 0.38 parts of ammonium persulfate into 7.87 parts of deionized water. This solution was sparged with nitrogen for half an hour just prior to use. The addition of monomer solution and ammonium persulfate solution to the reactor vessel was carried out over 2.25 hr and 2.5 hr, respectively. The polymerization reaction was performed at 65° C. The reaction solution was maintained under the nitrogen purge throughout the course of reaction.
[0093] The pH of the final product was equal to 3.1, bulk viscosity was equal to 90 cP (measured using Brookfield viscometer model DV-III, #3 spindle, 12 rpm, at 25° C.) and viscosity of a 2% polymer solution was equal to 12 cP (measured using Brookfield viscometer model DV-III, #2 spindle, 30 rpm, at 25° C.). Molecular weight of this polymer (Mw) is equal to 227,000 daltons.
Example 2
[0094] A low molecular weight 90/10/5 mole % acrylamide/[2-(methylacryloyloxy)ethyl]trimethylammonium chloride/2-hydroxyethy methacrylate (AMD/Q6/HEMA) terpolymer was prepared by a free radical co-polymerization. The polymerization process was carried out by simultaneous, continuous addition of ammonium persulfate and monomer solutions to a reaction vessel that contained deionized water and chelating agent buffered with malic acid. The monomer solution was prepared by mixing 41.64 parts of 52.96% acrylamide solution, 10.11 parts of 75% Q6 solution, 2.44 parts of 97% HEMA solution, 2.4 parts of 2% sodium hypophosphite solution, and 55.86 parts of deionized water. The pH of this solution was equal to 3.82. The monomer solution was sparged with nitrogen for an hour before addition. The reactor vessel solution was prepared by mixing 278.27 parts of deionized water and 0.27 parts of 40% pentasodium diethylenepentaacetate. The pH of the reactor vessel solution was adjusted from 10.47 to 3.63 with 0.76 parts of 20% malic acid solution. The latter solution was sparged with nitrogen for an hour just prior to use. The initiator solution was prepared by addition of 0.38 parts of ammonium persulfate into 7.87 parts of deionized water. This solution was sparged with nitrogen for half an hour prior to use. The addition of monomer solution and ammonium persulfate solution to the reactor vessel was carried out over 2.25 hr and 2.5 hr, respectively. The polymerization reaction was performed at 65° C. The reaction solution was maintained under the nitrogen purge throughout the course of reaction.
[0095] The pH of final product was equal to 3.1, bulk viscosity was equal to 70 cP (measured using Brookfield viscometer model DV-III, #3 spindle, 12 rpm, at 25° C.) and viscosity of a 2% polymer solution was equal to 11 cP (measured using Brookfield viscometer model DV-III, #2 spindle, 30 rpm, at 25° C.). Molecular weight of this polymer (Mw) is equal to 257,000 daltons.
Example 3
[0096] Evaluation of polymers from Example 1 and 2 was done by preparation of ASA emulsions with these polymers, characterization of the emulsion particle size distribution (Table 1), addition of these emulsions to the paper slurry, forming paper handsheets and measuring handsheets sizing (Table 2).
[0097] Emulsification of ASA using Polymers
[0098] Alkenyl succinic anhydride (ASA) emulsions were prepared with polymers from example 1 and 2 at a 1/0.1 ASA/polymer ratio. Concentration of ASA during the emulsification was equal to 3.85 wt. %. ASA emulsions were prepared by following procedure:
Solution of each polymer was prepared at 0.4-wt. % concentration on real basis using DI water. 96.15 g of a polymer solution was placed in a small stainless steel blender jar, and the blender was started at a low speed. While mixing, 3.85 g of ASA was added to a polymer solution by the means of plastic syringe. The speed of blender was immediately changed from low to high and the timer was started. The emulsification was carried out for 3 min at a high speed. The emulsion particle size was measured using Particle Size Analyzer Horiba LA 700. A solution of 0.25 wt. % ASA concentration was prepared using deionized water adjusted with dilute hydrochloric acid to pH 3. The emulsion was placed in ice water and immediately used for handsheet preparation.
Handsheet Preparation Process
[0106] Handsheets were prepared using a furnish of a 50/50 mixture of bleached hardwood and softwood kraft pulp refined to a Canadian Standard Freeness of 500 to which 15% by weight of precipitated calcium carbonate was added, and pH was adjusted to 7.8.
[0107] Deionized water was used for furnish preparation, and additional 80 ppm of sodium sulfate and 50 ppm of calcium chloride were added.
[0108] While mixing, a batch of 0.71% solids containing 10 g of cellulose fibers and calcium carbonate was treated with an ASA emulsion. After 60-sec contact time, an anionic retention aid was added and mixing continued for 15 sec. Three 2.8-g sheets of paper were formed using Standard (8″×8″) Nobel & Woods handsheet mold, to target basis weight of 50 lb/Tappi Ream, pressed between felts in the nip of a pneumatic roll press at about 15 psi and dried on the rotary dryer at 240° F. The dose of 31b/T of ASA and 1 lb/T of an anionic retention aid were applied.
[0109] Evaluation of Paper Sizing
[0110] The sizing of handsheets was tested using Bayer Ink Penetration test (BIP).
[0111] The BIP size testing method provides a fully automated application of ink to the under surface of the paper together with automatic measurement of the optical end point. This method uses the same principle as the TAPPI T 530 test but uses an instrument of our design, which provides an automated design and different geometry for light sources and detector. In particular, all steps of the BIP test were performed automatically with this apparatus. On the push of a start button, ink was pumped into a well until the ink contacted the under surface of the paper, determined electronically, and the timing of the ink penetration was obtained from a reflectance measurement and was displayed digitally. Neutral ink buffered to pH 7.0 was used in all BIP testing and was prepared by dissolving 12.5 g of naphthol green B dye in 500 mL of deionized water, and a pH 7 buffer solution was then added to bring the total volume to 1000 mL at 23° C.
[0112] Handsheets were evaluated by the BIP test after a conditioning period of at least one day at 72 F and 50% relative humidity. Three handsheet specimens were tested, with two repetitions on each felt side, for a total of six tests.
[0113] To begin a BIP test, each paper specimen was inserted into the apparatus. A fiber optic source cable provided uniform illumination of the topside of the specimen.
[0114] A detector fiber optic cable viewed the same area of illumination. The initial reflectance of the specimen was determined automatically and stored for reference. The test ink was automatically metered by a metering pump from a reservoir into the bottom of a cone-shaped ink well until the ink contacted the underside of the paper specimen under test, at which time a timer was started electronically. The change in reflectance was periodically monitored automatically and the timer was stopped when a pre-specified percentage decrease in reflectance was reached. This decrease was about 20%, i.e., the specimen retained about 80% of its initial reflectance. The elapsed time of the test was displayed and recorded to the nearest second. Then a drain pump was started automatically and run for a period of time long enough to empty the ink in the well into a waste reservoir. The average test time for the three specimens on the felt side were calculated.
[0000]
TABLE 1
ASA Emulsion Particle Size Distribution
Median
Percent of Particles
Size Under Which
Particle Size
ASA/Polymer
Particle Size
Under 1 micron
Are 90% of
Distribution
Polymer ID
Ratio
(microns)
(%)
Particles (micron)
Graph
Example 1
1/0.1
0.631
72.6
1.771
Normal with
shoulder
Example 2
1/0.1
0.490
95.8
0.835
Normal
[0000]
TABLE 2
Sizing Efficiency of ASA Emulsion
ASA/Polymer
Sizing (sec)
Polymer ID
Polymer Description
Ratio
3 lb/T ASA
Example 1
Low MW Copolymer
1/0.1
146
Example 2
Low MW Terpolymer
1/0.1
290
[0115] In Table 1 it is shown that ASA emulsion prepared with a polymer from Example 2 has smaller median particle size and narrower particle size distribution. In Table 2 it is shown that ASA emulsion prepared with polymer from Example 2 provides higher sizing than ASA emulsion prepared with a polymer from Example 1.
Example 4
[0116] A low molecular weight 90/10/5/4 mole % acrylamide/[2-(methylacryloyloxy)ethyl]trimethylammonium chloride/2-hydroxyethy methacrylate/acrylic acid (AMD/Q6/HEMA/AA) tetrapolymer was prepared by a free radical co-polymerization. The polymerization process was carried out by simultaneous, continuous addition of ammonium persulfate and monomer solutions to a reaction vessel that contained deionized water and chelating agent buffered with malic acid. The monomer solution was prepared by mixing 99.13 parts of 52.96% acrylamide solution, 25.28 parts of 75% Q6 solution, 6.11 parts of 97% HEMA solution, 2.66 parts of 99% acrylic acid solution, 5.0 parts of 4% sodium hypophosphite solution, and 10.32 parts of deionized water. The pH of this solution was equal to 2.12. The monomer solution was sparged with nitrogen for an hour before addition. The reactor vessel solution was prepared by mixing 242.7 parts of deionized water and 0.27 parts of 40% pentasodium diethylenepentaacetate. The pH of the reactor vessel solution was adjusted from 10.69 to 4.53 with 0.28 parts of 20% malic acid solution. The latter solution was sparged with nitrogen for an hour prior to use. The initiator solution was prepared by addition of 0.96 parts of ammonium persulfate into 7.28 parts of deionized water. This solution was sparged with nitrogen for half an hour prior to use. The addition of monomer solution and ammonium persulfate solution to the reactor vessel was carried out over 2.25 hr and 2.5 hr, respectively. The polymerization reaction was performed at 65° C. The reaction solution was maintained under the nitrogen purge throughout the course of reaction.
[0117] The pH of final product was equal to 2.03, bulk viscosity was equal to 2310 cP (measured using Brookfield viscometer model DV-III, #3 spindle, 12 rpm, at 25° C.) and viscosity of a 2% polymer solution was equal to 7.0 cP (measured using Brookfield viscometer model DV-III, #2 spindle, 30 rpm, at 25° C.). Molecular weight of this polymer (Mw) is equal to 212,000 daltons.
Example 5
[0118] ASA emulsions were prepared with polymers from Examples 1, 2 and 4 at a 1/0.2 ASA/polymer ratio. Concentration of ASA during the emulsification was equal to 3.85 wt. %. ASA emulsions were prepared by the procedure described in Example 3 except that 0.8% polymer solution was used for emulsification. Handsheets were made and tested as it was described in Example 3.
[0000]
TABLE 3
ASA Emulsion Particle Size Distribution
Median
Percent of Particles
Size Under Which
Particle Size
ASA/Polymer
Particle Size
Under 1 micron
Are 90% of
Distribution
Polymer ID
Ratio
(microns)
(%)
Particles (micron)
Graph
Example 1
1/0.2
0.589
73.0
2.062
Normal with
(comparative)
shoulder
Example 2
1/0.2
0.509
86.0
1.210
Normal
Example 4
1/0.2
0.550
81.2
1.032
Normal
[0000]
TABLE 4
Sizing Efficiency of ASA Emulsion (Example 1, 2 and 3)
ASA/Polymer
Sizing (sec)
Polymer ID
Polymer Description
Ratio
3 lb/T ASA
Example 1
Low MW Copolymer
1/0.2
440
(comparative)
Example 2
Low MW Terpolymer
1/0.2
560
Example 4
Low MW Tetrapolymer
1/0.2
495
[0119] In Table 3 it is shown that ASA emulsions prepared with a polymer from Example 2 and 4 have smaller median particle size and narrower particle size distribution than ASA emulsion prepared with a polymer from Example 1. Table 4 shows that ASA emulsified with polymers from Example 2 and 4 provides higher sizing than ASA emulsified with a polymer from Example 1.
Example 6
[0120] ASA emulsion is prepared with a polymer from Example 4 at an ASA/polymer ratio of 1/0.2 and 1/1. These emulsions were compared to ASA emulsions prepared with conventional cationic starch at ASA/starch ratios of 1/0.2 and 1/1.
[0121] Emulsions were prepared as described in Example 3, except that a 0.8 wt. % polymer or starch solution was used to make an emulsion at 1/0.2 ASA/emulsifier ratio, and a 4 wt % solution of polymer or starch was used to make an emulsion at 1/1 ASA/emulsifier ratio. Stability of emulsions was checked after 2 hrs.
[0122] Handsheets were made and tested as it was described in Example 3.
[0000]
TABLE 5
ASA Emulsion Particle Size Distribution
Median
Percent of
Size Under
ASA/
Particle
Particles
Which Are
Particle Size
Emulsion
Polymer
Size
Under 1
90% of Particles
Distribution
After
Polymer ID
Ratio
(microns)
micron (%)
(micron)
Graph
2 hr
Example 4
1/0.2
0.599
81.2
1.363
Normal
No change
Example 4
1/1
0.55
89.5
1.032
Normal
No change
Starch
1/0.2
10.498
15.6
19.170
Bimodal
Separated
Starch
1/1
0.614
84.7
1.143
Normal
Agglomerated
[0000]
TABLE 6
Sizing Efficiency of ASA Emulsion (Example 3 and Starch)
ASA/Polymer
Sizing (sec)
Polymer ID
Ratio
3 lb/T ASA
Example 4
1/0.2
495
Example 4
1/1
733
Starch
1/0.2
0
Starch
1/1
1005
[0123] At a 1/0.2 ASA/polymer ratio, ASA emulsion prepared with polymer from Example 4 has small median particle, narrow particle size distribution and is stable for at least two hours. This emulsion provides sizing of paper.
[0124] At the ratio of 1/0.2 ASA/starch, ASA emulsion has large median particle size, bimodal distribution and separates within 30 min. This emulsion doesn't provide sizing.
[0125] At the ratio of 1/1 of ASA/polymer and ASA/starch, ASA emulsions prepared with polymer and with starch have small median particle size and narrow particle size distribution, however ASA/starch emulsion is not useable after 2 hour, while ASA/polymer emulsion is not changed for at least two hours.
[0126] At 1/1 ratio, ASA emulsion prepared with starch outperforms emulsion prepared with polymer.
Example 7
Comparative
[0127] A high molecular weight 90/10 mole % acrylamide/[2-(methylacryloyloxy)ethyl]trimethylammonium chloride copolymer (AMD/Q6) was prepared by a free radical co-polymerization. The polymerization process was carried out by simultaneous, continuous addition of ammonium persulfate and monomer solutions to a reaction vessel that contained deionized water and chelating agent buffered with malic acid. The monomer solution was prepared by mixing 45.62 parts of 52.96% acrylamide solution, 10.45 parts of 75% Q6 solution, and 56.30 parts of deionized water. The pH of the monomer solution was adjusted from 4.1 to 3.7 with 0.08 parts of 20% solution of malic acid. The monomer solution was sparged with nitrogen for an hour prior to addition. The reactor vessel solution was prepared by mixing 278.41 parts of deionized water and 0.27 parts of 40% pentasodium diethylenepentaacetate. The pH of the reactor vessel solution was adjusted from 10.8 to 3.8 with 0.62 parts of 20% malic acid solution. The latter solution was sparged with nitrogen for an hour prior to addition.
[0128] The initiator solution was prepared by addition of 0.22 parts of ammonium persulfate into 8.03 parts of deionized water. This solution was sparged with nitrogen for half an hour prior to use. The addition of monomer solution and ammonium persulfate solution to the reactor vessel was carried out over 2.25 hr and 2.5 hr, respectively. The polymerization reaction was performed at 65° C. The reaction solution was maintained under the nitrogen purge throughout the course of reaction.
[0129] The pH of final product was equal to 3.05, bulk viscosity was equal to 2389 cP (measured using Brookfield viscometer model DV-III, #3 spindle, 12 rpm, at 25° C.) and viscosity of a 2% polymer solution was equal to 62 cP (measured using Brookfield viscometer model DV-III, #2 spindle, 30 rpm, at 25° C.). Molecular weight of this polymer (Mw) is equal to 1,000,000 daltons.
Example 8
[0130] A high molecular weight 90/10/5 mole % acrylamide/[2-(methylacryloyloxy)ethyl]trimethylammonium chloride/2-hydroxyethy methacrylate (AMD/Q6/HEMA) terpolymer was prepared by a free radical copolymerization. The polymerization process was carried out by simultaneous, continuous addition of ammonium persulfate and monomer solutions to a reaction vessel that contained deionized water and chelating agent buffered with malic acid. The monomer solution was prepared by mixing 41.64 parts of 52.96% acrylamide solution, 10.11 parts of 75% Q6 solution, 2.44 parts of 97% HEMA solution, and 58.26 parts of deionized water. The pH of this solution was equal to 3.62. The monomer solution was sparged with nitrogen for an hour before addition. The reactor vessel solution was prepared by mixing 278.30 parts of deionized water and 0.27 parts of 40% pentasodium diethylenepentaacetate. The pH of the reactor vessel solution was adjusted from 10.87 to 3.81 with 0.73 parts of 20% malic acid solution. The latter solution was sparged with nitrogen for an hour prior to use.
[0131] The initiator solution was prepared by addition of 0.26 parts of ammonium persulfate into 7.99 parts of deionized water. This solution was sparged with nitrogen for half an hour prior to use. The addition of monomer solution and ammonium persulfate solution to the reactor vessel was carried out over 2.25 hr and 2.5 hr, respectively. The polymerization reaction was performed at 65° C. The reaction solution was maintained under the nitrogen purge throughout the course of reaction.
[0132] The pH of final product was equal to 3.16, bulk viscosity was equal to 1400 cP (measured using Brookfield viscometer model DV-III, #3 spindle, 12 rpm, at 25° C.) and viscosity of a 2% polymer solution was equal to 50 cP (measured using Brookfield viscometer model DV-III, #2 spindle, 30 rpm, at 25° C.). Molecular weight of this polymer (Mw) is equal to 1,050,000 daltons.
Example 9
[0133] ASA emulsions were prepared with polymers from Examples 7 and 8 at a 1/0.1 ASA/polymer ratio. Concentration of ASA during the emulsification was equal to 3.85 wt. %. ASA emulsions were prepared, and handsheets were made and tested as it was described in Example 3.
[0000]
TABLE 7
ASA Emulsion Particle Size Distribution
Median
Percent of Particles
Size Under Which
ASA/Polymer
Size Particle
Under 1 micron
Are 90% of
Polymer ID
Ratio
(microns)
(%)
Particles (micron)
Example 7
1/0.1
1.192
43.4
2.913
(comparative)
Example 8
1/0.1
0.773
59.8
2.412
[0000]
TABLE 8
Sizing Efficiency of ASA Emulsion
ASA/Polymer
Sizing (sec)
Polymer ID
Polymer Description
Ratio
3 lb/T ASA
Example 7
High MW Copolymer
1/0.1
131
(comparative)
Example 8
High MW Terpolymer
1/0.1
332
[0134] In Table 7 it is shown that an ASA emulsion prepared with the polymer from Example 8 has smaller median particle size than an emulsion prepared with the polymer from
[0135] Example 7. As it is shown in Table 8, sizing obtained with ASA emulsified Example 8 is significantly higher than sizing obtained with ASA emulsified with Example 7.
Example 10
[0136] A high molecular weight 90/10/5 mole % acrylamide/[2-(methylacryloyloxy)ethyl]trimethylammonium chloride/2,3-dihydroxypropyl methacrylate (AMD/Q6/DHPMA) terpolymer was prepared by a free radical co-polymerization. The polymerization process was carried out by simultaneous, continuous addition of ammonium persulfate and monomer solutions to a reaction vessel that contained deionized water and chelating agent buffered with malic acid. The monomer solution was prepared by mixing 40.93 parts of 52.96% acrylamide solution, 9.93 parts of 75% Q6 solution, 2.87 parts of 100% DHPMA, and 58.66 parts of deionized water. The pH of this solution was adjusted from 4.9 to 4.05 with 0.6 parts of 20% malic acid solution. The monomer solution was sparged with nitrogen for an hour before addition. The reactor vessel solution was prepared by mixing 278.65 parts of deionized water and 0.27 parts of 40% pentasodium diethylenepentaacetate. The pH of the reactor vessel solution was adjusted from 10.15 to 3.80 with 0.38 parts of 20% malic acid solution. The latter solution was sparged with nitrogen for an hour prior to addition.
[0137] The initiator solution was prepared by addition of 0.26 parts of ammonium persulfate into 7.99 parts of deionized water. This solution was sparged with nitrogen for half an hour prior to use. The addition of monomer solution and ammonium persulfate solution to the reactor vessel was carried out over 2.25 hr and 2.5 hr, respectively. The polymerization reaction was performed at 65° C. The reaction solution was maintained under the nitrogen purge throughout the course of reaction.
[0138] The pH of final product was equal to 3.16, bulk viscosity was equal to 920 cP (measured using Brookfield viscometer model DV-III, #3 spindle, 12 rpm, at 25° C.), and viscosity of a 2% polymer solution was equal to 39 cP (measured using Brookfield viscometer model DV-III, #2 spindle, 30 rpm, at 25° C.).
Example 11
[0139] ASA emulsions were prepared with polymers from Examples 7, 8 and 10 at a 1/0.1 ASA/polymer ratio. Concentration of ASA during the emulsification was equal to 7.4 wt. %. ASA emulsions were prepared as it was described in Example 3, except that 7.4 grams of ASA was added to 92.6 g of a 0.8 wt % polymer solution. Handsheets were made and tested as it was described in Example 3.
[0000]
TABLE 9
ASA Emulsion Particle Size Distribution
ASA
Median
Percent of Particles
Size Under Which
ASA/Polymer
Concentration
Particle Size
Under 1 micron
Are 90% of
Polymer ID
Ratio
(%)
(microns)
(%)
Particles (micron)
Example 7
1/0.1
7.4
0.909
55
2.153
(comparative)
Example 8
1/0.1
7.4
0.702
66.5
1.990
Example 10
1/0.1
7.4
0.714
65.7
1.942
[0000]
TABLE 10
Sizing Efficiency of ASA Emulsion (Examples 4 and 5)
ASA/Polymer
Sizing (sec)
Polymer ID
Polymer Description
Ratio
3 lb/T ASA
Example 7
High MW Copolymer
1/0.1
206
(comparative)
Example 8
High MW Terpolymer
1/0.1
349
Example 10
High MW Terpolymer
1/0.1
327
[0140] In Table 9 it is shown that ASA emulsions prepared with polymers from Example 8 and 10 have smaller median particle size than the emulsion prepared with the polymer from Example 7. As it is shown in Table 10, sizing obtained with ASA emulsified with polymers from Examples 8 and 10 is significantly higher than sizing obtained with ASA emulsified with the polymer from Example 7.
[0141] Although the present invention has been described in detail with reference to certain preferred versions thereof, other variations are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the versions contained therein.
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The invention relates to polymers useful as a papermaking additives. The invention also relates to methods for making and using such additives.
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BACKGROUND
[0001] 1. Field
[0002] Embodiments relate to a secondary battery.
[0003] 2. Description of the Related Art
[0004] In general, secondary batteries can be charged and discharged, and used repetitively. Secondary batteries are used in such portable electronic devices as mobile phones, laptops, computers, cameras, and camcorders, or used as power sources for driving motors of high-power hybrid electric vehicles, electric vehicles, electric scooters, etc.
[0005] A secondary battery includes an electrode assembly, a case accommodating the electrode assembly, and a cap assembly coupled with an upper portion of the case.
SUMMARY
[0006] Embodiments are therefore directed to a secondary battery, which substantially overcome one or more problems due to the limitations and disadvantages of the related art.
[0007] It is therefore a feature of an embodiment to provide a secondary battery that includes a vent cover to protect a safety vent before the safety vent is in operation.
[0008] It is therefore another feature of an embodiment to provide a secondary battery that allows gas to be discharged when the safety vent is in operation.
[0009] Embodiments may be realized by providing a secondary battery including a case having an interior cavity and an upper opening, an electrode assembly disposed in the interior cavity of the case, a cap assembly, and a vent cover disposed on an outer surface of the cap plate and at least partially covering the safety vent. The cap assembly may include a cap plate and a safety vent formed within the cap plate, the safety vent being thinner than a remainder of the cap plate, and the cap plate coupled with the upper opening of the case. A portion of the vent cover corresponding in position to the position of the safety vent may be thinner than a remaining portion of the vent cover.
[0010] According to some embodiments, the vent cover may include at least one of a groove or notch on a surface of the vent cover facing the safety vent. According to some embodiments, the groove may have a shape that is identical to a shape of the safety vent. According to some embodiments, the groove may include a first groove and a second groove, and the second groove may be intersecting with the first groove. According to some embodiments, the first groove and the second groove may intersect orthogonally. According to some embodiments, the first groove and the second groove may be linear.
[0011] According to some embodiments, the first groove and the second groove are a plurality of dotted lines. According to some embodiments, the groove may include a first groove disposed at a center of the vent cover and a second groove and a third groove which extend from both ends of the first groove toward corners of the vent cover. According to some embodiments, the first groove, the second groove, and the third groove may be linear.
[0012] According to some embodiments, the groove may include a branched groove having a main groove, and first and second V-shaped grooves extending from opposing ends of the main groove. According to some embodiments, the main groove may be in a center of the vent cover and the V-shaped grooves may extend towards corners of the vent cover. According to some embodiments, the groove may be linear.
[0013] According to some embodiments, the notch may include a first notch and a second notch, the first notch and the second notch may be intersecting each other. According to some embodiments, the first notch and the second notch may intersect orthogonally. According to some embodiments, the first notch and the second notch may be a plurality of dotted lines. According to some embodiments, the plurality of notches may include a first plurality of notches arranged in a first line and a second plurality of notches arranged in a second line. The first and second lines may be intersecting. According to some embodiments, the first and second lines may intersect orthogonally.
[0014] According to some embodiments, the notch may include a branched notch having a main notch, and first and second V-shaped notches extending from opposing ends of the main notches. According to some embodiments, the notch may be linear. According to some embodiments, the vent cover may be formed of an insulating material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The above and other features and advantages will become more apparent to those of ordinary skill in the art by describing in detail exemplary embodiments with reference to the attached drawings, in which:
[0016] FIG. 1 illustrates a perspective view of a secondary battery according to an embodiment in a disassembled state;
[0017] FIG. 2 illustrates a perspective view of the secondary battery of FIG. 1 in an assembled state;
[0018] FIG. 3 illustrates a sectional view of a vent cover of the secondary battery of FIG. 2 ;
[0019] FIG. 4 illustrates an enlarged perspective view of the vent cover of the secondary battery of FIG. 2 ;
[0020] FIG. 5A illustrates an enlarged perspective view of a vent cover of a secondary battery according to another embodiment;
[0021] FIG. 5B illustrates an enlarged perspective view of a vent cover of a secondary battery according to another embodiment;
[0022] FIG. 6A illustrates an enlarged perspective view of a vent cover of a secondary battery according to another embodiment;
[0023] FIG. 6B illustrates an enlarged perspective view of a vent cover of a secondary battery according to another embodiment;
[0024] FIG. 7A illustrates an enlarged perspective view of a vent cover of a secondary battery according to another embodiment; and
[0025] FIG. 7B illustrates an enlarged perspective view of a vent cover of a secondary battery according to another embodiment.
DETAILED DESCRIPTION
[0026] Korean Patent Application No. 10-2011-0014658 filed on Feb. 18, 2011, in the Korean Intellectual Property Office, and entitled: “Secondary Battery” is incorporated by reference herein in its entirety.
[0027] Example embodiments will now be described more fully hereinafter with reference to the accompanying drawings; however, they may be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
[0028] In the drawing figures, the dimensions of layers and regions may be exaggerated for clarity of illustration. It will also be understood that when a layer or element is referred to as being “on” another layer or substrate, it can be directly on the other layer or substrate, or intervening layers may also be present. Further, it will be understood that when a layer is referred to as being “under” another layer, it can be directly under, and one or more intervening layers may also be present. In addition, it will also be understood that when a layer is referred to as being “between” two layers, it can be the only layer between the two layers, or one or more intervening layers may also be present. Like reference numerals refer to like elements throughout.
[0029] Hereinafter, embodiments will be described in detail with reference to the accompanying drawings.
[0030] FIG. 1 is a perspective view illustrating a secondary battery according to an embodiment in a disassembled state, and FIG. 2 is a perspective view illustrating the secondary battery of FIG. 1 in an assembled state. FIG. 3 is a sectional view illustrating a vent cover of the secondary battery of FIG. 2 , and FIG. 4 is an enlarged perspective view illustrating the vent cover of the secondary battery of FIG. 2 . Here, FIG. 4 illustrates a state in which a lower surface of the vent cover faces upwards.
[0031] Referring to FIGS. 1 and 2 , a secondary battery 100 of the current embodiment may include an electrode assembly 110 , a case 120 , a cap assembly 130 , an insulating case 140 , and a vent cover 150 .
[0032] The electrode assembly 110 may be a laminate formed by winding or overlapping a first electrode plate 111 , a separator 113 , and a second electrode plate 112 . The first electrode plate 111 , the separator 113 , and the second electrode plate 112 may each be formed as a thin plate or film. In addition, the electrode assembly 110 may include a first electrode tab 114 and a second electrode tab 115 .
[0033] The first electrode plate 111 may include a first electrode collector. The first electrode collector may be formed of aluminum foil. A first electrode active material may be disposed in the first electrode collector. A material such as lithium cobalt oxide may be used as the first electrode active material.
[0034] The second electrode plate 112 may include a second electrode collector formed of copper foil, and a second electrode active material disposed in the second electrode collector. A material such as carbon may be used as the second electrode active material.
[0035] The first electrode plate 111 may be positive electrode, and the second electrode plate 112 may be negative electrode. In addition, the first electrode plate 111 and the second electrode plate 112 may have different polarities.
[0036] The separator 113 may be formed of polyethylene, polypropylene, or a copolymer of polyethylene and polypropylene. The separator 113 may have a larger width than the first electrode plate 111 and the second electrode plate 112 to prevent a short circuit between the electrode plates. According to some embodiments, the separator 113 may have a larger width than the combined widths of the first electrode plate 111 and the second electrode plate 112 . According to some embodiments, the separator 113 may have a larger width than the width of the first electrode plate 111 . According to some embodiments, the separator 113 may have a larger width than the width of the second electrode plate 112 .
[0037] FIG. 1 shows the first electrode tab 114 and the second electrode tab 115 extending out of the first electrode plate 111 and the second electrode plate 112 , respectively. The first electrode tab 114 and the second electrode tab 115 may be disposed in the first electrode plate 111 and the second electrode plate 112 , respectively. The first electrode tab 114 may be pulled to extend out of the first electrode plate 111 . The second electrode tab 115 may be pulled to extend out of the second electrode plate 112 . Insulating tape 116 a may be provided at boundary portions or edge portions of the first electrode plate 111 from which the first electrode tab 114 extends. Insulating tape 116 b may be provided at boundary or portions or edge portions of the second electrode plate 112 from which the second electrode tab 115 extends. Insulating tapes 116 a and 116 b may prevent short circuit between the electrode plates.
[0038] The case 120 may be a metal can. The case 120 may be formed by a processing method such as deep drawing. The case 120 may be formed of such a lightweight conductive metal as aluminum or aluminum alloy. Thus, the case 120 may act as an electrode. According to some embodiments, the case 120 may act as a positive electrode. The case 120 may contain the electrode assembly 110 and an electrolyte. An upper opening of the case 120 , which is configured to receive the electrode assembly 110 , may be sealed with the cap assembly 130 .
[0039] The cap assembly 130 may include a cap plate 131 , a stopper 134 , a safety vent 135 , and an electrode terminal 136 .
[0040] The cap plate 131 may be a metal plate having a size and a shape corresponding to a size and a shape of the upper opening of the case 120 . The cap plate 131 may be coupled with the case 120 by, for example, welding, and may act as a positive electrode like the case 120 . A terminal hole 132 may be disposed at a center of the cap plate 131 . In addition, an electrolyte inlet 133 may be defined in the cap plate 131 proximate a first end of the cap plate 131 .
[0041] The electrolyte may be injected into the case 120 through the electrolyte inlet 133 . The stopper 134 may be configured to seal the electrolyte inlet 133 after the electrolyte is injected into the case 120 . In general, the stopper 134 may be ball-shaped base metal. The metal may be aluminum or a metal containing aluminum. The stopper 134 may be pressed into the electrolyte inlet 133 mechanically, and engage the electrolyte inlet 133 .
[0042] The safety vent 135 may be disposed in the cap plate 131 , proximate a second end of the cap plate, which opposes the first end of the cap plate 131 . The safety vent 135 may further protect the secondary battery 100 by discharging gas when an internal pressure of the secondary battery 100 is larger than a reference pressure, for example, due to overcharge.
[0043] The electrode terminal 136 may pass through the cap plate 131 via the terminal hole 132 . The electrode terminal 136 may be inserted into a tube-shaped gasket 137 prior to insertion in the terminal hole 132 . The tube-shaped gasket may cover or surround at least a portion of an outer surface of the electrode terminal 136 to insulate the electrode terminal 136 and the cap plate 131 . An insulating plate 138 may be disposed on a lower surface of the cap plate 131 , and a terminal plate 139 may be disposed on a lower surface of the insulating plate 138 . A bottom surface of the electrode terminal 136 may be electrically connected to the terminal plate 139 . The electrode terminal 136 may be electrically connected to the second electrode plate 112 of the electrode assembly 110 through the second electrode tab 115 of the electrode assembly 110 . The first electrode plate 111 of the electrode assembly 110 may be electrically connected to the cap plate 131 through the first electrode tab 114 .
[0044] The insulating case 140 may be disposed between the electrode assembly 110 and the cap assembly 130 . The insulating case 140 may prevent an electric short circuit between the electrode assembly 110 and the cap assembly 130 , and may support and/or fix the first electrode tab 114 and the second electrode tab 115 . Therefore, the insulating case 140 may be formed of an insulating material.
[0045] The vent cover 150 may be disposed on an outer surface of the cap plate 131 to cover the safety vent 135 . When, for example, an upper cover using a hot-melting resin is disposed on the cap plate 131 , the vent cover 150 may protect the safety vent 135 from a melting pressure of the hot-melting resin, and may prevent the safety vent 135 from being damaged by the melting pressure. In addition, the vent cover 150 may prevent the safety vent 135 from being damaged by an external force before the safety vent 135 is put into operation.
[0046] Hereinafter, the safety vent 135 and the vent cover 150 are described in more detail. The safety vent 135 may include an indented portion or thinner portion of the cap plate 131 , as shown more clearly in FIG. 3 . The safety vent 135 may be formed by providing a groove in the top surface, bottom surface, or both top and bottom surfaces of the cap plate 131 . The safety vent 135 may be fractured first when the internal pressure of the secondary battery 100 is larger than the reference pressure, to facilitate discharge of gas.
[0047] Referring to FIGS. 3 and 4 , at least a part of the vent cover 150 corresponding to or aligned with the safety vent 135 may be thinner than the rest of the vent cover 150 . According to an embodiment, the vent cover 150 may include a groove 151 disposed on a surface facing the safety vent 135 . The vent cover 150 may protect the safety vent 135 before the safety vent 135 is in operation. When the safety vent 135 is in operation and is fractured, the groove 151 may be fractured to facilitate discharge of gas out of the secondary battery 100 through the vent cover 150 .
[0048] Although the groove 151 is illustrated as having a smaller size than the safety vent 135 , the groove 151 may be bigger than the safety vent 135 . The groove 151 may have a shape identical to a shape of the safety vent 135 and may be disposed at a position corresponding to the safety vent 135 , so that gas may be discharged more efficiently. The vent cover 150 may be formed of an insulating material such as insulating tape.
[0049] As described above, the secondary battery 100 according to an embodiment including the vent cover 150 , may have the groove 151 defined therein, so that at least the part of the vent cover 150 corresponding to the safety vent 135 is thinner than the rest of the vent cover 150 . The vent cover 150 may protect the safety vent 135 before the safety vent 135 is in operation. When the safety vent 135 is in operation and is fractured, the groove 151 may be fractured to facilitate discharge of gas out of the secondary battery 100 through the vent cover 150 . Therefore, the secondary battery 100 according to the embodiment may provide increased stability.
[0050] A secondary battery will now be described according to another embodiment. FIGS. 5A and 5B are enlarged perspective views illustrating another embodiment of a vent cover of the secondary battery, which is designated 250 . FIGS. 5A and 5B illustrate a lower surface of the vent cover 250 facing upwards. The secondary battery may include the vent cover 250 instead of the vent cover 150 , and all other components, as well as the function of the secondary battery, may be as described above for the secondary battery of FIG. 1 . Therefore, the description that immediately follows relates primarily to the vent cover 250 .
[0051] Referring to FIG. 5A , the vent cover 250 may be similar to the vent cover 150 except that the vent cover 150 may have an X-shaped groove 251 instead of the groove 151 . The X-shaped groove 251 of the vent cover 250 may include a first rectangular groove 252 and a second rectangular groove 253 , which intersect each other to form an X shape. Each of the first rectangular groove 252 and the second rectangular groove 253 can have a narrow width. Pressure created by gas that is discharged from the safety vent 135 when the safety vent 135 is in operation and is fractured, may be concentrated on the groove 251 , resulting in fracturing of the vent cover 250 .
[0052] Although FIG. 5A illustrates the vent cover 250 with grooves 251 that have a predetermined width, the vent cover 250 may, instead, be simply configured to include an X-shaped notch 251 a, as shown in FIG. 5B . In other words, the notch 251 a may simply be narrow or be formed without controlling for a predetermined width or depth. In this case, the X-shaped notch 251 a may include a first notch 252 a and a second notch 253 a, which intersect each other to form an X-shape.
[0053] As described above, the secondary battery according to an embodiment having the vent cover 250 , may have an X-shaped groove 251 or an X-shaped notch defined in the vent cover 250 , to facilitate fracturing of the vent cover 250 to discharge gas when the safety vent 135 is in operation and is fractured. Therefore, the secondary battery according to the embodiment may provide increased stability.
[0054] A secondary battery will now be described according to another embodiment. FIGS. 6A and 6B are enlarged perspective views of another embodiment of a vent cover of the secondary battery, which is designated 350 in the figures. Here, FIGS. 6A and 6B illustrates a lower surface of the vent cover, facing upwards. The secondary battery may include the vent cover 350 instead of the vent cover 150 , and all other components, as well as the function of the secondary battery, may be as described above for the secondary battery of FIG. 1 . Therefore, the description that immediately follows relates primarily to the vent cover 350 .
[0055] Referring to FIG. 6A , the vent cover 350 may be similar to the vent cover 150 except that the vent cover 350 may include an X-shaped arrangement of a plurality of grooves 351 instead of the groove 151 . The X-shaped arrangement of a plurality of grooves 351 may include a first plurality of grooves 352 and a second plurality of grooves 353 . The first plurality of grooves 352 may include a first set of individual grooves aligned in a linear fashion with respect to one another. The second plurality of grooves 353 may include a second set of individual grooves aligned in a linear fashion with respect to one another. The first plurality of grooves 352 and the second plurality of grooves 353 may intersect each other to form an X shape. Each individual groove of the first plurality of grooves 352 and the second plurality of grooves 353 can have a narrow width. Pressure created by gas that is discharged from the safety vent 135 when the safety vent 135 is in operation and is fractured, may be concentrated on the groove 351 , resulting in fracturing of the vent cover 350 . Even when the pressure created by the gas discharged from the safety vent 135 is weak, the fracturing of the vent cover 350 may be facilitated. In other words, the reference pressure which is set to put the safety vent 135 into operation is adjustable.
[0056] Although FIG. 6A illustrates the vent cover 350 including the X-shaped arrangement of a plurality of grooves 351 which has a predetermined width, the vent cover 350 may, instead, be simply configured to include an X-shaped arrangement of a plurality of notches 351 a, as shown in FIG. 6B . In this case, the X-shaped arrangement of a plurality of notches 351 a may include a first plurality of notches 352 a and a second plurality of notches 353 a, which intersect each other to form an X-shape.
[0057] As described above, the secondary battery according to an embodiment having the vent cover 350 , may have an X-shaped arrangement of a plurality of grooves, to facilitate fracturing of the vent cover 350 to discharge gas when the safety vent 135 is in operation and is fractured. Even when the pressure created by the gas discharged from the safety vent 135 is weak, the fracturing of the vent cover 350 may be facilitated. Therefore, the secondary battery according to the embodiment may provide increased stability.
[0058] A secondary battery will now be described according to another embodiment. FIGS. 7A and 7B are enlarged perspective views illustrating another embodiment of a vent cover of the secondary battery, which is designated 450 in the figures. Here, FIGS. 7A and 7B illustrate a lower surface of the vent cover 450 , facing upwards. The secondary battery may include the vent cover 450 instead of the vent cover 150 , and all other components, as well as the function of the secondary battery, may be as described above for the secondary battery of FIG. 1 . Therefore, the description that immediately follows relates primarily to the vent cover 450 .
[0059] Referring to FIG. 7A , the vent cover 450 may be similar to the vent cover 150 except that the vent cover 450 may include a branched groove 451 instead of the groove 151 . The branched groove 451 may include a rectangular main groove 452 having first and second opposing ends, a first V-shaped groove 453 extending from the first end toward a first edge of the vent cover 450 , and a second V-shaped groove 454 extending from the second end toward a second, opposing edge of the vent cover 450 . Specifically, the rectangular main groove 452 may extend horizontally across a center of the vent cover 450 . The branched groove 451 may have a narrow width. Pressure created by the gas discharged from the safety vent 135 when the safety vent 135 is in operation and is fractured, may be concentrated on the rectangular main groove 452 , resulting in fracturing of the vent cover 350 . In addition, the first V-shaped groove 453 and the second V-shaped groove 454 may be fractured when the rectangular main groove 454 is fractured, and an area through which the gas of the secondary battery may be discharged may be widened.
[0060] Although FIG. 7A illustrates the vent cover 450 including the branched groove 451 which has a predetermined width, the vent cover 450 may, instead, be simply configured to include a branched notch 451 a, as shown in FIG. 7B . In this case, the branched notch 451 a includes a first V-shaped notch 453 a and a second V-shaped notch 454 a that extend from opposing ends of a rectangular main notch 451 a.
[0061] As described above, the secondary battery according to an embodiment having the vent cover 450 having the branched groove 451 or the branched notch 451 a, may easily discharge gas by facilitating fracturing of the vent cover 450 and by widening the area through which the gas of the secondary battery is discharged when the safety vent 135 is in operation and is fractured. Therefore, the secondary battery according to the embodiment may provide increased stability.
[0062] The secondary battery according to various embodiments, which includes the vent cover having a groove, so that at least the part of the vent cover corresponding to the safety vent is thinner than the rest of the vent cover, may protect the safety vent before the safety vent is put into operation. The secondary battery may easily discharge gas by facilitating the fracturing of the vent cover when the safety vent is in operation and is fractured. Therefore, the secondary battery according to embodiments may provide increased stability.
[0063] Example embodiments have been disclosed herein, and although specific terms are employed, they are used and are to be interpreted in a generic and descriptive sense only and not for purpose of limitation. In some instances, as would be apparent to one of ordinary skill in the art as of the filing of the present application, features, characteristics, and/or elements described in connection with a particular embodiment may be used singly or in combination with features, characteristics, and/or elements described in connection with other embodiments unless otherwise specifically indicated. Accordingly, it will be understood by those of skill in the art that various changes in form and details may be made without departing from the spirit and scope of the present invention as set forth in the following claims.
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A secondary battery includes a case having an interior cavity and an upper opening, an electrode assembly disposed in the interior cavity of the case, a cap assembly, and a vent cover disposed on an outer surface of the cap plate and at least partially covering the safety vent. The cap assembly includes a cap plate and a safety vent formed within the cap plate, the safety vent being thinner than a remainder of the cap plate, and the cap plate coupled with the upper opening of the case. A portion of the vent cover, corresponding in position to the position of the safety vent, is thinner than a remaining portion of the vent cover.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application is related to and claims priority to U.S. provisional Ser. No. 60/325,199 filed on Sep. 28, 2001, which is herein incorporated by reference in its entirety. The present application is also related to International application serial no. PCT/US02/28140, filed on Sep. 25, 2002, which claims priority to U.S. provisional application Ser. No. 60/325,188 filed on Sep. 28, 2001. Those applications are herein incorporated by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates generally to a plasma material processing apparatus and more particularly to apparatus for and method of plasma generation of the induction coupling type in which induction plasma is excited by applying electromagnetic energy to a branching RF antenna.
BACKGROUND OF THE INVENTION
Many types of plasma material processing methods are widely accepted for semiconductor fabrication and plasma generation including: sputter etching, plasma-enhanced chemical etching, reactive ion etching, plasma-enhanced vapor deposition, ionized sputter deposition and magnetically enhanced plasma etching. Different types of well-known plasma sources are used in these processes such as the popular inductively coupled plasma (ICP) sources as well as others including: capacitively coupled plasma (CCP) sources, microwave plasma sources (including those that utilize the electron-cyclotron resonance for improved efficiency of power deposition into the plasma), surface wave plasma sources, and helicon plasma sources. In many sources, radio frequency (RF) power can be applied to a RF antenna such that process gas supplied to the plasma generating space is excited, disassociated and ionized. This excitation occurs due to a radio frequency electromagnetic field formed by RF currents in the antenna generating the plasma.
The inductively coupled plasma source and antenna geometry are significant factors in determining plasma and processing uniformity inside the chamber. The growing demands for processing larger and larger wafers or LCD (liquid crystal display) substrates and providing higher and higher degrees of plasma uniformity challenge the current ICP type antenna designs and push development of sources.
Traditional spiral RF antennas are becoming too long for larger wafers or LCD substrates and cannot generate uniform plasmas. Furthermore, such RF antennas are unable to provide the required plasma homogeneity in both, flat and dome-shaped, geometries. Problems with RF antennas occur due to the lengthening of antenna elements relative to the electromagnetic wave and because of the standing wave effects. The standing wave effects become stronger during increased frequency operation of increased wafer or substrate size, limiting the RF antenna's area of application and reducing uniformity.
In addition, radially extended RF antennas are becoming non-efficient because they are not able to uniformly cover the entire plasma processing area over the substrate. Area coverage reduces outwardly from the endpoint such that there is satisfactory coverage closer to the center of the antenna, but unsatisfactory coverage between any two radially extending “arms” of the antenna.
The dome-type antennas are similarly unable to perform adequately given the increasing size of the plasma area and substrates.
Finally, the antennas wired around the sides of the vacuum chamber are becoming inefficient because they cannot provide adequate RF fields in the inner half of the plasma volume.
What is required is a redesigned RF antenna apparatus and method for generating more uniform plasma coverage over larger areas.
BRIEF SUMMARY OF THE INVENTION
The present invention has been made in consideration of the above-described problems whose appearance in conventional plasma material processing of the RF induction coupling type where induction plasma excitation is created by applying power to a RF antenna. Accordingly, it is an object of the present invention to provide a novel branching RF antenna for use in plasma material processing operations.
It is another object of the present invention to improve the uniformity of plasma generation.
It is still another object of the present invention to reduce standing wave effects for improved plasma material processing.
According to the present invention, there is provided a plasma reactor for generating uniform plasma using an inductively coupled plasma (ICP) source, comprising: a branching radio frequency (RF) antenna coupled to a RF power source for creating an electromagnetic field wherein the electromagnetic field excites process gas in a processing chamber and converts the process gas into plasma; and a window through which the electromagnetic field can penetrate into the plasma reactor.
In addition, there is also provided a method for generating uniform plasma using an inductively coupled plasma (ICP) source, the method comprising the steps of: placing a sample on a work surface; continuously exhausting plasma reactor to pressure-reduced conditions; inputting gas into the plasma reactor; and applying RF power to a branching RF antenna, the branching RF antenna providing a uniform field to the gas in a processing chamber wherein uniform plasma is generated.
In a first aspect of the present invention, the branching RF antenna comprises a plurality of major and minor branches with embedded cooling channels extending from a central feed element. This preferred embodiment provides more homogenous plasma generation and thus more uniform coverage of the plasma area.
The plasma processing system for subjecting a target object to a plasma process comprises a process chamber formed in a process vessel; a gas supply system for supplying a process gas to the process vessel; an exhaust system for exhausting and controlling pressure in the process chamber; a susceptor arranged in the process chamber, the susceptor having a work surface for supporting the target object in the process chamber; and an ICP RF source having a branching antenna for sustaining a large uniform plasma during the plasma process.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention where:
FIG. 1 a is a schematic diagram showing a plasma etching system according to a preferred embodiment of the present invention;
FIG. 1 b is a schematic diagram showing a plasma etching system in accordance with an alternate embodiment of the present invention;
FIG. 1 c is a schematic diagram showing a plasma etching system according to another alternate embodiment of the present invention;
FIG. 2 a illustrates a schematic view of a branching RF antenna in accordance with a preferred embodiment of the present invention;
FIG. 2 b illustrates a schematic view of a branching RF antenna in accordance with an alternate embodiment of the present invention;
FIG. 3 illustrates a simplified view of a second type of branching RF antenna in accordance with an alternate embodiment of the present invention;
FIG. 4 illustrates a simplified view of a third type of branching RF antenna in accordance with an alternate embodiment of the present invention;
FIG. 5 illustrates a simplified view of a fourth type of branching RF antenna in accordance with an alternate embodiment of the present invention;
FIG. 6 illustrates a simplified view of an alternate configuration for the fourth type of branching RF antenna in accordance with an alternate embodiment of the present invention;
FIG. 7 illustrates a simplified view of a first type of branching in accordance with a preferred embodiment of the present invention; and
FIG. 8 illustrates a simplified view of a fifth type of branching RF antenna in accordance with an alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described hereinafter with reference to the accompanying drawings. In the following description, the constituent elements having substantially the same function and arrangement are denoted by the same reference numerals, and repetitive descriptions will be made only when necessary.
FIG. 1 a is a schematic diagram showing a plasma etching system 100 according to a preferred embodiment of the present invention. Plasma etching system 100 comprises an ICP source having a branching antenna.
An airtight process chamber 102 of plasma etching system 100 is constituted by a substantially cylindrical process vessel 104 and top plate 106 . Process vessel 104 and top plate 106 are made of a conductive material, such as stainless steel and are grounded through ground line 108 .
Faraday shield 140 is electrically coupled to the sidewalls of process vessel 104 .
In the illustrated embodiment, Faraday shield 140 comprises a number of conductive elements 145 and spaces 147 arranged in a first pattern. Conductive elements 145 are connected to process vessel 104 via grounding means 148 . In this manner, conductive elements 145 are electrically grounded. Alternately, a dual Faraday shield 140 can be used that consists of at least two layers of conductive elements.
In other embodiments of the present invention, the branching RF antenna can be used without a Faraday shield, and it can be located above the dielectric window, or below the dielectric window, or there can be no dielectric window at all, so the branching RF antenna is located within the processing chamber. Desirably, conductive elements 145 are the same size. Alternately, conductive elements 145 can have different sizes. Also, Faraday shield 140 can be DC biased, or a RF power can be applied to it.
Dielectric window 155 is coupled to process vessel 104 and provides a ceiling for process chamber 102 . Desirably, dielectric window 155 comprises a dielectric material and provides a dielectric window for antenna 110 .
In a preferred embodiment, gas supply line 133 is coupled to the processing chamber 102 to supply processing gas. Gas supply line 133 is coupled to gas source unit 134 through at least one opening/closing valve (not shown) and at least one flow control valve (not shown). The gas source unit 134 has gas sources for a plurality of different gases to be supplied to process chamber 102 , e.g., CF4, C4 F8, CO, O2, Ar, and N2.
In an alternate embodiment, gas supply line 133 is coupled to Faraday shield 140 , which is used to supply processing gas to chamber 102 .
Branching RF antenna 110 is arranged above Faraday shield 140 . In a preferred embodiment, branching RF antenna comprises a plurality of major and minor branches. Preferably, the branching RF antenna branches are equally loaded, an advantage for the RF power source and for design simplicity. Maintaining equal loads, especially in the case of n major branches when each major branch covers an n-th part of the plasma area is desirable. However, the principle of equal loads is not required for the invention. In alternate cases, different loads can be used, and other antenna configurations can be used.
Branching RF antenna 110 is connected through a matching unit 112 and transmission line 113 to RF power supply 114 . Desirably, RF power supply 114 outputs a plasma generating RF power to branching RF antenna 110 and operates in a RF frequency range of 10-1000 MHz. Alternately, a different number of matching units and/or transmission lines can be used.
In alternate embodiments, branching RF antenna 110 can be connected to at least one other RF power supply (not shown), so different branches can be fed by different RF power supplies, possibly with different frequencies.
Susceptor 116 comprises a conductive material and is arranged in the lower portion of the process chamber 102 . Susceptor can be grounded or electrically isolated in the case when RF power is not applied to the susceptor 116 (as in FIG. 1 b ). However, in preferred embodiment ( FIG. 1 a ), the susceptor is under RF potential supplied by a second RF power supply 126 through the corresponding matching network 124 . The RF frequency of the second RF power supply 126 is in the range of 500 kHz-10 MHz. This provides additional biasing potential on the wafer W and improves directionality of charged particle fluxes going from the plasma (not shown) to the wafer W.
The upper surface of the susceptor 116 serves as a wafer-holding surface and an insulating layer 115 made of, e.g., polyimide is adhered to the upper surface. On the insulating layer 115 , a conductive electrostatic chuck electrode 117 and a resistive layer 121 are arranged. The chuck electrode can be prepared by forming a silver or palladium film on the lower surface of the resistive layer. A conductive line (not shown) covered by an insulating cable is provided in the susceptor and connected to the chuck electrode 117 . On the other end, this conductive line is connected to a DC power supply through a switch (not shown).
A gas supplying passage (not shown) is provided through the resistive layer 121 to the rear surface of the wafer W for supplying a heat conductive gas, such as He. Further, there is a plurality of pusher pins, e.g. three, for moving a wafer up and down with respect to the upper surface of the resistive layer.
The susceptor is mounted on the cooling block 119 made of a thermo-conductive material such as aluminum, which carries tubes with circulating coolant such as liquid nitrogen. The cooling block 119 is coupled to the bottom part of the process chamber through an insulating member 118 .
An elevating shaft 120 is movable in the vertical direction by the elevating mechanism (not shown). It is designed to move the entirety of the work table 123 including susceptor 116 , electrostatic chuck 117 , cooling block 119 , as well as the wafer W, in vertical direction, so the distance between the wafer W and the branching RF antenna 110 can be properly adjusted.
Bellows 122 comprises an airtight member. Bellows 122 is coupled to insulating member 118 , surrounds elevating shaft 120 , and is coupled to the bottom surface of process chamber 102 . Hence, even if the susceptor 116 is moved vertically, the airtightness in process chamber 102 is not impaired.
Process chamber 102 is connected to exhaust line 136 of an exhaust system. Exhaust line 136 is connected to exhaust pump 138 through an opening/closing valve and a flow control valve (not shown). Exhaust pump 138 can exhaust process chamber 102 and set process chamber 102 at a vacuum of, e.g., from 10 mTorr to 100 mTorr.
In a preferred embodiment, controller 170 is coupled to first RF power supply 114 , matching network 112 , gas source 134 , exhaust pump 138 , second RF power supply 126 , and second matching network 124 . Controller 170 comprises hardware and software to control the operation of first RF power supply 114 , matching network 112 , second RF power supply 126 , second matching network 124 , gas source 134 , and exhaust pump 138 . For example, controller 170 can control the frequency, phase, amplitude, and bias of the signals provided by the RF power supply. In addition, controller 170 can control process gas and flow rate to the process chamber 102 . Also controller 170 can control the temperature of Faraday shield 140 , branching RF antenna 110 , and the wafer W by controlling the flow of fluids through cooling channels (not shown).
In plasma etching system 100 shown in FIG. 1 a , a process is performed as follows. First, wafer W is placed on the worktable 123 arranged in process chamber 102 . Subsequently, process chamber 102 is exhausted by the exhaust system connected to process chamber 102 , thereby setting the entire interior of process chamber 102 to a predetermined pressure-reduced atmosphere.
Worktable 123 with wafer W is moved vertically to the working position, so the distance between the wafer W and the branching RF antenna is set to predetermined value defined by the process.
While process chamber 102 is continuously exhausted, a process gas is supplied from process gas supply system 134 to process chamber 102 . In a preferred embodiment, the process gas is provided from gas supply system to at least one gas supply pipe, and from the at least one gas supply pipe to process chamber 102 . In alternate embodiment, the processing gas is supplied to the Faraday shield; it then enters process chamber 102 from Faraday shield 140 through gas supply holes (not shown in FIG. 1 ).
In this state, plasma generating RF power is provided to branching RF antenna 110 so that the process gas supplied to process chamber 102 is excited, dissociated, and ionized, thereby generating a uniform wide-area plasma.
In order to prevent Faraday shield 140 from being inductively heated, and to effectively use the input energy from branching RF antenna 110 for generating the plasma, no electric current passageway should be formed in any direction, which is the same as that of an RF electric field. For example, a branching RF antenna 110 may be formed using an almost radial configuration of elements and arranged to have a geometric center aligning with that of wafer W. In such a case, the RF electric field generated by branching RF antenna 110 has an electric field direction which is also mostly in the radial direction. For this reason, a corresponding Faraday shield 140 would be provided with a number of slots, which are arranged concentrically, so the conductive elements in the Faraday shield have mostly azimuthal direction. In other words, slots 147 extend in directions that are substantially perpendicular to the direction of the RF electric field generated by branching RF antenna 110 . With this arrangement, the electromagnetic field generated by branching RF antenna 110 is transmitted into process chamber 102 without being cut off, so that the RF electric field is generated in process chamber 102 , while capacitive component is considerably reduced. As a result, the input energy from branching RF antenna 110 is effectively used for generating the plasma.
In alternate embodiments, top plate 106 is not required. For example, the process chamber can be formed using a dielectric window, isolation layer, branching RF antenna, and/or gas dispensing apparatus.
FIG. 1 b is a schematic diagram showing a plasma etching system according to an alternate embodiment of the present invention. FIG. 1 b illustrates a plasma etching system in which a RF power supply system is not coupled to the susceptor.
FIG. 1 c is a schematic diagram showing a plasma etching system according to another alternate embodiment of the present invention. FIG. 1 c includes all the features described for the apparatus of FIG. 1 a . FIG. 1 c ., however, illustrates a different geometry for the branching RF antenna, and in the illustrated embodiment, geometry of the dielectric window and the Faraday shield is not flat, but curved. The curvature and configuration of the RF antenna is designed such that a uniform plasma is provided at the surface of wafer W.
FIG. 2 illustrates a simplified view of a branching RF antenna in accordance with a preferred embodiment of the present invention. FIG. 2 a illustrates a branching RF antenna with cooling channels in all branches, in accordance with a preferred embodiment of the present invention. FIG. 2 b illustrates a branching RF antenna with cooling channels in some branches, in accordance with an alternate embodiment of the present invention.
Branching RF antenna 200 comprises a plurality of major branches 208 and a plurality of minor branches 210 . Each major branch comprises a first number of branches that extend radially from central feed elements 202 in substantially the same direction to branching point 214 . Desirably, each branch in a major branch lies in a different plane, but all of the branches in a major branch have the same projection on the plane parallel to the substrate. For example, the branches in a major branch can be electromagnetically coupled and/or electrically coupled to each other but not physically coupled to each other.
At branching point 214 , at least one minor branch 210 is coupled to each major branch. Each minor branch extends from branching point 214 in a different direction. Desirably, a substantial portion of each minor branch lies in the same plane. As shown in FIG. 2 , three minor branches are coupled to each major branch at the branching point, but this is not required for the invention. In alternate embodiments, at least two minor branches are coupled at one or more branching points to each major branch.
In preferred embodiment, branching RF antenna of FIG. 2 a is powered by RF power supply 114 ( FIG. 1 ) through the matching network 12 at the center 202 and is grounded at the outer points 206 on antenna periphery. This provides RF current through major branches 208 and minor branches 210 . Desirably, each branch in a major branch is independently coupled to central feed elements 202 .
In alternate embodiment, the outer points 206 are connected to the ground through capacitors (not shown).
Major branches 208 have symmetrical geometry and loading for significantly simplifying antenna tuning and ensuring more homogeneous plasma generation. Each major branch 208 covers different azimuthal area.
In alternate embodiments, a different number of major branches 208 and/or a different number of minor branches can be used.
In a preferred embodiment, antenna 200 has cooling channels 212 extending through all its branches. For high RF power, cooling channels 212 can be provided in both major and minor branches 208 and 210 . However, an absence of cooling channels 212 in some minor branches 210 ( FIG. 2 b ) can be tolerated when using moderate RF power, relying on minor branches 210 cooling via the high thermo-conductivity of the metal parts of the antenna 200 and proximity of minor branches 210 to other cooled branches.
In an alternative embodiment, branching RF antenna 200 can be placed on a dome-shaped or other non-flat surface. For a dome-shaped, the common center of all the major branches is located at the center of the dome (center of symmetry). For a stepped surface, the common center of all the major branches can be located at the center of the topmost step.
In an alternative embodiment, the branches of any branching RF antenna can be powered at the antenna periphery and grounded at the common center. However, this embodiment can complicate construction due to the increased number of points requiring connection to the power source.
In another embodiment, the major branches can be powered by different RF sources. Also, the major branches can be powered by RF with different phases and/or different frequencies.
Major and minor branches are fabricated using a metal such as anodized aluminum. For example, antenna branches can have a single conductive surface that can be fabricated using a metal such as anodized aluminum. Antenna branches 208 , 210 can be fabricated differently for the different antenna configurations.
As shown in FIG. 2 , the coupling angle between the minor branches and the major branches is less than ninety degrees, but this is not required for the invention. In alternate embodiments, these coupling angles can be equal to and/or greater than ninety degrees.
As shown in FIG. 2 , each major branch comprises one branching point, but this is not required for the invention. In alternate embodiments, at least one major branch can comprise more than one branching point.
FIG. 3 illustrates a simplified view of a second type of branching RF antenna in accordance with an alternate embodiment of the present invention. FIG. 3 is a simplified view showing a branching RF antenna in accordance with a preferred embodiment of the present invention. FIG. 3 illustrates a branching RF antenna with cooling channels in all branches.
Branching RF antenna 300 comprises a plurality of major 308 branches and a plurality of curved minor branches 310 . Each major branch comprises a first number of branches that extend radially from central feed elements 302 in substantially the same direction to branching point 314 . Desirably, each branch in a major branch lies in a different plane, but all of the branches in a major branch have the same projection on the plane parallel to the substrate. For example, the branches in a major branch can be electromagnetically coupled and/or electrically coupled to each other but not physically coupled to each other.
At branching point 314 , at least two curved minor branches 310 are coupled to each major branch. Each curved minor branch extends from branching point 314 in a different direction. Desirably, a substantial portion of each curved minor branch 310 lies in the same plane, and curved minor branches 310 have the same projection on the plane parallel to the substrate. As shown in FIG. 3 , two curved minor branches 310 are coupled to each major branch 308 at branching point 314 , but this is not required for the invention. In alternate embodiments, at least two minor branches are coupled at one or more branching points to each branch of the major branch.
Desirably, branching RF antenna 300 is powered by RF power supply 114 ( FIG. 1 ) through the matching network 112 at central feed elements 302 and is grounded at the outer points 306 . This provides RF current through major branches 308 and minor branches 310 . Each branch in a major branch can be independently coupled to central feed elements 302 . In other embodiments, the outer points 306 are connected to the ground through capacitors (not shown).
Major branches 308 have symmetrical geometry and loading for significantly simplifying antenna tuning and ensuring more homogeneous plasma generation. Each major branch 308 covers different azimuthal area.
In alternate embodiments, a different number of major branches 308 and/or a different number of minor branches can be used.
In the illustrated embodiment, antenna 300 has cooling channels 312 extending through all its branches. For high RF power, cooling channels 312 can be provided in both major and minor branches 308 and 310 . However, an absence of cooling channels 312 in minor branches 310 ( FIG. 4 ) can be tolerated when using moderate RF power, relying on minor branches 310 cooling via the high thermo-conductivity of the metal parts of the antenna 300 and proximity of minor branches 310 to other cooled branches.
In an alternative embodiment, branching RF antenna 300 can be placed on a dome-shaped or other non-flat surface. For a dome-shaped, the common center of all the major branches is located at the center of the dome (center of symmetry). For a stepped surface, the common center of all the major branches can be located at the center of the topmost step.
In another embodiment, the major branches can be powered by different RF sources. Also, the major branches can be powered by different phases and/or different frequencies.
In another embodiment, branching RF antenna 300 comprises a plurality of coplanar major branches 308 extending radially from central feed element 302 and a plurality of coplanar curved minor branches 310 . In this example, branching occurs in the plane of branching RF antenna 300 or on the same surface.
The decreased number of end points 306 simplifies construction of the antenna 300 . Preferably, all curved branching elements 310 have symmetrical geometry and loads to significantly simplify antenna tuning and ensure more homogeneous plasma generation. However, alternative embodiments need not require symmetry.
In alternative embodiments, similar to description of branching antenna of FIG. 2 , the RF power feed can be arranged going to the end points 306 , while the center point 302 is grounded. In yet other alternative embodiments the grounding connecting can be arranged through capacitors (not shown).
Branching RF antenna 300 shown in FIG. 3 can be adjusted to a dome-shape or other non-flat surface.
FIG. 4 illustrates a simplified view of a third branching RF antenna in accordance with an alternate embodiment of the present invention.
Branching RF antenna 400 comprises a plurality of major branches 408 and a plurality of minor 410 branches. Major branches 408 are coplanar and extend radially from central feed element 402 . Each major branch 408 comprises branching point 414 . A number of minor branches 410 are coupled to the branching point 414 of each major branch 408 . In addition, central feed element 402 can also be coupled to transmission line 113 (FIG. 1 ).
In the illustrated embodiment, branching RF antenna 400 has eight major branches 408 , which provide a common geometrical center. Each major branch 408 begins from central feed element 402 and extends radially. Branching point 414 is located a first length 424 from central feed element 402 . Major branches 408 have symmetrical geometry and loading for significantly simplifying antenna tuning and ensuring more homogeneous plasma generation. Each major branch 408 covers different azimuthal area.
In the illustrated embodiment, three minor branches 410 extend from each branching point 414 . Minor branch length 426 is the distance from branching point 414 to grounded outer point 406 on antenna periphery 404 . Along antenna periphery 404 , each minor branch 410 has distinct endpoint 406 . Moderate differences in the geometry and loads of minor branches 410 can be tolerated in this preferred embodiment.
In other alternate embodiments, a different number of major branches 408 and/or a different number of minor branches can be used.
In addition, branching RF antenna 400 can comprise cooling channels 412 that can extend through one or more major branches 408 . For high RF power, cooling channels 412 can be provided in both major and minor branches 408 and 410 .
In the illustrated embodiment, the flat coplanar branching RF antenna 400 provides a more uniform covering of a larger area thus providing a more homogenous plasma generation as required for larger substrates.
In another alternative embodiment, however, branching RF antenna 400 can be placed on a dome-shaped or other non-flat surface, rather than the preferred flat surface. For a dome-shaped, the common center of all the major branches is located at the center of the dome (center of symmetry). For a stepped surface, the common center of all the major branches can be located at the center of the topmost step.
FIG. 5 illustrates a simplified view of a fourth type of branching RF antenna in accordance with an alternate embodiment of the present invention.
Branching RF antenna 500 comprises a plurality of major branches 508 and a plurality of minor 510 branches. Major branches 508 are coplanar and extend radially from central feed. Each major branch 508 comprises branching point 514 . A number of minor branches 510 are coupled to the branching point 514 of each major branch 508 . Central feed element 502 is coupled to transmission line 113 (FIG. 1 ), and the ends 506 on the periphery are grounded.
In the illustrated embodiment, branching RF antenna 500 has three major branches 508 , which provide a common geometrical center. Each major branch 508 begins from central feed element 502 and extends mainly radially. Major branches 508 have symmetrical loading for significantly simplifying antenna tuning and ensuring more homogeneous plasma generation. Each major branch 508 covers different azimuthal area.
In the illustrated embodiment, three minor branches 510 extend from each branching point 514 . Along antenna periphery 504 , each minor branch 510 has distinct endpoints 506 . Moderate differences in the geometry and loads of minor branches 510 can be tolerated in this preferred embodiment.
In other alternate embodiments, a different number of major branches 508 and/or a different number of minor branches can be used.
In addition, branching RF antenna 500 can comprise cooling channels that can extend through major branches 508 and some of minor branches 510 . For high RF power, cooling channels can be provided in both major and minor branches 508 and 510 .
In the illustrated embodiment, the flat coplanar branching RF antenna 500 provides a more uniform covering of a larger area thus providing a more homogenous plasma generation as required for larger substrates.
In another alternative embodiment, however, branching RF antenna 500 can be placed on a dome-shaped or other non-flat surface, rather than the preferred flat surface. For a dome-shaped, the common center of all the major branches is located at the center of the dome (center of symmetry). For a stepped surface, the common center of all the major branches can be located at the center of the topmost step.
FIG. 6 illustrates an alternate configuration for the fourth type of branching RF antenna in accordance with an alternate embodiment of the present invention. As illustrated, there are not visible break points shown between the major and minor branches, and the projections on the wafer plane are not combined into single major branches, but there is still significant grouping of branches.
Near the common center 602 the antenna branches are significantly grouped (in the case illustrated in FIG. 6 , there are three groups 608 of branches, corresponding to major branches 508 of FIG. 5 ). In the outer area, the antenna branches 610 go further from each other, similar to the minor branches 510 in FIG. 5 .
All branches are fed at the center 602 and grounded at the end points 606 in the periphery 604 . Alternately, the antenna branches can be fed at the end points 606 and grounded at the common center 602 . Yet alternately, the electrical grounding can be arranged through capacitors (not shown). Cooling channels (not shown) can go through the antenna branches.
In the illustrated embodiment, the flat coplanar branching RF antenna 600 provides a more uniform covering of a larger area thus providing a more homogenous plasma generation as required for larger substrates.
In another alternative embodiment, however, branching RF antenna 600 can be placed on a dome-shaped or other non-flat surface, rather than the preferred flat surface. For a dome-shaped, the common center of all the major branches is located at the center of the dome (center of symmetry). For a stepped surface, the common center of all the major branches can be located at the center of the topmost step.
FIG. 7 illustrates a simplified view of a first type of branching in accordance with a preferred embodiment of the present invention. Each major branch 708 consists of a few branches having the same (or close to be the same) projections on the wafer surface. At the branching point 714 , the branches split off each other, thus forming the plurality of minor branches 710 . The cooling channels 712 can go through the antenna branches to ensure acceptable temperature regime for the antenna.
The present invention allows several types of antenna branching to be considered. The preferred type of branching corresponds to the case ( FIG. 7 ) when the projection of the antenna's field on the plane of the wafer looks like a major branch is branching (i.e. when the minor branches split off the major branches). Actually, each major branch consists of a few branches (see, FIG. 7 ); it is just their projection on the wafer plane looks like it is almost a single major branch. This provides more uniform electromagnetic (EM) field above the wafer and, respectively, more uniform plasma generation throughout the whole area of the wafer both near the wafer center and closer to its periphery.
An alternate type of branching is coplanar branching, where the major and minor branches of the antenna lie substantially in the same plane.
In addition, modifications to the branching principle are allowed. For example, when the projections on the wafer plane are not exactly combined into single major branches, but still there is significant grouping of branches (see, FIG. 6 , as compared with FIG. 5 ), are covered under the present invention as well.
Another type of branching is illustrated in FIG. 8 . In this case, the full length of antenna (such, for example, as the flat spiral antenna) is divided into a few branches, so the electrical length of each branch is short enough to avoid standing wave effects). The principle of equal (or close to equal) electric load of each branch is beneficial in most usual situations and is chosen as a preferred embodiment, as the antenna tuning and uniform plasma generation would be most easily supported.
Still, there might be cases when one would prefer a non-uniform plasma generation (e.g., higher plasma generation rate at the wafer periphery). In that case, the principle of equal load for the branches might not be applicable.
FIG. 8 illustrates a simplified view of a fifth type of branching RF antenna and second type of branching significantly different from those presented in FIGS. 2-6 , in accordance with embodiments of the present invention. Branching RF antenna 800 comprises a plurality of branches 810 , 820 and 830 each branch is a part of a planar spiral. Each branch 810 , 820 and 830 has a different radial area Branches 810 , 820 and 830 are fed at the first ends, i.e. 812 , 822 and 832 , respectively, while the other ends, 814 , 824 and 834 are electrically grounded. In addition, a single RF power generator can power all branches or different RF power generators (with the same or different RF frequencies, phases or amplitudes) can power different branches. The powered and grounded ends of each branch can be switched, which would exchange powered and grounded ends.
In the illustrated embodiment, outer branch 830 comprises a single turn; middle branch 820 comprises about one and a half turns; and inner branch 810 comprises about two turns. A turn is a single revolution of the negative or positive direction. Alternatively, branches 810 , 820 , and 830 can have different numbers of turns. Outer branch 830 has a first end 832 and second end 834 . Middle branch 820 has a first end 822 and second end 824 . Inner branch 810 has first end 812 and second end 814 . To obtain equal loads, a preferred configuration for antenna 800 should have a different number of turns for each branch with inner branch 810 having the highest number of turns.
Furthermore, in cases when the load for the branches differ due to the radial dependence of certain processes as well as the rate of plasma and gas diffusion, different matching networks and/or RF sources can drive the different branches. The specific tuning of the antenna branch parameters are needed to compensate for the radial dependence of processes thus providing a radially independent plasma density profile. When the generation of radially non-uniform plasma is required in special circumstances, the embodiment shown in FIG. 8 can be conveniently applied.
The surface of branching RF antenna 800 shown in FIG. 8 can be flat, but such an antenna can also be adjusted to the dome-shape or other non-flat surface.
The present invention can be effectively applied to plasma processing apparatus such as an etching apparatus. The present invention can also be applied to a plasma processing apparatus other than an etching apparatus, e.g., a film-forming apparatus or an ashing apparatus. The present invention can also be applied to a plasma processing apparatus for a target object other than a semiconductor wafer, e.g., an LCD glass substrate. Additional advantages and modifications will readily occurs to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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The inductively coupled plasma source and antenna geometry are significant factors in determining plasma and process uniformity inside the chamber. Growing demands for processing larger and larger wafers or LCD substrates and providing higher and higher degrees of plasma uniformity challenge the current ICP type antenna designs and push development of sources. Branching RF antenna, featuring a plurality of major and minor branches, provides improved coverage of processing area, reduced standing wave effect, improved uniformity of inductively coupled electromagnetic field, more uniform plasma production, and more homogeneous processing conditions throughout the whole processing area.
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BACKGROUND OF THE INVENTION
The invention relates to a training device, especially for downhill skiers learning and practicing wedeln and as well as short turns such a slalom turns as well as wider turns with parallel skis including also intermittent downhill skiing between turns.
In alpine skiing the skier changes direction by means of wide or short so called "parallel ski turns". The velocity of the skier depends on the angle of the slope in view of the fact that the skier does not ski straight downhill but traverses the slope diagonally and turns from one diagonal direction to an opposite diagonal direction by means of the so called "parallel ski turns" which differ from so called "stem turns". In wedel skiing the velocity of the skier can also be predetermined in relation to the slope, whereby the short turns follow each other more rapidly along a wave line. The wedeln motion and the turns are effected by the skier by shifting the center of gravity and the turning of the body of the skier. The learning and controlling of these rhythmic movements are some of the most difficult skills for a skier to acquire. It is particularly difficult to learn to maintain your equilibrium during the turning motion, which turning motions must be introduced by a small jump in order to maneuver the skier's parallel skis into a new direction. Such movements could heretofore only be carried out on a real ski slope. Since such wedeln requires a large number of rapid rhythmic movements this type of skiing is particularly difficult to learn for the average weekend skier who only has a few hours of skiing available to him on occasional weekends.
There are already known a number of training devices for learning how to ski. One of these known training devices includes a number of elastic planks which swing in a parallel plane by means of which ski turns can be learned. However, such a training device does not require the person using the training device to actually use centrifugal forces when training on the device so that the training effect on such a device is limited to hip movements without thereby sufficiently training the person using the device in maintaining his or her equilibrium.
In order to train a person to maintain his or her equilibrium under the influence of centrifugal forces, while learning how to effect parallel turn skiing, there has already been proposed to position a skier within the periphery of a rotating disk and, by shifting his or her center of gravity, to compensate for the centrifugal forces generated by the movements of his or her body. With such a known training device the skier can also assume various crouching positions to train for such skiing motions. In view of the fact that the use of this training device does not involve changing directions and the skier does continuously turn with the disc, the exercise and training effect of this known training device are also limited.
SUMMARY OF THE INVENTION
The object of the invention is to provide a training device which is particularly adapted for learning and for training parallel turn skiing which device simulates skiing conditions more realistically as the prior art devices have been able to simulate heretofore.
Based on this object, it is proposed to provide a training device which includes at least two operatively connected oppositely rotatable disks having slightly domed shapes in cross-section for supporting at least one skier who shifts position from one to the other disk to simulate the wedeln or parallel ski turning motions. The wedeln motions are effected tangentially from one disc to the other. The wedeln is introduced by the skier at the right moment carrying out a small jumping motion, whereby he leaves the disc on which he supports himself or herself in a tangential direction, and, if the wedeln movements are correctly carried out, lands on the other disc in a tangential direction as well. These motions of the human body correspond closely to the transitional body movements when wedel skiing along of one arc on the ski slope during wedeln to an other oppositely curved arc on the ski slope. The skier must, during his dwell time on one rotating disc, compensate for the centrifugal forces engendered by the shifting of his center of gravity, and then must assume an essentially erect position during the jump, and, at the moment of landing on the oppositely rotating adjacent disc, carry out a shift of his center of gravity in the opposite direction. In the event the training device includes only two adjacent discs, the skier carries out on one disc almost a complete revolution before he or she shifts again to the other adjacent disc.
In order to enable beginners to also use the training device an adjustable driving mechanism for regulating the rotational speed of the discs can be provided. The training device can therefore be adjusted in a stepless manner to rotate at a slower speed for beginners and at gradually higher speeds for more advanced or expert skiers. In a further embodiment of the invention the angle and conditions of the actual ski slope can be simulated by providing the training device with a mechanism for adjustably inclining the planes of the rotating discs relative to each other or to a ground plane of reference. In this way the slope, undulations of the ground and ground depressions can be simulated.
For the wedeln training exercise the circumferential peripheries of the pair of oppositely rotating discs are arranged so as to be in contact with each other or in close proximity to each other. The surfaces of the pair of oppositely rotating discs can be mounted at a short distance from each other and the space there between can be formed by a platform which is covered by a gliding or rolling surface material. In such an embodiment the skier does not jump directly from one disc to the other adjacent disc, but jumps first onto the platform having the gliding surface which is disposed between the pair of discs and glides or rolls over this surface in a tangential direction relative to the rotating disc and jumps at the right moment onto the adjacent oppositely rotating disc. In such an embodiment the body of the skier remains, during the gliding or rolling motion over the surface material of the platform, in an attitude in which the center of gravity is positioned over the feet of the skier and only shifts the center of gravity again when he or she has reached the second oppositely rotating disc. This exercise corresponds to the movements of a skier traversing short or wide parallel ski turns along a path which is diagonal to the ski slope.
The discs can be driven at different rotational speeds and can also have different diameters in order to train for short or wide parallel ski turns.
In order to also simulate the so called mogels on a ski slope there can be provided a mechanism for shifting periodically the vertical position of each disc.
In order to facilitate the transfer from one to an other closely mounted disc and to include the use of the usual ski poles there can be mounted between the pair of discs a pair of elastic ski poles. This pair of ski poles is mounted on the platform located between the pair of discs in such a way that the ski poles can be briefly gripped by the skier at the moment the skier jumps from one disc to the adjacent disc.
In order to prevent any injuries to a beginner learning how to ski on the device of this invention the skier who loses his balance may be connected to a tether which permits complete freedom of movement but prevents a crash landing of the skier by braking his fall with the tether.
It is also possible, of course, to provide, instead or in addition to a tether, a safety fence or a cushioned area around the training device. Instead of the cushioned area the entire device can be mounted in a swimming pool so that the skier when falling off the device simply falls into the swimming pool.
In order to simulate in particular the wedeln exercise, a larger number of discs, for example eight or ten discs can be mounted in a row, one behind the other, each disc of the row of discs rotates in an opposite direction relative to the adjacent disc and the row of discs is mounted on an inclined surface. Such an arrangement simulates in addition to the wedeln a forward ski movement over an extended track.
In order to intensify the downhill wedeln effect the angle of the ski slope can be adjusted (i.e. increased) by mounting the entire arrangement on an inclined support the angle of inclination of which can be adjusted by a suitable mechanism.
If spatial conditions permit it three, four or a larger plurality of rotatable discs can be mounted in triangular, square, etc. arrangements.
In order to simulate slalom skiing conditions a slalom flag pole can be elastically mounted on each the rotating disc at a predetermined distance from its axis of rotation.
The training device of this invention can not only be used as a training device for learning alpine skiing , but also as a fitness training device for rehabilitating persons suffering from equilibrium maintenance problems and also as a recreational device in amusement parks or can be installed and used at a fair.
BRIEF DESCRIPTION OF THE DRAWING
With these and other objects in view, which will become apparent in the following detailed description the present invention, which is shown by example only, will be clearly understood in connection with the accompanying drawing, in which:
FIG. 1 illustrates schematically a wedeln ski track with wherein the turning points are indicated;
FIG. 2 illustrates schematically a longer more gradual ski track in which the turning points are also illustrated;
FIG. 3 is a cross-sectional view through the training device of this invention;
FIG. 4 is a plan view of the training device as illustrated in FIG. 3;
FIG. 5 is a plan view of a second embodiment of the training device of this invention in which the pair of oppositely rotating discs are mounted at a greater distance from each other;
FIG. 6 is a side elevational view of a third embodiment of a training device in accordance with this invention in which a plurality of discs are mounted in a row on an support the angle of inclination of which is adjustable;
FIG. 7 is a plan view of fourth embodiment of training device in accordance with the invention in which four rotatable discs are mounted along a square on a support:
FIG. 8 is a cross-sectional view of a rotatable disc of the training device of the invention;
FIG. 9 is a cross-sectional schematic view of a fifth embodiment of the invention wherein the training device is mounted in a swimming pool;
FIG. 10 is a plan view of the training device illustrated in FIG. 9;
FIG. 11a is schematic view in perspective of a sixth embodiment of the invention in which a slalom flag pole is elastically mounted on each rotating disc of a pair of oppositely rotating discs and a ski pole is mounted on the stationary support platform there between;
FIG. 11b is a schematic view in perspective of the device shown in FIG. 11a in which a skier, connected to a tether, is shown using the training device; and
FIG. 11c is a schematic plan view showing the relationship of the position of the flagpole on the rotating disc when being contacted by the skier and the angle of rotation which is being traversed by the rotating disc thereafter before the skier jumps on the adjacent oppositely rotating disc.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a ski track which is traversed by a skier who is wedeln downhill on a ski slope. This ski track includes several short track sections 1 each one of which has a turning point 2. The skier shifts his center of gravity at the turning points 2 while simultaneously turning his body and the parallel skis, whereby a turning by the skier is carried out. To carry out such movements the skier must, while traversing the track section 1, compensate for the engendered centrifugal forces by shifting his center of gravity inwardly, then straighten his or her body at the turning points 2 and shift the center of gravity to the opposite side.
While in wedeln the short ski track sections directly follow each other without any intervening transitional ski track sections, there are illustrated in FIG. 2 more or less extended intervening ski track sections 3 which are connected to each by means of short or wide parallel turns 4 at the turning points 2. This type of skiing at each turn, when the skier must shift his or her the center of gravity inwardly, is followed by a transitional straight track during which the center of gravity of the skier must be located over his or her feet.
The sequence of movements of the skier for wedeln as illustrated in FIG. 1 can be closely simulated by the device of this invention as illustrated in FIGS. 3,4,6,8 and 9. The sequence of movements of the skier for parallel turn skiing as illustrated in FIG. 2 can be closely simulated by the device of this invention as illustrated in FIG. 5. In order to train for both sequence of movements as illustrated in FIGS. 1 and 2 a combination of the first and second embodiments of the invention, illustrated in FIGS. 4 and 5, mounted on one support, can be provided.
In its simplest construction the training device of the invention comprises a pair of discs 8 which are operatively connected to a platform 9 and the entire arrangement is mounted over a ground support surface 5. Each one of the discs 8 is supported by a driving member 7, which respectively rotates each disc 8 at adjustable speeds. The driving members 7 preferably include, in addition to the driving mechanism, a lifting and raising and lowering mechanism as well as a hydraulic swivel mechanism 26 to simulate mogels. The driving mechanisms 7 may therefore lift or lower the discs 8 relative to the ground surface 5 and platform 9 by means of, for example, a hydraulic cylinder-piston arrangement while at the same time also tilting the discs relative to each other to simulate the skiing conditions when skiing over mogels. The tilting can be effected by a separate hydraulic piston-cylinder arrangement 28 which slidably engages the underside of each rotating disc 8 to move each disc 8 to a preselected tilted position as shown in dashed lines in FIGS. 4 and 5. The position shown in dashed lines represents a simulation of the skiing condition while skiing over a mogel, while an opposite tilted position would simulate skiing over a subsequent depression on the ski slope. The platform 9 is covered with a soft material (not illustrated) to cushion the falls of the person using the training device and to simulate snow. An elastic ski pole mechanism 10 is mounted between the pair of discs 8 either on the ground surface 5 (FIG. 4) or on the platform 9 (FIG. 5). The various raising and lowering effects of the discs 8 is effected by moving the various hydraulic mechanisms in the directions shown by the double arrows in FIG. 4.
The elastic ski pole mechanism 10 may include a cylinder 28 housing a spring 29 and rod fixed on the ground support surface 5 or platform 9 which supports the cylinder 28, A wrist support loop 27, fixed near the hand grip of the ski pole mechanisms, can be optionally provided and serves to further simulate actual skiing conditions. The ski pole is grasped by the skier at the moment that a skier normally uses a ski pole to assist in turning by inserting the ski pole into the ground. At the moment the skier grasps the ski pole he carries out a small jump away from one rotating disc onto the another oppositely rotating adjacent disc. At the moment the skier is no longer in contact with the disc 8 he or she moves in a tangential direction along the arrow 12 (FIG. 4) and lands also in a tangential direction on the adjacent disc 8. If during this transitional movement the skier carries out the necessary shifting of his or her center of gravity in a correct manner he then follows the rotation of the disc 8 on which he has just landed for nearly a 360° angle and then transfers again in the aforedescribed manner onto the adjacent oppositely rotating disc. During these transitional movements the skier grasps alternately the ski pole with his right or left hand depending in which tangential direction the transfer is taking place.
The surface of the discs 8 is made of a composite material which prevents slippage even at high rotational speeds of the discs 8. The surface of the platform 9 or 13 is, however, made of a material which is slippery to simulate the surface of real snow. For example the surface can be made of known synthetic materials which are used for artificial ski slopes or it can be made of rollers or balls which are rotatable in all directions.
The entire arrangement presents a substantially closed imperforate surface to the skier to prevent any clamping, pinching, squeezing or any other kind of injury to the human body by a person training on the device. To further prevent any injury an elastic fence 11 can be mounted around the outer periphery of the training device to elastically prevent the skier from falling outside of the training device thereby further preventing an injury. In addition or in lieu of the elastic fence a tether arrangement can be provided to which the skier using the device is tied during use.
An underground compartment 6 of preselected size is provided in the ground surface 5 to accommodate therein the pair of driving mechanisms 7 and the tilting mechanism 28 as shown in FIG. 4.
While in the embodiment of FIG. 4 the transfer by a person using the training device is carried out directly from one rotating disc to the adjacent oppositely rotating disc, the transfer in the embodiment of FIG. 5 is carried out indirectly. In this embodiment the pair of discs 8 are mounted at a greater distance from each other and a portion of the surface of the platform 13 is disposed there between. The surface of the platform is made of a material, such as a synthetic ski surface material or material covered with balls or rollers that have superior gliding properties so that the skier, when leaving one rotating disc 8 glides in a tangential direction along the arrow 14 over the surface of the platform 13 and lands on the oppositely rotating disc 8 by means of a small jump. The skier then dwells on the disc 8 while rotating through an angle of about g270° and then leaves the disc 8 in a tangential direction and now glides over the platform 13 in the direction towards the other disc 8. The skier preferably only wears sport shoes or ski boots when training on the device of FIG. 4. However, when training on the device of FIG. 5 the skier preferably should wear ski boots and optionally short skis.
The embodiment of FIG. 6 comprises a larger than two plurality of discs 8 which are mounted on a support member 15. All of the discs 8 are rotatable in opposite direction to the adjacent discs 8 by suitable driving mechanisms of the type described in conjunction with the embodiment of FIG. 3. These driving mechanisms are operatively mounted on the support member 15 as shown in FIG. 6. The top surface of the top and bottom portion of the support member 15 is also provided with a synthetic ski surface material. An elastic ski pole (not illustrated), as described in conjunction with FIG. 3, can be provided between each pair of adjacent discs 8. The support member 15 is pivotally supported at its bottom end by means on the ground surface 5 by means of a conventional hinge 16. The top portion is pivotally connected to a hydraulic piston-cylinder arrangement 17 which is in turn pivotally supported by an other conventional hinge 16. By raising or lowering the support member 15 by means of the piston-cylinder arrangement 17 the steepness of the slope angle of the entire device can be adjusted to simulate actual skiing conditions.
There is schematically illustrated in FIG. 7 a fourth embodiment of the invention in which four discs 8 are mounted closely to each other rotatably on a support (not illustrated) in square-shaped pattern. The discs 8 are oppositely rotated by previously described driving means and the person using the device leaves each disc in a tangential direction as indicated by the arrows 1.2. The arrows 18 and 19 indicate the dwell times on the discs 8 of the person using the device. Thus the arrow 18 indicates the dwell time on one pair of discs 8 only amounting to about a half revolution of the discs 8, whereas on the other pair of discs 8 the person using the device remains on the respective disc 8 for almost a complete revolution of the discs 8.
The fourth embodiment as illustrated in FIG. 7 provides the person using the device a more variable form of exercise as the embodiments of FIGS. 4 and 5 without requiring as much space as does the embodiment of FIGS. 5 and 6.
The disc diameter can vary from 0.75 meters to 3.0 meters, depending on whether wedeln or wider turns are to be the training object of the device. The device may include discs of different diameters and the individual discs may be driven at different speeds.
There is illustrated in FIG. 8 a cross-sectional view of a rotatable disc 8 of the training device of the invention. This disc 8 has a step like protruding annular portion 23 the top of which forms a circumferential surface 24. A ring member 25 can be mounted on top of the central portion 24 and serves as a hand rail for a person using the device. Adjoining the annular portion 23 is an outer annular portion 22. The angle of inclination of the inner portion 23 is steeper than that of outer annular portion 22. The arrangement of various surfaces as illustrated in FIG. 8 further simulate actual skiing conditions because it causes the feet of the person using the device to assume the positions which most frequently occur during skiing over uneven ski slope surfaces having varying degrees of steepness.
FIGS. 9 and 10 illustrate schematically in cross-section (FIG. 9) and plan view (FIG. 10) a fifth embodiment of the invention which is mounted in a swimming pool. The obvious advantage of this embodiment is that it cushions the fall of the skier should he or she fall of one of the rotating discs 8. In this embodiment the discs 8 are mounted so that their top surfaces rotate slightly above the surface of the water in the swimming pool 20. There is mounted on the ground surface 5 a spout 21 emitting a water jet which is directed to the area between the pair of rotating discs 8, so as to rotate them jointly in opposite directions as shown by the arrows in FIG. 10. Alternately or additionally the driving of the discs 8 can be effected by having a pair of waterspouts 21a mounted eccentrically relative to the axial support shafts of the discs 8 and being rigidly connected thereto by conduits 21b which emit water jets through spouts 21a to rotate the discs 8. The discs 8 can also or alternatively be driven by conventional motor driven underwater driving means.
FIGS. 11a to 11c illustrate schematically in perspective the device of FIG. 4. In addition to the ski pole 10 an elastically mounted flag pole 30 is mounted on each rotating disc 8 at a predetermined distance from the axis of rotation. The distance of the flagpole 30 from the axis of rotation can be adjusted by mounting it on an adjustable arm 31 which fixed to the axial driving mechanism 7. The skier 32 can be optionally connected by means of a belt 33 to a tether mechanism 34. The position of the flag pole 30 relative to the point at which the skier is suppose to jump to the adjacent disc is shown by the angle between the arrows in FIG. 11c.
The training device of this invention makes it possible to train year-round for most of the movements which a skier performs during alpine skiing. By making the diameters of the discs 8 sufficiently large and/or providing a larger than two plurality of discs mounted in a row or in a multi-corner pattern several skiers may train on the device simultaneously.
The training device of the invention can not only be used in an exercise hall for ski training but in a swimming pool of a ski resort or in a rehabilitation center for training persons having equilibrium maintenance problems and also as a recreational device in amusement parks or fairs.
While the invention has been described in detail by specific reference to preferred embodiments thereof, it is understood that variations and modifications may be made without departing from the true spirit and scope of the invention.
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A training device is capable of simulating for a person being trained by the device the motion of a slalom or "wedeln" skiing. The device includes at least two rotating disks which are operatively connected to each other and rotate in opposite directions. The disks function as platforms for supporting a skier who is being trained by the device. The person being trained changes his or her position by jumping or stepping rhythmically from one platform to the other in simulation of wedeln and/or slalom and or wider downhill ski turns on parallel skis.
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BACKGROUND OF THE INVENTION
The present invention relates to a solid-state switch, in particular, a switch to protect the input circuitry of a high-precision measurement device.
Description of the Prior Art
It is common in such devices as voltage and current measurement instruments to include a large protection resistor (e.g. 100-200 Kohms) in the input circuit to prevent large currents from flowing into the measurement circuitry. The Johnson noise associated with this protection resistor can result in a large noise level (e.g. 1 microvolt).
In addition, the input of these devices is often switched by relays. These relays must be able to switch high voltages (e.g. 1,000 volts) and large surge currents, and yet not introduce errors (e.g. thermal offsets and drift) in high-precision measurements. For example, a large, expensive, relay with a limited life is required to limit thermocouple effects to below 1 microvolt and still switch the required voltage and current.
SUMMARY OF THE INVENTION
The present invention provides excellent overload protection while greatly reducing the Johnson noise. In addition, the expense and bulk of input switching relays is avoided. The invention provides very low thermal offsets (e.g. <500 nanovolts) and very low thermal drift.
The current-limiting solid-state switch of the invention includes a first enhancement mode MOSFET having a first drain, a first source and a first channel. The first drain is connected in series relationship to the switch input.
Also included is a second enhancement mode MOSFET having a second drain, a second source and a second channel. The second drain is connected in series relationship with the switch output.
A first and a second current-sensing resistor are connected in series relationship between the first source and the second source, there being a common point between the resistors.
A first photovoltaic source having a first terminal and a second terminal is also included. The first terminal is connected to the first and second gates and the second terminal is connected to the common point.
Also included are selectable illumination means, wherein the switch input and output are disconnected when the first photovoltaic source is not illuminated and the input and output are bi-polarly connected but current-limited when the first photovoltaic source is illuminated.
The photovoltaic source may be, for example, an array of series connected diodes and the illumination means an LED.
In addition, a first voltage-limiting means may be connected in parallel relationship with the first photovoltaic source. This first voltage-limiting means may be a zener diode.
To improve the "off" isolation of the switch, a second photovoltaic source having a third terminal and a fourth terminal may be added to the switch. The third terminal is connected to the common point. Also added is a first diode connected in series relationship between the first drain and the fourth terminal and a second diode connected in series relationship between the second drain and the fourth terminal.
The second photovoltaic source is illuminated when the first photovoltaic source is not illuminated and the second photovoltaic source is not illuminated when the first photovoltaic source is illuminated. In this way, the capacitance of the first and second MOSFETs is minimized when the switch is open.
To increase the voltage handling limit, the switches can be cascaded in series.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE is a schematic diagram of a circuit according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the figure, a circuit 10 has an input terminal 12 that is connected to the first terminal of a fusible resistor 14 (e.g. 1,000 ohms). The other terminal of the fusible resistor 14 is connected to the first terminal of a spark gap surge arrestor 16, which becomes a short circuit when a threshold is exceeded (e.g. 1,500 volts). The other terminal of the surge arrestor 16 is connected to a common tie point 18.
The drain of an n-channel enhancement MOSFET 22 is connected to the first terminal of the surge arrestor 16. An anti-parallel diode 20 is a parasitic element of the MOSFET 22 itself, appearing between its source and drain. The source of the MOSFET 22 is connected to the first terminal of a resistor 24. The other terminal of the resistor 24 is connected to the first terminal of a resistor 26, to the anode of a zener diode 28, and to the cathode of a photovoltaic diode array 30.
The other terminal of the resistor 26 is connected to the source of an n-channel enhancement MOSFET 32. An anti-parallel diode 34 is a parasitic element of the MOSFET 32.
The cathode of the zener diode 28 and the anode of the array 30 are both connected to the gates of the MOSFETs 22, 32.
The resistors 24, 26 may be, for example, 1,000 ohms each and the zener voltage of the zener diode may be, for example, 6.2 volts.
The array 30 is optically coupled to an LED 36.
The drain of the MOSFET 32 is also connected to the anode of a diode 38 and to the drain of an n-channel enhancement MOSFET 42. An anti-parallel diode 44 is a parasitic element the MOSFET 42. The source of the MOSFET 42 is connected to the first terminal of a resistor 46. The other terminal of the resistor 46 is connected to the first terminal of a resistor 48, to the anode of a zener diode 50 and to the cathodes of a pair of photovoltaic arrays, 52, 54.
The other terminal of the resistor 48 is connected to the source of an n-channel enhancement MOSFET 56. An anti-parallel diode 58 is a parasitic element of the MOSFET 56. The drain of the MOSFET 56 is connected to the cathode of a diode 60.
The cathode of the zener diode 50 and the anode of the array 54 are both connected to the gates of the MOSFETs 42, 56. The anode of the array 52 is connected to the anodes of the diodes 38, 60.
The resistors 46, 48 may be, for example, 1,000 ohms each and the zener voltage of the zener diode 50 may be, for example, 6.2 volts.
The array 52 is optically coupled to an LED 62 and the array 54 is optically coupled to an LED 64.
The drain of the MOSFET 56 is also connected to one juncture of a pair of diodes 66, 68 connected in opposite polarity parallel relationship and to the input of a switch 70 (e.g. an n-channel JFET). The output of the switch 70 is connected to the noninverting input of an op-amp 72.
The output of the op-amp 72 is connected to an output terminal 74, to the first terminal of a resistor 76 and to the inverting input of the op-amp 72. The other terminal of the resistor 76 is connected to the other juncture of the diodes 66, 68 and to one end of a pair of zener diodes 78, 80 connected in opposing serial relationship. The other end of the pair of zener diodes 78, 80 is through a resistor 82 to the common tie point 18.
The resistor 76 may be, for example, 1,000 ohms and the zener voltage of the pair of zener diodes 78, 80 may be, for example, 22 volts.
The output terminal 74 is also connected to the anode of the LED 36, to one side of the switch 84 and to the cathodes of the LEDs 62, 64. The other side of the switch 84 is connected to the cathode of the LED 36 and to the anode of a current regulator diode 86. The anode of the regulator diode is connected to a negative voltage source-V.
The anode of the LED 62 is connected to one output of a switch 88. The other output of the switch 88 is connected to the anode of the LED 64. The input of the switch 88 is connected to the cathode of a current regulator diode 90. The anode of the regulator diode 90 is connected to a positive voltage source +V.
The array 30 and the LED 36, the array 52 and the LED 62, and the array 54 and the LED 64 may be advantageously embodied in the form of integrated packages containing one or more array/LED pairs. Because the LEDs 36, 62, 64 are driven by the output of the op-amp 72, isolation resistance and capacitance are guarded out.
When the LED 36 is energized by opening the switch 84, the array 30 is illuminated and provides a light-generated voltage (e.g. 10 volts open-circuit), which is clamped to the zener voltage of the zener diode 28. This voltage then appears between the source and gate of the MOSFET 22 via the resistor 24 and, similarly, between the source and gate of the MOSFET 32 via the resistor 26.
This then allows a positive signal applied to the input terminal 12 to flow through the fusible resistor 14, to pass from the drain to the source of the MOSFET 22, through the resistors 24, 26 and through the MOSFET 32 (diode 34) to the drain of the MOSFET 32.
Conversely, a negative signal applied to the input terminal 12 flows through the fusible resistor 14, through the MOSFET 22 (diode 20), through the resistors 24, 26 and passes from the source to the drain of the MOSFET 32. This effectively connects the drain of the MOSFET 22 with the drain of the MOSFET 32, except as described below for currents in excess of a desired maximum.
When the LED 36 is turned off by closing the switch 84, no voltage is generated by the array 30 and the MOSFETs 22, 32 are off, preventing any signal from flowing between their respective drains and sources. This effectively disconnects the drain of the MOSFET 22 from the drain of the MOSFET 32. This disconnection or isolation can be further improved by means described below.
Similarly, when the LED 64 is energized through the switch 88, the array 54 generates a voltage that allows the MOSFETs 42, 56 to pass the signal at the drain of the MOSFET 42 to the drain of the MOSFET 56.
When the LED 64 is off, no voltage is generated by the array 54 and no signal flows from the drain of the MOSFET 42 to the drain of the MOSFET 56.
By using two stages of MOSFETs (i.e. MOSFETs 22, 32 (e.g. 900 volts maximum) and MOSFETs 42, 56 (e.g. 900 volts maximum)) a higher voltage may be switched (e.g. 1,800 volts).
The drain to gate capacitance of a MOSFET can be relatively high (e.g. >500 picofarads) if the drain to gate voltage is less than 10 volts. On the other hand, this capacitance is quite low (e.g. 40-50 picofarads) for a drain to gate voltage of 10 volts or more.
When the arrays 36, 64 are not illuminated, the LED 62 is energized through the switch 88. This illuminates the array 52, resulting in a voltage (e.g. 10 volts) being applied through the diodes 38, 60 across the respective drains and gates of the MOSFETs 42, 56. By applying this voltage across the MOSFETs 42, 56 the respective drain to gate capacitances are minimized and the isolation of the circuit 10 at high frequencies substantially improved.
Another advantage of the circuit 10 is that because the control voltages for the MOSFETs 22, 32, 42, 46 are actually produced by the arrays 30, 54 and the gate currents return to the respective array, the gate currents do not contribute to the input bias current of the op-amp 72.
When the arrays 30, 54 are illuminated and the array 52 is not illuminated, the circuit 10 is "on" and an input signal applied to the input terminal 12 appears at the drain of the MOSFET 56, where it is applied to the noninverting input of the op-amp 72 through the switch 70. The op-amp 72 then provides a buffered version of the input signal at the output terminal 74. In normal operation (not overloaded), the voltage at the drain of the MOSFET 56 is less than that of the zener voltages of the zener diodes 78, 80 and little or no current flows into the input terminal 12.
When the arrays 30, 54 are not illuminated and the array 52 is illuminated, the circuit 10 is "off" and a signal applied to the input terminal 14 is blocked from the op-amp 72.
The circuit 10 provides a solid-state switch that has an resistance for Johnson noise purposes equal to the sum of the resistors 14, 24, 26, 46, 48 (e.g. 5,000 ohms) when "on" (and not current-limited) and an isolation on the order of 10 10 when "off." The Johnson noise associated with the input resistance of the present invention can be quite low (e.g. 60 nanovolts peak-to-peak for a 0.1-10 Hz bandwidth).
To provide additional isolation in the "off" state the switch 70 is also opened. This eliminates leakage current at the noninverting input of the op-amp 72 that may otherwise flow through the diodes 66, 68 to the output of the op-amp 72. Without the switch 70, this leakage current would be on the order of the voltage at the input terminal 12 divided by 10 10 ohms.
It should be noted that in normal operation, the inverting and non-inverting input of the op-amp 72 are at equal potential and thus the diodes 66, 68 have zero volts across them and the leakage current for the zener diodes 78, 80 is supplied through the resistor 76.
In the prior art, a large input resistor (e.g. 200 Kohms) is provided for protection to limit current into the device (with a resulting large Johnson noise). In the circuit 10, the input resistance is much lower (e.g. 5,000 ohms). However, protection from large currents is still provided.
For protection from very large overloads, the surge arrestor 16 and fusible resistor 14 are provided. Before a voltage applied to the input terminal 12 exceeds the limits of the MOSFETs 22, 32, 42, 56, the surge arrestor 16 shorts and opens the fusible resistor 14, thereby protecting the remaining circuitry.
For less serious overloads, if a positive voltage is applied to the input terminal 12 that is greater than the sum of the diode drops of the diode 66 and the zener diode 80 and the zener voltage of the zener diode 78 or if a negative voltage is applied to the input terminal 12 that is greater than the sum of the diode drops of the diode 68 and the zener diode 78 and the zener voltage of the zener diode 80, the zener diode 78 or the zener diode 80, respectively, clamp the voltage at the drain of the MOSFET 56 to the respective sums.
This clamping protects the op-amp 72 from excessive voltages. Plus, if the clamping voltage is chosen to be within the active range of the op-amp 72, not only is the op-amp 72 protected, it remains in its active range allowing faster recovery from the overload. However, without the advantages of the invention, excessive currents could still flow through the portion of the circuit 10 ahead of the op-amp 72.
If a positive input voltage is applied to the input terminal 12 that is greater than the sum of the diode drops of the diode 66 and the zener diode 80 and the zener voltage of the zener diode 78, current flows immediately through the diode 66, the zener diode 78 and the zener diode 80. At high frequencies, the initial magnitude of this current is the input voltage at the input terminal 12 over the resistance of the resistor 14. This current flows "around" the MOSFETs 22, 42 through device capacitances.
As current flows through the MOSFETs 22, 42, it results in a voltage across the resistors 24, 46 that "bucks" the gate drive from the arrays 30, 54. When this bucking voltage becomes high enough, the MOSFETs 22, 42 begin to shut off, thus current-limiting the circuit 10. The resistors 24, 46 thus act as current-sensing resistors. In particular, the input current to the input terminal 12 is limited to less than the difference between the zener voltage of zener diode 28 (or the zener diode 50) less the gate-to-source threshold voltage of the MOSFET 22 (or the MOSFET 42) all divided by the resistance of the resistor 24 (or the resistor 46).
The value of the current limit can be chosen low enough to avoid device heating during overload conditions, while still allowing the use of relatively low resistance resistors 24, 46.
Similarly if a negative voltage is applied to the input terminal 12 a "bucking" voltage is developed across the resistors 26, 48 that limits the current through the MOSFETs 32, 56.
It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited.
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Two enhancement mode MOSFETs in series are used to provide a solid-state switch. The MOSFETs are turned on by a photovoltaic array. Resistors in series with the MOSFETs serve to provide a control voltage to current-limit the circuit. An additional photovoltaic array is used to supply drain to gate bias when the switch is off to minimize device capacitance. The circuits can be cascaded to raise the voltage-handling limits.
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This application is a division of nonprovision application Ser. No. 08/773,556, filed Dec. 27, 1996, entitled CONTRACTURE MEANS AND METHODS and now allowed, which is a nonprovisional continual application of provisional application Ser. No. 60/009,564 filed Jan. 3, 1996.
BACKGROUND OF THE INVENTION
After a stroke or other neurological disorder, tightness of the hand muscles of an individual can often lead to debilitating contracture of the fingers of the hand, resulting in a fist-like deformity. Often this condition can be prevented by the use of splinting and other medical means, but this can be painful and often the patient is unwilling to go through painful procedures such as stretching and range of motion exercises. The contracture or tightness, if not treated often becomes worse and can lead to the finger nails puncturing the flesh infection of palm and spaces between the finger and thumb can result from difficulty in cleaning the tightly fisted hand.
Health practitioners, such as occupational therapists, physical therapists and nursing staff, often try to wedge the hand open as with a folded washcloth or roll of gauze bandage. Other common means of keeping the hand open to prevent further contracture once started, include the use of conical tubes. Cone shaped tubes are generally made of rigid plastic and may be covered with some sort of thin material to make them more comfortable. Often lengths from 4 to 5 inches and widths tapering from 3/4 inch to 11/2 inches in diameter are used. Other methods dealing with contractures are the use of palm splints. Such splints fit in the palm and are intended to rest between the fingers and the palm surface and to act as a barrier to prevent the fingers from digging into the palm of the skin. In extreme cases, surgery where tendons are severed, is a last, painful and often ineffective resort. It is a particular problem with any of the known devices that their use requires the fingers to be pried open before inserting the device into the tightly-clenched fist. This opening of the fingers can be extremely painful and in some cases can cause dislocation of a joint when done by the therapist, other medical practitioner or family care giver. The force exerted during prying of the fingers can be considerable in order to insert a splint and or the aforementioned cone devices which require forcing of the cone through the widest opening of the clenched fist towards the narrowest opening of the fingers. To insert even a washcloth or gauze roll can be painful and traumatic for the patient because of the necessary finger prying apart.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a method of treating contractures of successive fingers of the hand by gently spreading the fingers of the hand apart through the use of a a yieldable, generally-conical element wherein prespreading of the fingers prior to use of the element is minimized or eliminated.
Another object of this invention is to provide an elongated yieldable element having an essentially small diameter and a large diameter end with a nonrigid body which is resiliently compressible to a second smaller diameter shape, with a narrow diameter end being small enough to minimize or eliminate preopening of a curl of the hand in a contracture of the fingers of the hand.
According to the invention, a method of treating a contracture of successive fingers of the hand of an individual wherein the fingers are curled to form an elongated restricted area having an elongated axis at the inside of the curl of the fingers, is provided. An elongated yieldable generally conical element is threaded through successive curled fingers of the hand with the conical element having a narrow diameter end and an enlarged diameter end. The threading is carried out by inserting the narrow diameter end as far under the curled area of each successive finger as possible without causing discomfort of the individual and then engaging the conical element at, or substantially at, the narrow diameter end to force the element further into the restricted area and gradually increase the size of the restricted area about the elongated axis and thus act to open the curl to at least some extent. The expanding action is enhanced by sliding of the conical element which provides a cushioning and gradually opening effect to the fingers acting as an inclined plane.
In the preferred embodiment, the conical element is pulled through the restricted area by attachment of a pulling device at the narrow diameter end. The pulling device can be an elongated yieldable rod which can be hooked to a thread or other attachment device at the narrow diameter end of the element. In some cases, the conical element can be an inflatable device which is preferably inflated prior to use.
Preferably an elongated yieldable conical element has an axial length at least about 41/2 inches with a large diameter end of at least about 3/4 inch and a small diameter preferably tapering to the tip of the cone. The narrow diameter end is dimensioned and arranged to be threaded through the curl without preopening of a curl so that the curl can be expanded by exerting gentle steady increading force using the conical member to gradually expand the curl by a sliding action thereof. In some cases the conical element can be inflatable and/or can carry means for attaching a pulling device to the small diameter end. When the pulling device is used, it is preferably an elongated rod attached to the means on the narrow diameter end of the element. In some cases, an elongated stiffening rod can be used internally in the element to enable the element to be pushed by a force applied through the large diameter end although in the preferred embodiments, force is applied as a pulling force acting through the small diameter end of the conical element.
It is a feature of this invention that since the small diameter end of the conical end tapers to substantially zero diameter, or zero diameter, it can be pulled into the hand at the small finger end and is relatively easy to slide through the fingers without prepulling the fingers before entry of the element, avoiding substantial prying of the fingers and allowing the element itself to open the fingers gradually. The process of introducing the device uses an inclined plane principal to exert force, while the hand need not be preopened to a diameter greater than the size of the device. In many known devices, such preopening was necessary and could cause substantial pain. Insertion of the elements of this invention can be carried out gently and slowly over a period of days or even weeks to minimize or eliminate pain and anticipated fear of pain in patients. Thus, one can build trust and increase compliance in users.
DESCRIPTION OF THE DRAWINGS
The above objects, features and advantages of the present invention will be better understood from the following specification when read in connection with the accompanying drawings in which:
FIG. 1 is a side view through a conical element in accordance with a preferred embodiment of this invention, with the other three sides not shown being identical to the side shown;
FIG. 2 is a top plan view thereof;
FIG. 3 is a cross sectional view through an alternate embodiment of the embodiment of FIG. 1;
FIG. 4 is a side view of another alternate embodiment of a conical element in accordance with this invention;
FIG. 5 is a pulling implement for use therewith;
FIG. 6 is a side cross sectional view through still another embodiment of the conical element of this invention;
FIG. 7 is a front perspective view of a hand with which the conical element of FIG. 4 is used; and
FIG. 8 is a side perspective view of an alternate embodiment of a pulling instrument useful in connection with this invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
According to the invention, as best seen in FIGS. 1, 2 and 7, a generally conical element 10 can be used for treating a contracture of successive fingers 11-15 of a hand 16 of an individual wherein the fingers are curled to form an elongated restricted area 17 having an elongated axis 18 inside the curl of the fingers.
The element 10 of the preferred embodiment has the shape and decoration of a carrot. Thus, it has an outer conical, tapering shell 21 to a narrow diameter end 22 with an enlarged diameter end 23. The narrow diameter end at 22, which in the preferred embodiment is of zero diameter. It is preferred that end 22 be kept as near zero as possible as will be better understood from the subsequent discussion of the method of this invention. In some cases, the narrow diameter end can have a diameter of 1/4 inch, but is preferably small enough to enter the curled restricted area without prior uncurling of the fingers. Within the conical shell or cover 21 is a stuffing which can be a resilient compressible material (shown at 30 in FIG. 3), foam particles, elastomeric materials or the like. In the preferred embodiment, the material 30 is wool fleece so that the carrot-like, conical element can be compressed in use as it is drawn through the fingers of the hand to expand the fingers. The shell 21 is preferably an orange colored cloth of cotton wool or synthetic fibers. The conical element allows a sliding action of the hand at the shell 21, and also allows some compression so as to provide a gradual opening of the fingers using an inclined plane principle.
The material 30 can be any compressible material such as elastomeric polymers, formed from foam or solid polymers in one piece or particles, such as polyvinyl chloride, synthetic or natural rubber and the like, fiber batting ravings such as cotton, wool or synthetic yarn which when compressed still allows insertion into the curl of the hand. The shell 21 can also be made of plastics such as polyethylene terephalate, nylon, polypropylene and the like to reduce friction. The shell 21 preferably uniformly tapers from end 23 to end 22.
In the preferred embodiment of FIG. 10, the carrot-like element has a length of from 41/2 to 81/2 inches, a narrow diameter of from zero to 3/8 inch and an enlarged end diameter of from 3/4 inch to 21/2 inches. The element is non-rigid when slight forces of the hand are applied to it. Thus, it can be bent, easily manipulated and is compressible and resiliently returns to its original shape. In the preferred embodiment, the compressibility of the carrot-like element is such that when the forces of the contracture are applied to it, the enlarged diameter end can, for example, be reduced by the pressure of the fingers to a diameter approximately one half its starting diameter.
The shell 21 is preferably of a cloth such as KONA cotton 100% cotton 45/45 threads/inch manufactured by Robert Telfman Co., Inc. Fabrics of the shell 21 can be natural, nonallergic, absorbent, fade resistant, shrinkage resistant, and the like. Preferably, they are washable as is the entire conical element. Other cloths such as cone broadcloth 45/45 inch 60% polyester 35% combed cotton as manufactured by Springfort of South Carolina can be used. Wool fleece for material 30 can be attained in rolls from P.O. Box 36, Harmony, Me. Other fillers such as foam, rubber, cloth and the like can be used. As best shown in FIG. 2, the preferred embodiment has a round upper surface with a plume 24 of cloth to closely simulate an artificial carrot.
In an alternate embodiment of the invention shown at 31 in cross section at FIG. 3, wool fleece 30 is provided as is the filler in the embodiment of FIG. 1. However, in this embodiment, a rigid plastic rod 25 is positioned within the carrot to enable the carrot to be pushed through the hand from the enlarged diameter end of the element 31. The rod 25 can be round, square or irregularly shaped in axial cross sections. Non-round cross-sections are preferred to prevent twisting of the filler 30 in use. This device is not as preferable as other devices of the invention since it is preferred to pull a device from its narrow diameter end wherein the pressure is exerted at the narrow diameter end. Since the narrow diameter end substantially is at zero diameter, it can be threaded through the fingers without preprying apart of the fingers to any substantial degree (this is in part due to the compressibility of the carrot as well as the substantially zero diameter end). Thus, devices such as the device of FIG. 1 are preferred since they can be pulled from the tip or narrow diameter end 22 allowing a gentler action in spreading the contracture and opening the fingers as the carrot passes through.
In another alternate embodiment of this invention illustrated in FIG. 4, a carrot-like conical element 10, as for example, shown the embodiment of FIG. 1 is shown where all elements which are identical to the embodiment of FIG. 1 are identically numbered. In this embodiment, the only difference is that in addition to the orange colored shell 21 and plume 24, a series of graduation lines are shown from 1 to 15. These graduations can be used to indicate the progress of the carrot through the hand over time. For example, measuring the graduation line at the top of the hand, as shown in FIG. 7 during processing, on each subsequent hour, day, or minute of relief of the contracture (by advancing the carrot pulling at its narrow diameter end), one can record the date, time and degree of passage of the carrot through the contracture. This is useful to determine and monitor the regime for treating patients to relieve the contracture.
The device of FIG. 4 further has a thread loop (32) passing through a suitably formed hole (not shown) and firmly attached to shell 21 at the narrow diameter end of the carrot-like element. The thread 32 enables one to attach a rod and hook to pull the device through the hand. A suitable pulling rod 40 is shown in FIG. 5 and preferably comprises a semi-rigid rod as, for example, of a nylon (nylon 6,6 or nylon 6 material) which is yieldable yet firm. The rod can have a length of from 4 to 10 inches or more. In a preferred embodiment of the rod 40, it has a slightly enlarged rounded end 41 and a hooked end 42. The rod can be hooked onto the threaded loop 32 and then the rod passed through the contracted fingers to enable one to pull the narrow diameter end of the carrot-like element through the contracture from its wider end to its narrow end. Since the rod is semi-rigid, it will bend to pass easily through the contracture. It can be made of narrow diameter such as from 1/4 inch and yet is strong enough to enable sufficient force to be exerted on the carrot to open the fingers as the carrot is passed through the contracture.
In a preferred embodiment of the rod, it can have a length of approximately 51/2 inches with the slight hook 42 at the far end, having a diameter of approximately 1/4 inch for about 4 inches of the axial length of the rod then tapered for an additional 4 inches to approximately 1/8 inch with a round ball tip 41 with the ball having a diameter approximately 3/16 inch. Since the nylon rod is by nature semi-flexible, it is easily and painlessly inserted into the hand, generally from the small finger end, but could be done from either end. Because it is a flexible rod, it can bend around any asymmetric obstructions (which may include another finger that is exorbitantly contracted). Thus, it becomes a flexible rod that can be threaded through the entire closed fist hand or a portion of the fist, exiting between the fingers.
FIG. 8 illustrates a rod 60 similar to rod 40 and for the same purpose as rod 40. In rod 60, all parts are the same as rod 40, except that the hook is replaced with an eyelet or hole 61 which may be oval as shown or of other shapes. The eyelet is integral with rod 60 and a far end comprises a post end 62. The rod 62 is used by having the end 63 of loop 32 pass through the eyelet and over end 62. Thus, the rod 60 acts as a hook and can be used to pull the conical element into the space 17 and thus expand the curl of a contracture in a gentle movement. The largest outer width of rod 60 at the outlet is preferably extremely small as for example 1/4 inch to facilitate passage of the eyelet into the contracture along axis 18 if desired.
FIG. 6 illustrates in cross-sectional view a carrot-like conical element 51 having an outer shell 21 of gas impermeable polyvinyl chloride, and an inflation plug 52 with a stopper 53. This device is an inflatable conical element and can be used in the same manner as the elements 10 of FIGS. 1 and 4. Preferably, the embodiment is inflatable prior to use to a degree less than full inflation. In some cases, the element 51 can be deflated, positioned along axis 18 of the hand and then inflated to gently open the curl of the fingers.
Generally, the devices of this invention are engaged at the narrow diameter end to force the element further into the restricted area and gradually increase the size of the restricted area about the axis of the contracture. The conical element is preferably pulled through the restricted area causing the fingers to gradually uncurl in conical fashion with minimized prying apart action as opposed to sliding and expanding action of the conical element, which forces the expanding of the curl. The conical element is preferably intermittently pulled into the contracture, with the extent of each axial movement permitting stretching to successive equilibrium positions without undue or excessive discomfort to the patients. The conical element can be inserted into the top or bottom of the curl of the contracture, but are preferably inserted at the top as shown in FIG. 7. Sliding is a preferred mechanism so that the cloth preferably does not have characteristics which would prevent sliding against the skin without injuring the skin. In some cases, the conical element is pushed through the restricted area by an elongated rod-like device but in the preferred embodiment it is pulled through. It can be pulled through with the use of flexible rod 40 or 60 which is engaged with a narrow diameter end of the carrot-like element.
While the carrot-like conical element has been described, the shape can vary somewhat from a true cone, it is only necessary for the element to have an inclined plane or gradually increasing pressure on the curled fingers as it is pulled through the hand. Preferably, the conical element is compressible to about half of its diameter along its central axis.
While specific embodiments, have been described and shown, additional variations are possible.
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An elongated yieldable conical element has a nonrigid body which is compressible to a conical shape increasing in diameter from a narrow diameter end. The conical element is used in a method of treating a contracture of successive fingers of the hand by threading a narrow and of the element through successive curled fingers of the hand and engaging the conical end at about the narrow diameter end to apply outwardly directed force to the fingers of the hand to open the curl to some extent with minimized discomfort to a user.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
In one of its aspects, the present invention relates to a seat and particularly, to a passenger seat for use in vehicles. More specifically, the present invention relates to a novel passenger seat for vehicles having an improved trim cover attachment system. In another of its aspects, the present invention relates to a process for producing a passenger seat, particularly a passenger seat for use in vehicles. In yet another of its aspects, the present invention relates to a system for producing a passenger seat, particularly a passenger seat for use in vehicles. In yet another of its aspects, the present invention relates to a mold for producing a passenger seat, particularly a passenger seat for use in vehicles.
2. Description of the Prior Art
Passenger seats in vehicles, such as automobiles, are typically fabricated from a foam (usually polyurethane) material which is molded into the desired shape and covered with an appropriate trim cover. The foamed material is selected to provide passenger comfort by providing a resilient seat and the trim cover is selected to provide the desired aesthetic properties.
To meet desired safety standards passenger seats in vehicles such as automobiles now often provide anti-"submarine" properties. Submarining is the term used to describe the tendency of the pelvis of a seated passenger to move forward and down during a collision. When the passenger is wearing a shoulder harness or lap type seatbelt, this tendency can result in the seatbelt strangling the passenger with potentially fatal consequences. Accordingly, it is known in the art to design passenger seats with anti-submarine properties. These properties may be provided by rigid or semi-rigid members embedded in the seat and which provide additional pelvic support to the passenger during a collision. To function properly, these members cannot move and thus, must be fixed (directly or indirectly) to the vehicle.
It is also known in the art that, while the resiliency of the foamed material in the seat provides passenger comfort, it does not provide the necessary structural strength for the seat. This necessitates additional reinforcement of the seat to provide the degree of structural strength required to ensure proper mounting of the seat within the vehicle and proper support of anti-submarine elements. Accordingly, prior art vehicular seats typically include a perimeter frame of metal which strengthens the seat. Further, support rails are typically mounted across the metal frame to stiffen the frame and to provide a suitable attachment point for the means used to anchor the seat to the vehicle. Conventionally, the metal frame and/or support rails are substantially completely embedded in the foam material when the seat is molded. In many cases, the metal frame will further comprise a plurality of apertures or other means for attaching a trim cover to the seat.
Of course, the requirement for such a perimeter metal frame and for support rails adds to the cost of manufacturing the seat and, more importantly, adds to the weight of the seat and the overall weight of the vehicle in which it is installed. This added weight increases both the cost of shipping the seat to the vehicle manufacturer and the eventual lifetime operating expense for the vehicle. Finally, the presence of metal frame and support rails or other components in the seat hampers the eventual recycling of the seat materials which is becoming increasingly important in today's environmentally concerned marketplace.
U.S. Pat. Nos. 5,400,490 Burchi! and 5,542,747 Burchi!, issued Mar. 28, 1995 and Aug. 6, 1996, respectively, the contents of each of which are hereby incorporated by reference, describe a passenger seat comprising a frame element molded from relatively high density, rigid foam; vehicle anchorage means connected to the frame element; and a seat body comprising a resilient material fixed with respect to the frame element. The provision of a frame element molded from relatively high density, rigid foam obviates the need for a conventional metal frame. The '490 and '747 patents also teach application of a trim cover to passenger seat. The trim cover may be attached using push pins or a combination of bottom flaps (see FIGS. 3 and 9 in the '490 and '747 patents) with conventional mechanical attachment means (e.g. Velcro™, J-retainers or push pins).
While the invention taught in the '490 and '747 patents represents a significant advance in the art, there is still room for improvement. One such area is in the attachment of the trim cover to the passenger seat. Specifically, in certain cases, for a number of reasons, it can be advantageous to avoid the use of push pins to attach the trim cover as taught in the '490 and '747 patents. First, the trim cover may have to be pre-drilled or otherwise pretreated to permit penetration of the push pins, involving additional manufacturing cost (this is especially true for trim covers made of an impermeable material such as vinyl or leather). Second, a large number of push pins is required to adequately secure the trim cover to the relatively high density, rigid foam frame, involving additional manufacturing cost, both in materials and labour. Third, the trim cover must be correctly positioned over the resilient material and the relatively high density, rigid foam frame independently of placement of the push pins, increasing the likelihood for improper placement and attachment of the trim cover.
Therefore, it would be desirable to have a passenger seat, particularly a vehicle seat, which comprises an improved trim cover attachment system. It would be further desirable if such a seat could be produced using an improved process and mold.
SUMMARY OF THE INVENTION
Accordingly, in one of its aspects, the present invention provides a passenger seat comprising: a frame element, vehicle anchorage means connected to the frame element, a seat body comprising a resilient material fixed with respect to the frame element and trim cover attachment means, the trim cover attachment means comprising a relatively high density, rigid foam member having a groove disposed in a surface thereof, the groove capable of receiving connection means comprised in a trim cover.
In another of its aspects, the present invention provides a process for producing a passenger seat in a mold comprising a first mold half and a second mold half engageable to define a mold cavity, the process comprising the steps of:
(i) placing a frame element in the first mold half, the frame element having connected thereto vehicle anchorage means;
(ii) placing trim cover attachment means in the first mold half;
(iii) dispensing a liquid foamable polymeric composition in at least one of the first mold half and the second mold half;
(iv) closing the first mold half and the second mold half;
(v) sealing at least a portion of the trim cover attachment means with respect to the liquid foamable polymeric composition; and
(vi) allowing the liquid foamable polymeric composition to expand to fill substantially the mold cavity to produce a relatively low density, resilient seat body which is fixed to at least a portion of the frame element;
wherein at least one of the following conditions is met: (A) the frame element comprises a relatively high density rigid foam, or (B) the trim cover attachment means is a relatively high density, rigid foam member comprising a relatively high density, rigid foam member having a groove disposed in a surface thereof, the groove capable of receiving connection means comprised in the trim cover.
In yet another of its aspects, the present invention provides a system for production of a passenger seat, the system comprising;
a first mold for producing a frame element constructed of a relatively high density, rigid foam, the first mold comprising a first mold half and a second mold half engageable to define a frame mold cavity, the first mold half adapted to convey to the frame element a trim cover attachment means disposed at a position corresponding to at least a portion of a periphery of the frame element and vehicle anchorage means;
a second mold for adhering the frame element to a relatively low density, resilient foam the second mold comprising a third mold half and a fourth mold half engageable to define a seat mold cavity, the third mold half adapted to carry the frame element in a manner such that trim cover attachment means in the frame element is adjacent to an interior surface of the third mold half, the third mold half further comprising sealing means on the interior surface at a location relatively peripheral to a position corresponding to the trim cover attachment means in the frame element.
In yet another of its aspects, the present invention provides a mold for production of a passenger seat comprising a frame element constructed of a relatively high density, rigid foam and comprising trim cover attachment means, the mold comprising a first mold half and a second mold half engageable to define a mold cavity, the first mold half adapted to carry the frame element in a manner such that trim cover attachment means in the frame element is adjacent to an interior surface of the first mold half, the first mold half further comprising sealing means on the interior surface at a location relatively peripheral to a position corresponding to the trim cover attachment means in the fame element.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will be described with reference to the accompanying drawings, in which:
FIG. 1 illustrates a perspective view, in cross-section, of an embodiment of the present passenger seat;
FIG. 2 illustrates a perspective view of an embodiment of a trim cover attachment system for use in the present passenger seat;
FIGS. 3-5 illustrate perspective views, respectively, of an alternate locking member useful in the trim cover attachment system illustrated in FIG. 2;
FIG. 6 illustrates a perspective view, in partial cross-section, of another embodiment of the present passenger seat;
FIG. 7 illustrates a sectional view taken along line VII--VII in FIG. 6;
FIG. 8 illustrates a mold useful in the production of the present passenger seat; and
FIG. 9 illustrates an enlarged sectional view of a portion of the mold illustrated in FIG. 8 in a closed position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Accordingly, an aspect of the present invention relates to passenger seat. As used herein the term "seat" is intended to have its conventional meaning and includes one or both of a cushion (i.e. the portion of the seat on which the occupant sits) and a back or back rest (i.e. the portion of the seat which supports the back of the occupant). As is known in the automotive, airline and related industries, a "seat" includes both a cushion and a back (or backrest). Thus, as used herein, the term "seat" includes a cushion, a back (or back rest) or a unit construction comprising a cushion and a back (or backrest).
With reference to FIG. 1, there is illustrated a passenger seat 10. Passenger seat 10 comprises a frame element 20. Frame element 20 includes a groove 15 and a pelvic support 25. Frame element 20 is constructed of a relatively high density, rigid foam. Such a foam is discussed in the Burchi patents discussed above and incorporated herein by reference. Preferably, frame element 20 is constructed of a foam having an indentation force deflection at 25% deflection in the range of from about 150 to about 4000 pounds, more preferably from about 500 to about 2500 pounds, most preferably from about 900 to about 2000 pounds, when measured pursuant to ASTM 3574-B 1 .
Preferably, frame element 20 is constructed of a polyurethane foam. More preferably, the polyurethane foam of frame element 20 preferably has a specific gravity of less than about 0.40, more preferably in the range of from about 0.10 to about 0.25. Preferably, the liquid foamable polyurethane composition used to produce frame element 20 has a few rise density of from about one to about twenty pounds per cubic foot, more preferably from about two to about eight pounds per cubic foot. For most molded foams, this would give use to a foam core having a density in the range of from about 1.5 to about 24 pcf, more preferably from about 2.5 to about 12 pcf.
Non-limiting and preferred examples of suitable polyurethane foams for use in producing frame element 20 are conventional rigid polyurethane foams
Generally, the polyurethane foam suitable for use in producing frame element 20 and having the requisite characteristics may be produced from the following general non-limiting formulation:
______________________________________Component Amount______________________________________Polymer Polyol 100-0 partsPolyol 0-100 partsCrosslinker 0-30 parts/100 parts total polyolCatalyst 0.05 to 3.5 parts/100 parts total polyolSilicone Surfactants 0-1.5 parts/100 parts total polyolH.sub.2 O 0.5 to 3.5 parts/100 parts total polyolIsocyanate Adequate quantity for an index of from about .60 to 1.30 ratio of NCO equivalents to the equivalents of NCO reactive sites.______________________________________
suitable polymer polyols, polyols and isocyanates are described in U.S. Pat. Nos. 3,304,273, 3,383,351, 3,523,093, 3,939,106 and 4,134,610, Belgian patent 788,115, Canadian Patent 785,835 and "Polymer/Polyols, a New Class of Polyurethane Intermediate", Kuryla, W. C. et al., J. Cellular Plastics, March (1966), the contents of which are hereby incorporated by reference. See also, "Flexible Polyurethane Foam" by Herrington et al. (1991), the contents of which are hereby incorporated by reference.
Suitable crosslinkers, catalysts and silicone surfactants are described in U.S. Pat. Nos. 4,107,106 and 4,190,712, the contents of which are hereby incorporated herein by reference.
The preferred polyurethane foam suitable for use in frame element 20 may be produced from the following formulation:
______________________________________Component Amount______________________________________Polymer Polyol.sup.1 20-100 partsPolyol.sup.2 0-80 partsCrosslinker.sup.3 5-15 parts/100 parts total polyolCatalyst.sup.4 0.5-1.2 parts/100 parts total polyolSilicone Surfactants.sup.5 0.3-1.1 parts/100 parts total polyolH.sub.2 O 1.75-2.75 parts/100 parts total polyolIsocyanate.sup.6 Adequate quantity for an index of from about 0.8 to 1.1 ratio of NCO equivalents to the equivalents of NCO reactive sites.______________________________________ .sup.1 AC West Virginia Polyol Co. NIAX 3128 .sup.2 5000 MW propylene oxide adduct of glycerine with 75% primary capping .sup.3 BASF 953 .sup.4 DABCO R8020 .sup.5 Goldschmidt B4113 .sup.6 Dow Chemical Company PAPI 901
Passenger seat 20 further comprises a resilient body 30 which covers frame element 20. Resilient body 30 may be constructed of any material conventionally useful in the production of seats. The resilient body may be made of a foam or non-foam material. Non-limiting examples of useful non-foam materials include fibers matrices such as horse hair, organic fibers and the like. The resilient body may also be constructed of any suitable foam material. Ideally, the resilient body is constructed of a relatively low density, resilient foam, more preferably a polyurethane foam. Polyurethane foams useful for this purpose are well known in the art.
Passenger seat 10 further comprises a trim cover 35 which covers resilient body 30 and the periphery of frame element 20. Trim cover 35 comprises a tongue member 40 in locking engagement with a groove 15 in frame element 20. The interaction of tongue member 40 and groove 15 will be described in more detail hereinbelow.
With reference to FIGS. 6 and 7, there is illustrated an alternate embodiment of the present passenger seat. In this embodiment, like numerals represent like parts in FIG. 1. The major difference in this embodiment is the use of a rigid, non-foam frame element 20'. Rigid, non-foam frame element 20' is constructed of any suitable material such a metal, plastic and the like. For example, rigid, non-foam frame element 20' may be a conventional metal frame. In this embodiment, groove 15 is located in a plurality of rigid foam members 23' which are located at a position correspondingly along the periphery of the underside of passenger seat 10 inside the periphery of rigid frame element 20'. The number and location of rigid foam members 23' is within the purview of a person skilled in the art and should be chosen to provide suitable attachment of trim cover 35. Preferably, rigid foam member 23' is constructed of a foam having the same properties and composition of frame element 20 discussed hereinabove with respect to FIG. 1.
With reference to FIG. 2, there is illustrated an enlarged view of trim cover attachment system illustrated in FIG. 1. Tongue member 40 may be constructed of any suitable material. Preferably, tongue member 40 is constructed of a plastic material such as polyethylene, polypropylene and the like. The plastic material can be recycled or virgin. Tongue member 40 is attached to trim cover 35 by stitching 45. Those of skill in the art will immediately recognize that the precise manner of attaching tongue member 40 to trim cover 35 is not particularly restricted and variations such a gluing, stapling and the like may be used. Preferably, groove 15 comprises an elongate passageway 50 having an open end to permit entry of tongue member 40 and a closed end 55 having a substantially circular cross-section.
Trim cover 35 may be attached to frame element 20 by inserting tongue member 40 into groove 15 in the direction of arrow 60. Insertion is carried out until the end of tongue member 40 engages closed end 55 of groove 15. At this point, tongue member 40 is in locking engagement with groove 15 of frame element 20. Since frame element 20 is constructed of a foam material, it is possible to withdraw, upon application of sufficient force, tongue member 40, if necessary.
With reference to FIG. 3 where there is illustrated an alternate embodiment of tongue member 40 in FIG. 2. Thus, FIG. 3, tongue member 40' comprises three jagged sections 41',42',43'. Tongue member 40' may be used with frame element 20 comprising groove 15 as illustrated in FIG. 2.
With reference to FIG. 4, there is illustrated an alternative to tongue member 40' illustrated in FIG. 3. Specifically, in FIG. 4, a portion of tongue member 40' which contains jagged sections 41',42',43' is bent at angle substantially perpendicular to the remaining portion of tongue member 40' to which is attached trim cover 35. The advantage of this alternative is the provision of a flush fit of trim cover 35 with the uuderside of frame element 20 of passenger seat 10. This is especially important if tongue member 40 or 40' is constructed of a relatively rigid material which is likely to partially protrude from groove 15 after insertion.
With reference to FIG. 5, there is illustrated yet another embodiment of a tongue member for insertion in groove 15 of frame element 20. In FIG. 5, tongue member 40" comprises a single jagged section 41". Tongue member 40" may be inserted in groove 15 of frame element 20 as described hereinabove.
Of course, the shape and design of various other tongue members will be immediately apparent to those of skill in the art. The shape and design of tongue member 40 is not particularly restricted provided that it, in combination with groove 15, provides an interference fit of sufficient strength that trim cover 35 will not readily detach from frame element 20. Similarly, the precise design of groove 15 is not particularly restricted and, in some cases, may be dictated by the design of tongue member 40.
The interference fit provided by the engagement of tongue member 40 with groove 15 should extend along at least a partial periphery of frame element 20. Preferably, this trim cover attachment system extends along substantially all of the periphery of frame element 20. Further in certain applications, it may be convenient to have groove 15 disposed about substantially the entire periphery of frame element 20 but use judicious placement of tongue member 40 to engage only a portion of groove 15 sufficient to provide the interference fit described above. In such a case, the proportion of tongue member 40 (i.e. with respect to groove 15) and the positioning thereof is within the purview of a person skilled in the art.
With reference to FIG. 8, there is illustrated a step in the process of producing an embodiment of the present passenger seat. Thus, frame element 20, shown with a pair of wire sections 18 which serve to anchor the finished passenger seat to the vehicle (not illustrated in earlier Figures for clarity), is provided. Frame element 20 may be produced utilizing a conventional clam-shelf foam mold which has been suitably adapted to provide groove 15 in frame element 20.
The present passenger seat is preferably produced in a mold 100. Mold 100 comprises an upper mold half 105 (also known in the art as a "lid") and a lower mold half 110 (also known in the art as a "bowl"). Upper mold half 105 and lower mold half 110 are engageable to define a mold cavity in the shape of the passenger seat to be produced.
Upper mold half 105 comprises apertures 118 which are positions to receive wires 18 in frame element 20. Upper mold half 105 further comprises a ridge 108 around the periphery thereof which serves as a dam to ingress of liquid foamable polymeric composition to groove 15 (this will be discussed in more detail hereinbelow).
Lower mold half 10 comprises a pair of projections 115 which are angled into the mold cavity from a side wall of lower mold half 110. The purpose of projections 115 will be discussed in more detail hereinbelow. Frame element 20 is positioned in upper mold half 105 in the direction of arrow 120 such that wires 18 in frame element 20 enter apertures 118 in upper mold half 105.
After placement of frame element 20 on upper mold half 105, a liquid foamable polymeric composition is dispensed in lower mold half 110 (not shown). The manner by which the liquid foamable polymeric composition is dispensed in lower mold half 110 is conventional and is not particularly restricted--see, for example, FIG. 7 of the '490 and '747 patents discussed above and incorporated herein by reference.
The precise nature of the liquid foamable polymeric composition is not particularly restricted. Preferably, the liquid foamable polymeric composition comprises a polyurethane derived from a diphenylmethane diisocyanate (MDI)-based system of low index and a high molecular weight conventional polyol. Such a system is typically completely "water blown" using highly-catalyzed odorless amincs and cell regulators. Typically, this system cures at room temperature in about 3 minutes or less. Alternatively, the polyurethane is a toluene diisocyanate (TDI)-based system of low index and of a high molecular weight conventional polyol. When such a TDI-based system is used, the cells of the foam in the finished product should be opened. Opening of such foam cells is within the purview of a person skilled in the art. It can be accomplished by any conventional means such as crushing, kneading, roll pressing, chemical treatment, pressurization and the like of the product while ensuring that the trim cover (if present) is not damaged during the step. It will be appreciated that the liquid foamable polymeric composition may comprise a mixture of MDI-based and TDI-based systems.
After the liquid foamable polymeric composition is dispensed into lower mold half 105. the composition begins to expand. At this point, upper mold half 105 and lower mold half 110 are closed.
Shortly prior to or shortly after closing of upper mold half 105 and lower mold half 110, frame element 20 is preferably pressed against upper mold half 105. This can be accomplished in a number of ways. Preferably, pressing may be accomplished by pulling wires 18 through apertures 118 in a direction away from the mold cavity. This is best illustrated in FIG. 9. Specifically, a cylinder 125 having a movable piston 130 is connected to wire 18 via a link 135. Cylinder 125 may be pneumatically or hydraulically operated to actuate piston 130 in the directions shown at arrow 140. Thus, when it is desired to produce the passenger seat, cylinder 125 is operated to retract piston 130 away from the mold cavity thereby pressing frame element 20 against upper mold half 105.
Alternatively, frame element 20 may pressed against upper mold half 105 by projections 115. As illustrated in FIG. 9, when upper mold half 105 and lower mold half 110 are closed projections 115 press frame element 20 against upper mold half 105.
In certain cases, it may be desirable to use both cylinder 125 and projections 115 in combination to press frame element 20 against upper mold half 105.
Regardless of the mode by which frame element 20 is pressed against upper mold half 105, the pressing means should be designed so as to establish an "interference seal" between ridge 108 in upper mold half 105 and frame element 20. Specifically, upon the application of sufficient pressing force, ridge 108 will be compressibly forced against frame element 20 to provide a seal against ingress of liquid foamable polymeric composition into groove 15.
The present inventors have discovered that, if no steps are taken to seal the periphery of frame element 20 during expansion of the liquid foamable polymeric composition, the latter will flow into and clog groove 15 thereby rendering it unsuitable for application of a trim cover.
Those of skill in the art will readily recognize that the precise shape of ridge 108 is not particularly restricted. The present inventors have discovered that a ridge having a pointed apex is convenient since minimal pressing force is required to obtain the "interference seal" referred to above. Preferably, the ridge has a height less than about 10 mm, more preferably in the range of from about 2 to about 8 mm, even more preferably in the range of from about 2 to about 6 mm, most preferably in the range of from about 2 to about 4 mm.
As illustrated in FIG. 9 use of such a "interference seal" obviates ingress into groove 15 of liquid foamable polymeric composition which forms resilient body 30.
During expansion of the liquid foamable polymeric composition, it is preferred that mold 100 be vented to exhaust expansion gases formed during the reaction of the composition. Such venting is conventional--see, for example, U.S. Pat. No. 5,482,721 Clark et al.!, the contents of which are thereby incorporated by reference.
Upon completion of expansion of the liquid foamable polymeric composition, the foam seat product may be removed from mold 100. Thereafter, trim cover 35 may be applied to the foam product. Preferably, this is done by compressing the foam product and then inserting tongue member 40 into groove 15.
Optionally, the present process can be combined with conventional "foam in-place" processes which serve to bond resilient body 30 to trim cover 35 at the upper surface of seal 10. This would supplement attachment of trim cover 35 to frame element 20. See for example the '490 and '747 patents discussed above and incorporated herein by reference, and U.S. Pat. No. 5,132,063 Hughes!, the contents of which are hereby incorporated by reference.
Preferably resilient body 30 is bonded to frame element 20. However, it is possible to utilize trim cover 35 to mechanically secure resilient body 30 with respect to frame element 20. Optionally, such trim cover attachment can be supplemented by bonding trim cover 35 to resilient body 30--see, for example, U.S. Pat. No. 5,089,191 Hughes! and 5,096,639 Hughes!, the contents of which are hereby incorporated by reference.
While specific embodiments of the present invention have been described hereinabove, those of skill in the art will recognize that a number of modifications and variations are possible without departing from the spirit and scope of the invention.
For example, in the present process, it is possible to substitute frame element 20 with a combination of a conventional metal frame and rigid foam members 23'. In this case, the passenger seat would be produced by fixing the rigid frame member and the rigid foam member to the upper mold half and foaming the liquid foamable polymeric composition in a manner such that the resulting resilient body adheres to the rigid frame element and the rigid foam members. In this instance, ridge 108 can be formed of a non-rigid material such that upon pressing against the rigid frame member, the advantageous "interference seal" is formed.
Further, those of skill in the art will appreciate that various embodiments are possible for the trim cover attachment system. Generally, the trim cover attachment system useful herein is based on the provision of a groove which is adapted to receive and engage a tongue or similar member.
Further, it is possible to modify the present process such that use is made of a foam frame element which has embedded therein a metal wire or the like for fixation to the trim cover. In this instance, the "interference seal" produced by pressing the frame element against the upper mold half would be to retain a portion of the metal wire exposed for later attachment to the trim cover. It should be appreciated that this embodiment is less advantageous than the one described hereinabove relating to the provision of a groove in the foam frame element. Specifically, provision of such a groove results in the elimination of a metal part from the foam seat product--this is always desirable from an engineering viewpoint. Further, elimination of metal from the foam seat product improves the recyclability of the foam seat product.
Still further, it is possible to produce the present passenger seat with or without at least one pelvic support element connected to the frame element. If the pelvic support element is to be used, it is preferred that it be integrally molded with the foam frame element. Further, it is preferred that the vehicle attachment wire (or other means) be molded into the frame element.
Still further, it is contemplated that, in certain applications it is desirable that the underside (i.e. the side of the seat opposite the trim cover) of the seat have structural properties (i.e. able to bend but not break) properties. This is especially desirable if the passenger seat is to be used in a seatback application which is devoid of a metal frame. In such an application, the design challenge is to mitigate the occurrence of projection of heavy articles in the trunk of a vehicle through the rear passenger seat (i.e. the seatback) upon impact of the vehicle. In such cases it may be desirable and preferred to incorporate a reinforcing layer on one or both of the major surfaces of the foam frame element.
The choice of reinforcing layer is not particularly restricted and may be a non-metal or a metal. Preferably, the reinforcing layer is flexible and, more preferably, permeable (i.e. to air, water, etc.). The flexible reinforcing layer may be fibrous or non-fibrous. Non-limiting examples of fibrous reinforcing layers include at least one member selected from the group consisting essentially of glass fibers (e.g. in the form of a cloth or a mat, chopped or unchopped, such as Nico 754 I oz/ft 2 ), polyester fibers, polyolefin fibers (e.g. polyethylene and polypropylene), Kevlar fiber, polyamides fibers (e.g. nylon), cellulose fibers (e.g. burlap), carbon fibers, cloth materials such spun bound polyesters (e.g. Lutravil 1DH7210B/LDVT222 and Freudenberg PTLD585G/PTLD600B) and paper (e.g. Kraft #60). It will be appreciated that the fibrous reinforcing layer may be woven or non-woven. Non-limiting examples of a non-fibrous reinforcing layer comprise at least one member selected from the group consisting essentially of thermosets (e.g. polyurethanes, polyesters and epoxics), metals such as aluminum foil, polycarbonates (e.g. I exan Dow Calibre), polycarbonate/ABS alloys (e.g. Dow Pulse). ABS terpolymers (e.g. Royalite 59 and Dow Magnum), polyester terphthalate (PET), vinyl, styrene maleic anhydride (e.g. Arco Dylark), and fibreglass reinforced polypropylene (e.g. Azdel). It will be appreciated that many non fibrous reinforcing layer materials may themselves be reinforced with fibrous materials and thus, the flexible reinforcing layer may be a combination of fibrous and non-fibrous materials, either mixed or composite in construction. The manner of incorporating a reinforcing layer on a polyurethane foam such as the one used in the frame element 20 is disclosed, inter alia, in U.S. Pat. No. 5,389,316 Kerman!, the contents of which are hereby incorporated by reference.
Other modifications and variations within the scope and spirit of the invention will be apparent to those of skill in the art.
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A passenger seat having trim cover attachment structure includes a frame element, vehicle anchorage structure connected to the frame element, and a seat body having a resilient material fixed with respect to the frame element. Trim cover attachment structure is provided and includes a relatively high density, rigid foam member having a groove disposed in a surface thereof. The groove is capable of receiving connection structure included in the trim cover.
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This application is a continuation-in-part of U.S. application Ser. No. 08/964,459, filed Nov. 4, 1997 now U.S. Pat. No. 5,988,947.
FIELD OF THE INVENTION
The present invention relates generally to a soil remediation device, and more particularly to a multi-section soil remediation device having at least one section for applying a variety of soil treatment regimes. The multi-section device can be adapted to mount to a vehicle for operation in the field.
BACKGROUND OF THE INVENTION
It is widely recognized that years of industry has produced numerous environmentally hazardous sites throughout the country and the world which pose substantial health hazards to the world's population. In recent years, efforts to clean up or remediate environmentally contaminated sites have increased dramatically. Numerous methods and devices for cleaning up or disposing of environmental contamination in water, air, and soil have been devised. The magnitude of the environmental contamination is enormous in comparison to the resources made available to solve this problem.
To address the problem of environmental contamination and particularly soil contamination, a variety of soil treatment and decontamination techniques have been developed. These techniques involve, but are not limited to the application of fluids, biological agents, heat, vacuum, pressurized gases, and mechanical agitation. In order to remediate contaminated soil, it is often necessary to apply several different treatment techniques either alone or in some combination and order that is usually determined by the particular contaminate or contaminates under remediation.
As a consequence, there is an urgent need for a device that can be easily adapted in the field to apply a variety of treatment techniques. This device should be relatively uncomplicated, rapidly configured and assembled in the field, and cost effective. The present invention addresses and solves many of the above-mentioned problems associated with currently available systems.
SUMMARY OF THE INVENTION
The present invention relates to a multi-section soil remediation device having at least one section for applying a variety of soil treatment regimes. The multi-section device can be adapted to mount to a vehicle for operation in the field.
The multi-section device includes at least two soil remediation chambers each having an inlet, an outlet, and a soil conveyor for conveying soil from the chamber inlet to its outlet. The soil remediation chamber is arranged such that the outlet of at least one remediation chamber feeds soil into the inlet of at least one other remediation chamber. The multi-section device also includes a soil treatment delivery system connected to and in communication with at least one of said soil remediation chambers. The soil treatment delivery system delivers soil treatment to the soil that is conveyed within the soil remediation chamber.
It is an object of this invention to provide a multi-section soil remediation device that is relatively uncomplicated, rapidly configured and assembled in the field for applying various treatment techniques in cost effective manner to remediate environmentally contaminated sites. It is another object of this invention to provide a highly mobile apparatus for remediating environmental contaminants. It is yet another object of this invention to provide a method of remediating contaminated soil in situ and without removal or disposal of the treated or contaminated material to a remote location. It is yet another object of the invention to provide a method that is capable of remediating contaminated soils and sludge in a continuous manner.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, there is shown in the drawings a form which is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 is an illustration of a multi-section soil remediation device as contemplated by the present invention.
FIG. 2 is an illustration of a multi-section soil remediation device as contemplated by the present invention having an alternate soil conveying mechanism.
FIG. 3A is an illustration of a multi-section soil remediation device as contemplated by the present invention shown attached to a vehicle.
FIG. 3B is an illustration of a multi-section soil remediation device as contemplated by the present invention having an alternate discharge arrangement.
FIG. 3C is an illustration of a multi-section soil remediation device as contemplated by the present invention having a horizontal arrangement of elements and shown attached to a vehicle.
FIG. 4 is an illustration of a portion of the multi-section soil remediation device as contemplated by the present invention having a magnetohydrodynamic apparatus for soil remediation.
FIG. 5 is an illustration of a portion of the multi-section soil remediation device as contemplated by the present invention having a laser apparatus for soil remediation.
FIG. 6 is an illustration of a multi-section soil remediation device as contemplated by the present invention having an alternate arrangement of elements and shown attached to a vehicle.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is a multi-section soil remediation device having at least one section for applying a variety of soil treatment regimes. The multi-section device can be adapted to mount to a vehicle for operation in the field.
Referring now to the drawings, wherein like numerals indicate like elements, there is shown in FIG. 1 a multi-section soil remediation device 10 as contemplated by the present invention. The multi-section soil remediation device 10 includes a plurality of soil remediation chambers 20 . Each chamber 20 a, 20 b, 20 c having an inlet 60 , an outlet 70 , and a soil conveyor 80 therein for conveying soil from the chamber inlet 60 to its outlet 70 . The soil remediation chambers 20 being arranged such that the outlet 70 of at least one remediation chamber feeds soil into the inlet 60 of at least one other remediation chambers 20 .
The inlet 60 of one soil remediation chambers 20 is designed to fit within the outlet 70 of another soil remediation chambers 20 . For example, the shape of the inlet 60 and outlet 70 are matingly frustoconical such that one fits within the other forming a tight seal. The seal can be further enhanced by form gaskets or elastic collars. The soil remediation chambers 20 are typically arranged in a vertical orientation and supported by a frame that maintains the position of the soil remediation chambers 20 and the seal between the inlet 60 and outlet 70 . However, it is understood that the arrangement of the soil remediation chambers 20 can be in any orientation including vertical, horizontal, or some combination thereof. In addition the form, mating, and seal between the inlet 60 and outlet 70 of two soil remediation chambers 20 can also be varied in shape and material.
The multi-section soil remediation device 10 also includes a soil treatment delivery system 40 having a plurality of treatment delivery elements 40 a, 40 b, 40 c connected to and in communication with at least one of said soil remediation chambers 20 for delivering soil treatment to soil conveyed within the soil remediation chambers 20 . The soil conveyor 80 is powered by a commercially available drive system 85 such as, but not limited to, a gear and chain arrangement powered by a gas or diesel engine or hydraulic motor (not shown).
In one aspect of the present invention as shown in FIG. 1, the soil remediation chambers 20 are preferably cylindrical tubes. However it is understood that the soil remediation chambers 20 are not limited to cylindrical tubes and can be any shape such as, but not limited, to oval or rectangular. The chambers 20 have a screw-type conveyor 80 that is operative within the cylindrical tubes 20 a, 20 b, 20 c and move the soil received through the inlet 60 until discharged through the outlet 70 by the cylinders 20 a, 20 b, 20 c.
In another aspect of the present invention as shown in FIG. 2, the chambers 20 have a belt-type conveyor 90 that is operative within the cylindrical tubes 20 a, 20 b, 20 c. The belt-type conveyor 90 moves the soil received by the inlet 60 so that it can be discharged through the outlet 70 . The soil is treated as it is conveyed through the cylindrical tubes 20 a, 20 b, 20 c by materials injected in and removed from the tubes by the treatment delivery system 40 .
In another aspect of the present invention as shown on FIG. 3A, the soil remediation chambers 20 of the multi-section soil remediation device 10 are arranged in a vertical plane and supported by a frame 240 attached to a track vehicle 200 . In this aspect of the multi-section soil remediation device 10 , the conveyors (not shown) are powered by equipment on the track vehicle 200 . The soil is fed into the inlet 60 of the soil remediation chambers 20 where it is remediated and discharged through the outlet 70 . It is understood that the location of the inlet 60 and outlet 70 can be anywhere on or near the track vehicle 200 . For example, FIG. 3A shows the outlet the soil remediation chamber 20 c to be within the body of the track vehicle 200 . In another example, FIG. 3B shows the outlet the soil remediation chambers 20 c to be outside the body of the track vehicle 200 .
In another aspect of the present invention as shown in FIG. 3C, a multi-section soil remediation device 10 is shown having a horizontal arrangement of soil remediation chambers 400 also shown attached to a vehicle 480 . The conveyors (not shown) within the soil remediation chambers 400 are powered by a power unit 430 on the track vehicle 480 .
In all aspects of the present invention, the multi-section soil remediation device 10 includes a soil treatment delivery system 40 adapted to inject or extract, individually or in combination, solid, liquid, or gaseous soil treatment compounds, at a selected temperature, into, or from, the soil remediation chambers 20 , 400 .
For example, the soil treatment delivery system 40 shown in FIG. 3B includes a vapor, liquid and solid emission recovery system 310 for recovering vapor emissions produced in the soil remediation chambers 20 . Soil treatment delivery systems and emission recovery systems are described in greater detail in U.S. Pat. No. 5,631,160 and U.S. application Ser. No. 08/693,629, invented and owned by the present inventor and are incorporated herein by reference.
In FIG. 3B the emission recovery system 310 can recover emissions such as, but not limited to, vapor, liquid and solid produced or remediated in the soil remediation chambers 20 . The emission recovery system 310 includes, but is not limited to, a thermal oxidation system or an activated carbon system. For example, thermal oxidation systems such as flameless oxidizers for VOC and HAP control are made by Thermatrix Inc. can be incorporated directly into a remediation chamber 20 or added at any point along or between a remediation chamber 20 .
In one aspect of the present invention the emission recovery system 310 has a hydraulic power source 210 which includes a combustion engine, a hydraulic pump driven by the engine and a hydraulic reservoir for storing and supplying hydraulic fluid to the hydraulic pump. It is understood that the power source need not be hydraulic and can be provided by a power source that is external to the multi-section soil remediation device 10 .
The power source 210 may further include ancillary hydraulically powered appliances and related attachments including, but not limited to: fluid pumps, air blowers, fluid storage containers, and air treatment canisters 220 . The power source further includes a hydraulic distribution system which directs the hydraulic power to the ancillary appliances of the power unit and to the auxiliary equipment associated with the vehicle. The distribution system may be separate from or incorporated with the hydraulic pump. The power source 210 may further include a control console (not shown) and related circuitry adapted for mounting on a vehicle in proximity to its operator. The control console is used to control and operate the ancillary appliances of the power source 210 and the auxiliary equipment associated with a vehicle 200 .
In another aspect of the present invention as shown in FIG. 4, a portion of the multi-section soil remediation device 10 as contemplated by the present invention has a magnetohydrodynmic plasma apparatus 200 for soil remediation. The magnetohydrodynmic plasma apparatus 200 has a probe 250 that allows plasma energy to contact and treat the soil on a conveyer 90 within the soil remediation chambers 20 . It is contemplated that plasma devices such as Arc Plasma Systems and Induction Coupled Plasma (ICP) technology would be used by the present invention. An example of one such ICP system is described in Plasma Technology, Inc., Induction Coupled Plasma (ICP) in Comparison with ARC Plasma Systems An Introduction, and is incorporated herein by reference.
It is also contemplated that soil remediation can be accomplished by other processes such as biodegradation, hot air injection, and/or the use of phosphate or carbonate sources. For example, degradation of coal tar and its constituents can be accomplished by white rot fungi or by phanerochaete chrysosporium as described in U.S. Pat. Nos. 5,597,730 and 5,459,065, respectively and are incorporated herein by reference. Hot air injection can be accomplished by utilizing the exhaust heat that is generated by engines on-board or in proximity to the invention. In another example, remediation of soils or slurries containing heavy metals such as arsenic, cadmium, chromium, copper, lead, or zinc can be accomplished by applying phosphate, carbonate or sulfate sources as described for example in U.S. Pat. Nos. 5,202,033, 5,037,479 and 4,889,640 and are incorporated herein by reference.
In yet another aspect of the present invention as shown in FIG. 5, a portion of the multi-section soil remediation device 10 as contemplated by the present invention has a laser apparatus 100 for soil remediation. The laser apparatus 100 has an aperture 150 that allows laser energy to contact and treat the soil in the conveyer 90 with in the soil remediation chambers 20 . It is contemplated that laser devices such as, but not limited to, a LUMONICS Corporation MW3000 focus head would be used by the present invention.
Multiple laser apparatus 100 and magnetohydrodynmic plasma apparatus 200 can be mounted to the soil remediation chambers 20 . These apparatus can be positioned to provide 360° area coverage of laser or plasma energy on the soil as it is conveyed through the soil remediation chambers 20 . The laser apparatus 100 and magnetohydrodynmic plasma apparatus 200 can be mounted on one or all of the soil remediation chambers 20 as needed to ensure complete treatment of the soil.
Power for the laser apparatus 100 and magnetohydrodynmic plasma apparatus 200 can be supplied by the power source 210 as shown in FIG. 3 A. It is recognized that laser and plasma treatment can induce extremely high temperatures within the soil remediation chambers 20 . Heat sensors and air emission monitoring equipment can employed to maintain environmental compliance and the interior components of the soil remediation chambers 20 can be made of suitable heat resistant materials to ensure proper operation of the equipment.
In yet another aspect of the present invention (not shown), at least one soil remediation chambers 20 is a membrane treatment system such as, but not limited to, a Kenterprise Research, Inc. MLM-20 oil separator as described by James Keane, Membrane-Like-Material A New Approach for Oily Water Treatment Spills Control Management 1996 and incorporated herein by reference.
In yet another aspect of the present invention (not shown), at least one soil remediation chambers 20 is an oxygen treatment system such as, but not limited to, a PermeOx® Solid Peroxygen system made by FMC Corporation as described in PermeOx® Solid Peroxygen Can Enhance Conventional Bioremediation Methods, FMC Corporation 1994 and incorporated herein by reference.
In yet another aspect of the present invention (not shown), at least one soil remediation chamber 20 is equipped with an ultraviolet light source for treatment of contaminates susceptible to ultraviolet light.
In yet another aspect of the present invention (not shown), the track vehicle 200 is equipped with a Ground Penetrating Radar System (GPR) for locating underground utility installations, geologic formations, and debris. In addition, the track vehicle can have magnetic material removal devices, screening, shredding and crushing devices for additional treatment of the soil within the soil remediation chambers 20 .
In yet another aspect of the present invention, the present invention 10 including the track vehicle 200 and can be manually operated on-board, remotely operated or configured to automatically operate according to pre-selected parameters stored in an on-board computerized control system.
In another aspect of the present invention as shown in FIG. 6, the multi-section soil remediation device 10 can be attached to an in-situ trenching tool 500 as described in U.S. Pat. No. 5,631,160. FIG. 6 shows the vehicle 200 , power source 210 and emission recovery system 310 for operation in cooperation with the trenching tool 500 .
The trenching tool 500 penetrates the ground, churns, comminutes, and macerates the soil in situ with a plurality of chain driven carbide-tipped teeth (not shown). A portion of the soil is feed into a soil remediation chambers 20 where a remediation fluid is discharged into the soil as it is conveyed through the remediation chambers 20 . In one aspect of the present invention, a screw type conveyer (as shown in FIG. 1) is used which comminutes the soil allowing it to macerate with the treatment fluids which further enhances the extraction of contaminates.
The contaminates are also removed from the soil remediation chambers 20 by a common or additional soil treatment delivery system 40 . It is understood that the remediation fluid may include, and is not limited to, decontamination solids, fluids or heated gases such as air as described in greater detail in U.S. Pat. No. 5,631,160.
As shown in FIG. 6, a remediation fluid injection apparatus 40 is mounted to the remediation chambers 20 to inject a remediation fluid and extract contaminants from a portion of the soil provided by the trenching tool 500 . The injection apparatus 40 includes a plurality of injectors positioned along the length of the remediation chambers 20 . The injectors are supplied with remediation fluid by the emission recovery system 310 . This in-situ soil remediation treatment apparatus and procedure is further explained in related U.S. Pat. No. 5,631,160.
It is further contemplated that the multi-chambered apparatus may be used to execute a chemical oxidative remediation scheme, particularly for the degradation of contaminant organic compounds. A preferred method of chemical oxidative remediation incorporates principles of the Fenton's reaction, in which hydroxyl radicals are generated by decomposition of hydrogen peroxide over a ferrous ion catalyst. Hydroxyl radicals, in turn, react with organic compounds and facilitate those compounds' degradation to innocuous compounds, or further to CO 2 and water. Prior art applications of this chemistry include U.S. Pat. Nos. 5,525,008 and 5,611,642.
Chemical oxidative remediation is applicable to saturated or unsaturated soil, sediment, or sludge (collectively, “soil”) contaminated with polychlorinated biphenyls (PCB's), polynuclear aromatic hydrocarbons (PAH's), chlorinated solvents, nitro-aromatic compounds, organic pesticides, mineral oil products, cyanide, and volatile organic compounds (such as gasoline constituents benzene, toluene, ethylbenzene, xylene, etc.). The remediation method using the multi-chambered apparatus is preferably undertaken as follows. The type and concentration of contamination at a target site determines the amount of oxidative treatment reagents that must be employed. A source of ferrous ion (Fe +2 ), such as ferrous sulfate, is then introduced to the contaminated soil.
The ferrous sulfate or other source of ferrous ion can be delivered to the contaminated soil several ways. The ferrous ion source may be applied to the soil surface, then mixed into the soil by the comminuting action of a trenching tool. The ferrous ion source may alternatively be injected into the soil during the trenching operation by such trenching tool as disclosed in U.S. Pat. No. 5,830,752, bearing injection nozzles adjacent the trenching blade to deliver the ferrous ion source. As another alternative, the ferrous ion source may be introduced into the contaminated soil in the first chamber of a multi-section remediation apparatus, such as chamber 20 a of FIG. 1, mounted on a mobile trenching vehicle as shown in FIG. 6 .
The pH of the soil should be within the range of about 5 to about 7, and preferably between about 6.0 and 6.5, for a controlled, effective oxidative reaction to occur. Consequently, the pH of the soil is preferably measured after ferrous ion has been introduced. Soil showing higher pH values can be brought into a preferred range by addition of dilute HCl solution or sulfinic acid to the soil. Likewise, soils having a pH below the preferred range can be brought into the preferred range by addition of lime. The pH-adjusting agent (HCl or lime, for example) can be mixed into the soil in the same manner as described for the ferrous ion source, i.e. by trencher or in the next chamber of a multi-section remediation apparatus, such as chamber 20 b of FIG. 1
A source of hydroxyl radicals is then added to the contaminated soil. Aqueous hydrogen peroxide solution is a preferred source of hydroxyl radicals, as is sodium percarbonate. The hydrogen peroxide may be introduced to the soil in any of the ways described for the ferrous ion source, i.e. by trencher or in the next chamber of a multi-section remediation apparatus, such as chamber 20 c of FIG. 1 .
The remediation treatment may be done on saturated or unsaturated soils, sediment, or sludge. Dry soils may require that water be added to the soil to promote better reaction conditions.
An important aspect of the remediation treatment is that mechanical agitation is employed to mix the contaminated soil with the remediation reagents and catalysts. Such agitation is accomplished with the trenching tool noted above, or the means for conveying soil within the device of FIGS. 1 or 6 .
The advantages of mechanical agitation to promote mixing are several. Comminution of the soil creates better contact between organic compound contaminants, catalyst, and remediation reagent(s) to promote faster reaction rates and increase the likelihood that the degradative reactions will proceed to completion. Secondly, the thorough mixing enabled by mechanical agitation aids in controlling and dissipating then heat generated by the reactions. The oxidative degradation reactions are exothermic; in fact, runaway reactions can result in explosive conditions in the soil. This is a disadvantage of prior art remediation schemes that rely solely on the advective effects of groundwater to transport remediation reagents to contaminants in the soil or groundwater. Comminuting the soil breaks up dense soils such as clays and produces fissures in the soil that increase air circulation to carry off heat. This promotes better heat transfer, and results in safer operating conditions.
As noted, the device described in FIGS. 1 and 6 may serve as a tool for undertaking the method described above. Further, a single chamber mobile device may be adapted to employ the remediation method of the invention. In a preferred embodiment, the multi-section soil remediation device of FIG. 6 is employed. In such embodiment, contaminated soil is removed from the ground via a trenching tool 500 and fed into a first soil remediation chamber 20 a, wherein a ferrous ion source such as ferrous sulfate is discharged into the soil via soil treatment delivery system 40 as it is conveyed through the remediation chamber. i.e. by trencher or in the next chamber of a multi-section remediation apparatus, such as chamber 20 b of FIG. 1 . The soil then passes to a second remediation chamber 20 b, wherein a pH-adjusting agent is introduced, if necessary, via injection apparatus 40 . The soil then moves to a third remediation chamber 20 c, wherein hydrogen peroxide is introduced to the soil via injection apparatus 40 .
The conveyance mechanism in the soil remediation chambers is preferably a screw-type conveyor 80 to provide the mechanical agitation to promote mixing in the soil. A rotating drum may also be used to effectuate the necessary mixing. Temperature sensors (not shown) can provide feedback to the operators on the extent of the degradation reaction. The treated soil is then returned to the ground.
It will be appreciated that the present invention provides a highly flexible, highly adaptable soil remediation system which enables rapid and adaptable treatment of contaminated materials. In addition, the invention's multi-section construction greatly reduces complexity and cost of the equipment while providing greater efficiency and productivity. These and other advantages of the present invention will be apparent to those skilled in the art from the foregoing specification.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.
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The present invention relates generally to a soil remediation method, and more particularly to a soil remediation method relying on the chemical oxidation of organic contaminants in saturated or unsaturated soil and aided by mechanical agitation of the soil. The method may be carried out in ex-situ or in-situ schemes per the devices disclosed herein.
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FIELD OF THE INVENTION
[0001] This invention relates generally to the fabrication of nanotube based electronic devices, and, more particularly, to the fabrication of electronic devices using nanotubes grown in a reaction chamber using a solvent based catalyst.
BACKGROUND OF THE INVENTION
[0002] Carbon is one of the most important known elements and can be combined with oxygen, hydrogen, nitrogen and the like. Carbon has four known unique crystalline structures including diamond, graphite, fullerene and carbon nanotubes. In particular, carbon nanotubes refer to a helical tubular structure grown with a single wall or multi-wall, which can be obtained by rolling a sheet formed of a plurality of hexagons. The sheet is formed by combining each carbon atom thereof with three neighboring carbon atoms to form a helical tube. Carbon nanotubes typically have a diameter in the order of a fraction of a nanometer to a few hundred nanometers.
[0003] Carbon nanotubes can function as either a conductor, like metals, or a semiconductor, according to the rolled shape and the diameter of the helical tubes. With metallic nanotubes, it has been found that a one-dimensional carbon-based structure can conduct a current at room temperature with essentially no resistance. Further, electrons can be considered as moving freely through the structure, so that metallic nanotubes can be used as ideal interconnects. Introducing a defect into a metallic tube can result in a single electron charging effect. The single electron charging effect can be used to make a single electron transistor. When semiconductor nanotubes are connected to two metal electrodes, the structure can function as a field effect transistor wherein the nanotubes can be switched from a conducting to an insulating state by applying a voltage to a gate electrode. Therefore, carbon nanotubes are potential building blocks for nanoelectronic devices because of their unique structural, physical, and chemical properties.
[0004] Existing methods for the production of nanotubes, including arc-discharge and laser ablation techniques, yield bulk materials with tangled nanotubes. The nanotubes in the bulk materials are mostly in bundled forms. These tangled nanotubes are extremely difficult to purify, isolate, manipulate, and use as discrete elements for making functional devices. Originally, carbon nanotubes produced by an arc discharge between two graphite rods was discovered and reported in an article entitled “Helical Microtubules of Graphitic Carbon” (Nature, Vol. 354, Nov. 7, 1991, pp. 56-58) by Sumio Iijima. This technique is commonly used to produce carbon nanotubes, however, yield of pure carbon nanotubes with respect to the end product is only about 15%. Thus, a complicated purification process must be carried out for particular device applications.
[0005] Another conventional approach to produce carbon nanotubes, which was described in an article entitled “Epitaxial Carbon Nanotube Film Self-organized by Sublimation Decomposition of Silicon Carbide” (Appl. Phys. Lett. Vol. 71, pp. 2620, 1977), by Michiko Kusunoki, is to produce carbon nanotubes at high temperatures by irradiating a laser onto graphite or silicon carbide. In this case, the carbon nanotubes are produced from graphite at about 1200° C. or more and from silicon carbide at about 1600 ° C. to 1700 ° C. However, this method also requires multiple stages of purification which increases the cost. In addition, this method has difficulties for large-device applications.
[0006] Some of the drawbacks of these two methods are that the tubes are formed under an extremely high temperature environment and are usually produced as bundles, embedded with catalyst particles which are covered with amorphous carbon. To fabricate devices using nanotubes produced from these methods, various cleaning and debundling steps are required. The debundled nanotubes are then suspended in a solution, which can then be positioned on a substrate with patterned electrodes or other circuitry. However, it is extremely difficult to control the placement and orientation of the nanotubes when using these methods. It is therefore very inefficient to fabricate electronic devices using nanotubes formed either by arc discharge or laser ablation.
[0007] U.S. Pat. No. 6,346,189 issued to Dai et al. on Feb. 12, 2002 discloses a method of selectively producing high quality single walled carbon nanotubes on a substrate using catalyst islands. The catalyst particles consisting of Fe 2 O 3 or other transition metal oxides are suspended in methanol. According to the method, a first lithography step is used to pattern a substrate with catalyst islands, wherein the first lithography step uses e-beam lithography. Nanotubes are then grown using a chemical vapor deposition process. Electrical contact to the nanotubes is made by performing a second lithography step to form electrodes. However, during the second lithography step, the nanotubes may be damaged and contaminated.
[0008] Accordingly, it is an object of the present invention to provide a new and improved approach for fabricating nanotube based electronic devices.
SUMMARY OF THE INVENTION
[0009] To achieve the objects and advantages specified above and others, a method of fabricating a nanotube structure is disclosed which includes providing a substrate, providing a mask region positioned on the substrate, and patterning and etching through the mask region to form at least one trench. A conductive material layer is deposited within the at least one trench and a nanoparticle catalyst is deposited onto the conductive material layer within the at least one trench. The mask region is removed using a conventional lift-off technique, such as a single step lift-off process, to form nanoparticle catalyst coated electrodes. The nanotubes are formed from the catalyst using a reaction chamber with a hydrocarbon gas atmosphere.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The foregoing and further and more specific objects and advantages of the instant invention will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment thereof taken in conjunction with the following drawings:
[0011] FIG. 1 is a cross sectional view of a step in a sequence of fabricating a nanotube structure;
[0012] FIG. 2 is a cross sectional view of another step in the sequence of fabricating a nanotube structure;
[0013] FIG. 3 is a cross sectional view of still yet another step in the sequence of fabricating a nanotube structure;
[0014] FIG. 4 is a cross sectional view of a step in the sequence of fabricating a nanotube structure;
[0015] FIG. 5 is a cross sectional view of another step in the sequence of fabricating a nanotube structure; and
[0016] FIG. 6 is a cross sectional view of still yet another step in the sequence of fabricating a nanotube structure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] Turn now to FIG. 1 which illustrates a step in a method to fabricate a nanotube structure 5 in accordance with the present invention. In the preferred embodiment, nanotube structure 5 includes a substrate 10 wherein substrate 10 includes silicon. However, it will be understood that other substrate materials may be appropriate, such as a glass, a ceramic, a metal, or other semiconductor materials. Other semiconductor materials can include, for example, gallium arsenide (GaAs) or the like. Further, substrate 10 can include control electronics or other circuitry, which are not shown in this embodiment for simplicity. Also, substrate 10 can include an insulating layer, such as silicon oxide (SiO), silicon nitride (SiN), or the like.
[0018] A mask region 13 is positioned on surface 11 of substrate 10 . In the preferred embodiment, mask region 13 includes a bi-layer resist of a photoresist layer 14 positioned on surface 11 and a photoresist layer 14 positioned on layer 12 . A bi-layer resist is used in the preferred embodiment to facilitate the lift-off process, as will be discussed separately.
[0019] As illustrated in FIG. 2 , mask region 13 is patterned and etched through layers 12 and 14 to form at least one trench. In the preferred embodiment, a trench 15 and a trench 17 are formed within mask region 13 , but it will be understood that it is anticipated that an array of trenches could be formed therewith. In this embodiment, two trenches are illustrated for simplicity and ease of discussion. Further, mask region 13 can be patterned using optical lithography, e-beam lithography, or other techniques well known to those skilled in the art.
[0020] Turning now to FIG. 3 , a conductive material layer 18 is deposited on surface 11 within trench 15 and a conductive material layer 20 is deposited on surface 11 within trench 17 . Further, it is anticipated that a conductive material layer 16 will be formed on mask region 13 as illustrated. In the preferred embodiment, layers 16 , 18 , and 20 include gold (Au), but it will be understood that other conductive materials, such as aluminum (Al), platinum (Pt), silver (Ag), copper (Cu), or the like, may be used.
[0021] Further, in the preferred embodiment, layers 16 , 18 , and 20 are illustrated to include the same conductive material for simplicity, but it will be understood that they can include different conductive materials. For example, layer 18 can include gold (Au), layer 16 can include aluminum (Al), and layer 20 can include platinum (Pt) wherein it will be understood that the fabrication sequence would be, in general, different from the preferred embodiment. However, the differences are well known to those skilled in the art and will not be elaborated upon further here.
[0022] Turning now to FIG. 4 , a solution containing nanoparticle catalyst 22 is deposited on conductive material layer 18 , a nanoparticle catalyst 24 is deposited on conductive material layer 16 , and a nanoparticle catalyst 26 is deposited on conductive material layer 20 . Nanoparticle catalysts 22 , 24 , and 26 include nanoparticles suspended within the solvent which is compatible with the material included in mask region 13 . In the preferred embodiment, the nanoparticles can include a transition metal, such as iron (Fe), nickel (Ni), cobalt (Co), or the like, or another suitable nanoparticle catalyst well known to those skilled in the art. Further, catalysts 22 , 24 , and 26 can be deposited by several methods including spraying on, spinning on, or the like, which are well known to those skilled in the art.
[0023] Turning now to FIG. 5 , a lift-off process is performed to remove mask region 13 from substrate 10 . Further, conductive material layer 16 with catalyst particles 24 thereon is also removed during the liftoff.
[0024] Turning now to FIG. 6 , nanotube structure 5 is placed in a reaction chamber with a hydrocarbon gas atmosphere to form at least one nanotube 28 . The reaction chamber can include a chemical vapor deposition chamber, a chemical beam epitaxy chamber, a molecular beam epitaxy chamber, or the like. Further, in the preferred embodiment, the hydrocarbon gas atmosphere includes methane. However, it will be understood that the hydrocarbon gas atmosphere can include other gases, such as ethylene, acetylene, carbon monoxide, or the like. In the preferred embodiment, a single nanotube 28 is illustrated, but it will be understood that a plurality of nanotubes could be formed and electrically connect layers 18 and 20 . However, a single nanotube is illustrated in this embodiment for simplicity and ease of discussion.
[0025] In the preferred embodiment, nanotube 28 is a carbon nanotube, but it will be understood that nanotube 28 can include other nanotube forming materials, such as boron nitride (BN), with the desired electrical and physical properties. In the preferred embodiment, an end 27 of nanotube 28 is electrically connected to conductive material layer 18 and an end 29 is electrically connected to conductive material layer 20 . During the formation of nanotube 28 , an electric field may be applied between layers 18 and 20 to align nanotube 28 in a preferred direction and facilitate the electrical connection therewith.
[0026] Thus, a new and improved method of fabricating a nanotube structure has been disclosed. The method involves using a single step patterning process which simplifies the fabrication process. A bi-layer resist patterning process is used to facilitate the lift off process and reduce residual catalyst particles that may be present in undesired regions when using a single resist layer. The method also involves using a solvent, which in the preferred embodiment is water (H 2 O), to suspend the nanoparticle catalyst. Water is a solvent that is compatible with most resist material included in mask region 13 , and, therefore, eliminates pattern deformation caused by the reaction between an organic solvent and mask region 13 . Another important aspect of this method is that contamination of the nanotubes is minimized. Further, the nanotubes are less likely to be damaged. Contamination and damage typically occur during a post nanotube growth patterning process. Further, this method allows the alignment of the nanotubes with an electric field during chemical vapor deposition processing.
[0027] Various changes and modifications to the embodiments herein chosen for purposes of illustration will readily occur to those skilled in the art. To the extent that such modifications and variations do not depart from the spirit of the invention, they are intended to be included within the scope thereof which is assessed only by a fair interpretation of the following claims.
[0028] Having fully described the invention in such clear and concise terms as to enable those skilled in the art to understand and practice the same, the invention claimed is:
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A method of fabricating a nanotube structure which includes providing a substrate, providing a mask region positioned on the substrate, patterning and etching through the mask region to form at least one trench, depositing a conductive material layer within the at least one trench, depositing a solvent based nanoparticle catalyst onto the conductive material layer within the at least one trench, removing the mask region and subsequent layers grown thereon using a lift-off process, and forming at least one nanotube electrically connected to the conductive material layer using chemical vapor deposition with a methane precursor.
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BACKGROUND OF THE INVENTION
[0001] This application is a CIP Patent Application of U.S. patent application Ser. No. 11/315,227 filed Dec. 23, 2005 and is hereby incorporated by reference.
[0002] The invention relates in general to display devices and more specifically to an apparatus and method for displaying a picture or postcard or other aesthetic article.
[0003] Picture display devices such as picture frames allow the presentation of a photograph or other planar item for easy viewing. Many picture frames can be placed on a flat surface such as table or desk such that the displayed item is positioned at a pleasing viewing angle. Conventional display devices, however, have several limitations. For example, many conventional designs partially obscure the displayed item with a frame or clip. Further, many conventional display devices are heavy, bulky, and relatively expensive. Many picture frames in include a glass panel to protect the displayed device and, therefore, may pose a danger if dropped or otherwise broken.
[0004] Postcards provide a mechanism for mailing a message along with a selected picture. Although the selected image may be attractive, humorous, or otherwise entertaining, available images are limited and are not personalized. Often the sending party would prefer to send a personal photograph rather than a generic postcard. Conventional techniques for mailing personal photographs include using an envelope, using a framed postcard device, and applying a sticker to the back of the photograph. Conventional mailing techniques, however, are limited in several ways. For example, some conventional techniques are limited in that the photograph is partially or completely obscured by the article used to mail the photograph. When a photograph is mailed in an envelope, the entire image is covered until the recipient opens the package. Other devices include a frame that covers a portion of the custom photograph or picture. In addition, conventional mailing products are limited in that the photograph or other displayed item can not be easily positioned for display. Mailed photographs must often be displayed by securing the photograph to vertical surface using tacks or magnets or by placing the photograph in a picture frame.
[0005] Accordingly, there is need for an apparatus and method for efficiently displaying a displaying a planer display item.
SUMMARY OF THE INVENTION
[0006] A display device, comprising a clear-front envelope formed by foldable blank including at least one backing flap folded around a transparent sheet leaving an opening for receiving the planar displayed item, such as a photo; postcard; etc. The opening is at least partially closed when a sealing flap integrally formed with said foldable blank is secured to the backing flap. A support flap is integral with the sealing flap, the support flap being configured to fold at fold line adjacent to the backing flap and having an end for resting on a horizontal surface to support the clear-front envelope at a viewing angle to the horizontal surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is an illustration of an exploded perspective view of an unsealed display device in accordance with the exemplary embodiment of the invention.
[0008] FIG. 2 is an illustration of a perspective view of the display device of FIG. 1 shown in a sealed state.
[0009] FIG. 3 is an illustration of a perspective view of the display device in use in a landscape orientation in accordance with the exemplary embodiment of the invention.
[0010] FIG. 4 is a diagram of a side view of the display device in use in a landscape orientation in accordance with the exemplary embodiment of the invention.
[0011] FIG. 5 is an illustration of a perspective view of the display device in use in a portrait orientation in accordance with the exemplary embodiment of the invention.
[0012] FIG. 6 is a diagram of side view of the display device in use in a portrait orientation in accordance with the exemplary embodiment of the invention.
[0013] FIG. 7 is an exploded perspective bottom view of an unsealed display device in accordance with the exemplary embodiment of the invention.
[0014] FIG. 8 is a perspective bottom view of a partially sealed display device in accordance with the exemplary embodiment of the invention.
[0015] FIG. 9 is an additional perspective bottom view of a partially sealed display device in accordance with the exemplary embodiment of the invention.
[0016] FIG. 10 is a perspective view of a sealed display device in accordance with the exemplary embodiment of the invention.
[0017] FIG. 11 is an illustration of a alternate embodiment of the present invention including a pop-up feature.
[0018] FIG. 12 shows the die-cut perforations in the connection portion.
[0019] FIG. 13 is an illustration of a further modified embodiment of the present invention including an optional magnet for attaching the frame to a suitable metallic surface.
[0020] FIG. 14 shows a thin planar magnet mounted for use on an assembled display device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] According to this invention, a foldable support flap is affixed to a backing flap of an envelope having a main window portion to form a photograph display device. A user encloses a photograph, postcard or other thin, planar item to be displayed into a pocket formed between the main window portion and the foldable paper backing by folding side flaps and sealing flap relative to the main window portion. A transparent sheet may be disposed at the main window portion. Any combination of indicia such as advertisements, decorative marking, and instructions may be included on either side of the transparent front sheet, the main window portion, the foldable paper backing, and/or the support flap. In the exemplary embodiment, the display device includes postcard indicia such a stamp placement square and address lines allowing the display device to be used as a personalized postcard for mailing photographs or other display items. The foldable blank is typically partially sealed to create the pocket or envelope for receiving a photograph or postcard. As such, a user can easily insert a photograph, seal the display device and mail the display device. In addition to minimizing production costs, an efficient, integrated construction provides a durable display device that requires minimal manipulation and assembly by the user. Although the device may be used for mailing display items, the display device may be used solely as a safe, lightweight, and inexpensive picture frame that allows full view of the display item.
[0022] FIG. 1 is an illustration of a perspective view of an unsealed and unfolded display device 100 in accordance with one embodiment of the invention. The display device 100 includes at least one support flap 104 and at least one foldable backing flap 106 connected to a main window portion 108 . Further, a pair of side flaps 107 , 109 may be disposed along opposite edges of the main window portion 108 . Disposed adjacent the main window portion 108 is a protective transparent plastic sheet 112 . The foldable backing flap 106 and the support flap 104 are formed from paper stock and connected to the main window portion 108 through respective living hinges 106 a , 122 a. Likewise, side flaps 107 , 109 are connected to the main window portion 108 via living hinges 107 a, 109 a.
[0023] FIG. 2 shows the display device of FIG. 1 in the folded in sealed state. Although in the exemplary embodiment the display device 100 has a rectangular shape, the display device 100 may be square, triangular, oval, circular or any other suitable, preferably planar, shape.
[0024] FIG. 3 is an illustration of a perspective view and FIG. 4 is an illustration of a side view of the display device 100 in use in a landscape orientation in accordance with the exemplary embodiment of the invention. Where the display device 100 is designed to display rectangular display items, the display device 100 displays the display item in a landscape orientation by placing a long side 202 of the display device parallel to a horizontal flat surface 300 such as a desk or table. Neither of the short sides 204 , therefore, rests on the horizontal surface 300 when the display device 100 is in the landscape orientation. The support flap 104 is folded back to the appropriate distance from the paper backing by the user to set the desired viewing angle, α, 302 of the display item. As the support angle, β, 304 is increased, the viewing angle, α, 302 also increases allowing the display item to be more easily viewed form higher elevation above the horizontal surface 300 .
[0025] FIG. 5 is an illustration of a perspective view and FIG. 6 is a side view of the display device 100 in use in a portrait orientation in accordance with the exemplary embodiment of the invention. Where the display device 100 is designed to display rectangular display items, the display device can be used to display the display item in a portrait orientation by placing either of the short sides of the display device parallel to the horizontal flat surface. Neither of the long sides, therefore, rests on the flat surface when the display device is in the portrait orientation. The support flap 124 has a shape that allows the display device 100 to present the displayed item at an esthetically pleasing viewing angle, θ, 504 where the viewing angle, θ, 504 is the angle formed between the front face of the display item 100 and the horizontal surface 300 . Although any viewing angle between 180 degrees and 90 degrees can be used, an example of a suitable viewing angle is 100 degrees. The viewing angle, θ, 504 is determined by the support flap cut angle, φ 502 . In the exemplary embodiment, the support flap 124 is symmetrically cut at each edge to form support flap cut angle, φ, 502 of approximately 11 degrees relative to the short side of the display device 100 .
[0026] FIG. 7 is a perspective view of the display device 100 in the unfolded condition. As discussed above, the display device 100 may have any one of several shapes. In the exemplary embodiment the display device has a shape configured to display a standard size photograph such as for example, 3 inch by 5 inch, 4 inch by 6 inch, 5 inch by 7 inch, and 8 inch by 10 inch photographs. Accordingly, a display device may be manufactured for each of the standard photograph sizes. The dimensions of the paper backing are slightly larger that the dimensions of the intended display item. The main window portion 108 should be sized to allow the display item to be easily inserted or otherwise disposed adjacent the transparent plastic sheet 112 while having dimensions small enough to minimize any movement of the display item after it is sealed. Also, the dimensions should be chosen such that amount of paper backing bordering the display item is minimized. An example of suitable dimensions is having a length and width that is approximately one millimeter larger than the intended display item. In some circumstances the dimensions may be selected to cause the front clear panel to bow slightly outward.
[0027] As discussed above, the support flap 124 is cut and angle, (P, that allows the display device 100 to have an appropriate viewing angle when positioned in the portrait display position. In the exemplary embodiment, the angles on the both sides of the support flap 124 are the same. In some circumstances, however, the angles may be different allowing the display device to have different viewing angles depending on which short side 204 is placed on the horizontal display surface.
[0028] As will be described below with reference to FIGS. 7-10 , the folding and sealing method employed by this invention will now be described. Starting with the flat panel or blank 100 shown in FIG. 7 , the transparent plastic sheet 112 is first disposed adjacent the main window portion 108 of flat foldable panel 100 and secured in place by adhesive or other suitable fastening means known to those of skill in the art. Next, the side panels 107 , 109 are folded along fold lines (living hinges) 107 a, 109 a to the positions shown by arrows A, B in FIG. 8 . Then, the foldable backing flap 106 is folded to secure the side flaps 107 , 109 in place as shown by arrow C in FIG. 8 ; the backing flap 106 is preferably secured by adhesive of other suitable retention system to retain the display device 100 in the shape shown in FIG. 9 .
[0029] By following this methodology, a clear front envelope assembly shown in FIG. 9 is formed by folding the plurality of foldable flaps 106 , 107 and 109 relative to the main window portion 108 and around the transparent plastic sheet 112 . Suitable adhesive or any other fastening mechanism adheres the transparent sheet 112 and the foldable flaps 106 , 107 and 109 relative to the main window portion 108 .
[0030] With the configuration of FIG. 9 , a photograph, postcard or other aesthetic display item may be inserted into the envelope arrangement shown in FIG. 9 .
[0031] As will be apparent to those of skill in the art, the sealing flap 118 is not adhered to the paper backing 116 until after a photograph or other display item is inserted into the clear front envelope or pocket defined by the foldable flaps 106 - 109 .
[0032] At least one sealing strip 120 may be disposed on the connection portion 122 of the support flap 104 and/or backing flap 106 to allow the user to peal off a protective tape, fold the support flap 104 and adhere the connection portion 124 of the support flap 104 to the backing flap 106 to seal the display item (e.g., photo, postcard or other item) inside the clear front envelope or pocket 133 of the display device 100 . Once the support flap 104 is adhered to the backing flap 106 , the display item is retained in the display device 100 and the article assumes the configuration shown in FIG. 2 .
[0033] The transparent sheet 112 may be adhered to the flaps 106 , 107 , 109 with adhesive that is applied at least along the perimeter of the main window portion 108 and/or the transparent sheet 112 . It is also contemplated by this invention that the transparent sheet is retained within the envelope or pocket without the use of adhesive.
[0034] In use, the connection portion 122 meets the stand portion 124 at a fold line 126 . The stand portion 124 is folded away from the backing flap 106 when the display device 110 is used to display the display item on a horizontal surface (not shown). The display device 100 may be used to display the display item in a portrait or in a landscape position.
[0035] As described above, a plurality of edges 106 , 110 of the transparent sheet 112 is adhered to the back 114 of the backing flap to form a clear front envelope 102 . An adhesive, such as a spray adhesive, is applied the back of the main window portion 108 and edges of the transparent sheet 112 are attached by the adhesive. A pocket 133 is formed between the front of the backing flap 106 and the transparent sheet 112 . A display item such a photograph is inserted into the pocket 133 .
[0036] In the exemplary embodiment, a section or peal of adhesive tape forms the adhesive strip 120 on one or both of the connecting portion 122 or backing flap 106 . Accordingly, the user removes a protective strip from the adhesive strip and presses the connecting portion 122 of the support flap 104 to the paper backing. User instructions in the form of printed indicia are included on the display device to assist the user in properly using the display device 100 as a display device and a personalized postcard mailer. The instructions may include directions on applying the sealing flap to the backing flap 106 and not to the support flap 104 .
[0037] FIG. 10 shows one example of the display item in the final sealed state with a display article mounted in the pocket 133 at the window frame defined by the window portion 108 .
[0038] FIG. 2 is an illustration of a perspective view of a sealed display device 100 with indicia indicating the appropriate location for postage 1102 is printed on the connection portion 122 of the support flap 104 . In some situations, the postage may be provided on the display device 100 . In addition to postcard indicia, the display device includes other indicia on one or more components of the display device 100 in the exemplary embodiment. For example, indicia such as advertising indicia, decorative indicia, logos, letters, numbers, symbols, or other types of printed or etched items may be included on the transparent sheet 112 , the paper backing 116 , the sealing flap 118 , or the support flap 104 . When included on the back side of the display device 100 , the indicia may be printed on the connection portion 122 of the support flap 104 , on the stand portion 124 of the support flap, or on the paper backing 114 as well as on any portion of the sealing flap 18 or the transparent sheet edges 106 , 108 , 110 . In some circumstances, the indicia may be included on the transparent sheet 112 such that it can be viewed when the display item is sealed with the clear front envelope 102 . Etching techniques may be used to form a logo, lettering or other design on the front face of the clear front envelope to allow the display item to be viewed with minimal interference. In some circumstances, the indicia may be included on the front of the paper backing 116 such that it can be viewed through the clear front envelope before a display item is inserted. For informational or decorative purposes, the display item 100 may include other features by using particular materials such as colored paper stock or colored transparent sheets 112 .
[0039] The indicia may be a generic decorative designs or images such as representations, for example, of historical or natural landmarks, seasonal or holiday depictions, or religious symbols. The representations may include any level of complexity and color and may be full color photos such as traditional photos found on postcard or may be single color sketch. For example, the back of the display device 100 may include a full color photograph of a beach or may simply include a single color image of a palm tree to express a vacation theme. Examples of holiday and seasonal indicia include depictions of Christmas trees, Santa Claus, hearts, clovers, snowmen, flags, winter scenes, flowers, witches, pumpkins, turkeys, colored leaves, as well as text. In some situations the indicia may express an invitation to an event such as a party or wedding and may include customized information. For example, the indicia may include date, time, location and other event specific information.
[0040] The display device may be used as a promotional mechanism or for advertising. For example, company logos, names, slogans, trademarks and other company identifiable symbols may be etched or printed in the clear envelope or on the back of the display device 100 . The promotional aspects of the exemplary display device 100 may be particularly useful at theme parks where symbols or marks may indicate the source of the picture. For example, an image of famous whale may be included on the display device to indicate that a photograph contained in the display device was taken at an aquatic adventure park. Further, famous cartoon characters may enhance the attractiveness of the display device when sold or otherwise provided at a well known theme park associated with those characters.
[0041] Additionally, the display device 100 may include a die-cut flap that serves as a pop-up feature to enhance the appearance and promotional aspects of the invention. With reference to FIG. 11 , the display device 100 may include the optional pop-up flap 140 die cut into the connection portion 122 between the sealing/adhesive strips 120 . FIG. 12 shows the die-cut perforations in the connection portion 122 . The user may optionally pivot the flap. 140 to be visible from the front side above the main window portion 108 to enhance the visual or promotional aspects of the invention. As will be understood by those of skill in the art, the pop-up flap 140 may be designed to promote a particular event or simply enhance the item being displayed in the viewing window. Further, a flat planar magnet may be disposed behind the pop-up flap 140 for mounting the display device on a metal surface such as a refrigerator.
[0042] In some circumstances, a thin planer magnet is attached to the display device 100 to allow the display device to be mounted on a metal surface such as a refrigerator. A suitable technique for attaching a magnet includes sealing a strip of thin, planar magnetic material between the paper backing and the connection portion of the support flap 104 .
[0043] To this end, the present invention further provides a modified design where a thin, planar magnetic 150 may be disposed on the backing flap 106 with a die-cut window 155 provided on the connection portion 122 . With reference to FIG. 13 , the magnet 150 is disposed to be selectively exposed by the user via the optional die-cut window 155 , which the user can tear off to expose the magnet 150 . FIG. 14 shows the magnet 150 mounted for use on an assembled display device 100 behind the die-cut window 155 . Also, optional hanging flaps 157 , 158 are provided for hanging the display device 100 in one of a portrait or landscape orientation.
[0044] The display device 100 , therefore, allows a display item such a photograph to be displayed in either a landscape or portrait orientation. The clear front envelope formed by the paper backing and the transparent sheet secures the display item without obscuring the image with a frame. The display device 100 is easy to use as an inexpensive, safe picture frame and also as a convenient envelope for forming a personalized postcard.
[0045] Clearly, other embodiments and modifications of this invention will occur readily to those of ordinary skill in the art in view of these teachings. The above description is illustrative and not restrictive. This invention is to be limited only by the following claims, which include all such embodiments and modifications when viewed in conjunction with the above specification and accompanying drawings. The scope of the invention should, therefore, be determined not with reference to the above description, but instead should be determined with reference to the appended claims along with their full scope of equivalents.
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A display device, comprising a clear-front envelope formed by foldable blank including at least one backing flap folded around a viewing window and leaving an opening for receiving the planar displayed item, such as a photo; postcard; etc. The opening is at least partially closed when a sealing flap integrally formed with said foldable blank is secured to the backing flap. A support flap integral with the sealing flap, the support flap configured to fold at fold line adjacent to the backing flap and having an end for resting on a horizontal surface to support the clear-front envelope at a viewing angle to the horizontal surface. Optional hanging flaps and a hidden magnet may be used to hang or otherwise mount the display device.
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BACKGROUND OF THE INVENTION
Walsworth U.S. Pat. application Ser. No. 410,497 filed Aug. 23, 1982 discloses a reciprocating fuel and oil pump in which the volume of oil pumped is variable relative to the fuel delivered. This permits the fuel to oil ratio to be varied to better suit the operating requirements of a two-stroke internal combustion engine. The oil pump piston of the fuel and oil pump has a variable stroke with the stroke being decreased by engagement with a stop positioned by means linked to the throttle linkage. The need for linkage between the throttle and the adjustable stop may impose design restraints.
SUMMARY OF THE INVENTION
This invention provides a two-stroke internal combustion engine of the type having separate fuel and oil pumps delivering their outputs for mixture prior to entering the carburetor, said oil pump having a variable output relative to the fuel pump output, the improvement comprising means responsive to the amplitude of the pressure wave in the engine crankcase to vary the output of the oil pump to optimize the fuel/oil ratio for the operating conditions.
The invention also provides a two-stroke internal combustion engine having carburetor, a fuel pump delivering fuel to the carburetor, a reciprocating oil pump delivering oil for mixture with the fuel in a ratio dependent upon the quantities of fuel and oil being delivered, means for varying the delivery of the oil pump relative to the delivery of the fuel pump to vary the ratio to suit the operating conditions of the engine, the pressure in the engine crankcase varying in a wave pattern with the amplitude of the waves being a function of engine operating conditions, and motor means responsive to the amplitude of said wave pattern to control said means for varying the stroke of the oil pump, said motor means including a housing having an interior which is divided into high and low pressure chambers by a movable wall, conduit means connecting the engine crankcase to the chambers and including first valve means to apply the high pressure component of said pressure wave to the high pressure chamber and second valve means to apply the low pressure component of the pressure wave to the high pressure chamber and second valve means to apply the low pressure component of the pressure wave to the low pressure chamber, said movable wall being moved by the pressure across the wall and acting to modify the delivery of the oil pump.
The invention also provides means responsive to the amplitude of the crankcase pressure wave to modify the output of the oil pump relative to the fuel pump supplying a two-stroke engine to thereby vary the fuel/oil ratio in accordance with engine operating conditions. The concept is applicable to various oil pumps.
This invention is not limited to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.
BRIEF DESCRIPTION OF THE DRAWING
The single FIGURE of drawings is a schematic showing of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The outboard motor 10 includes a power head 12 incorporating a two-stroke internal combustion engine 14. Lower unit 16 is secured to the power head 12 and supports a propeller 18 driven by the engine.
The engine includes a carburetor 20 for feeding a fuel/oil mixture to the crankcase 22 of the engine for subsequent induction into the cylinders of the engine. It may be noted that the pressure in the crankcase 22 varies in a wave pattern, the amplitude of which is related to the operating condition of the engine and to the throttle setting. The pressure wave may vary between -3 psi and +3 psi at idle speed, for example, thus giving an amplitude of 6 psi. At high speed operation, the wave pattern may vary between +5 and -6, for example, or +10 and -1, for example, either of which would have an amplitude of 11 psi. This wave pattern is used to indicate the operating condition of the engine and to control the amount of oil delivered to the engine relative to the amount of fuel to permit the fuel/oil mixutre to be varied to suit the engine operating conditions. The pressure wave is also used to actuate the fuel/oil pump, although any suitable means for developing a reciprocating motion or other pumping action can be utilized. So far as the pressure wave is concerned, and particularly the high and low pressure or amplitude, it may be noted that this terminology may embrace two positive pressures, or two negative pressures in addition to the plus and minus pressures already mentioned.
As indicated, the invention embraces a fuel/oil pump 24 which separately pumps fuel and oil for subsequent mixture prior to entering the carburetor. This, of course, differs from the typical two-stroke engine in which the fuel and oil are mixed in a predetermined ratio in a tank from which the mixture is then drawn for delivery to the carburetor and engine.
The oil and fuel pump and the method of actuating the pump are fully disclosed in U.S. Pat. application Ser. No. 410,497 along with several variations thereon. For the purpose of understanding the present invention, it need be only understood that the pressure in the crankcase 22 is sensed through conduit 26 which has a branch 28 leading to a pressure controlled stroke limiter 30 which will be fully described hereinafter.
The main condudit 26 communicates with a pressure responsive motor section 32 having diaphragm 34 and diaphragm pad 36 separating the motor into upper and lower chambers 38, 40 respectively. The positive pressure portion of the pressure wave in conduit 26 passes spring loaded check valve 42 into the lower chamber while the negative pressure wave can cause check valve 44 to unseat and permit the pressure in the upper chamber 38 to be reduced. Thus, there is a pressure differential established across the diaphragm and pad assembly causing the diaphragm pad to move upwardly against the bias of spring 46. Spring loaded by-pass valves 43 prevents excessive pressure in the high side by bleeding pressure to the low side.
Pressure acting across the valve member 48 holds the member 48 against the under side of the diaphragm pad 36 against the force of the light spring 50 to prevent leakage of pressure from the high to low pressure chamber 40, 38. Thus, the diaphragm moves upwardly against the spring 46 until the depending finger 52 strikes valve member 48 to unseat the valve member and permit the pressure to start to equalize across the diaphragm pad. At this time the light spring 50 will push the valve member 48 to its lower limit of travel and hold the valve away from the port 54 until the spring 46 has driven the pad to where the fingers or bosses 56 depending from the under side of valve 48 strike the partition 58 and prevents further downward movement of valve 48. The pad 36 continues down and strikes the valve and the pressure can now be re-established to hold valve 48 against the pad 36. Thus, the pressure differential derived from the engine crankcase is utilized to develop a reciprocating action of the diaphragm pad 36. This motion will be at a substantially slower rate than the frequency of the pressure wave occurring in the engine crankcase.
The cage 60 depending from diaphragm pad 36 is provided with a central rod 62 which passes through the partition 58 and is sealed relative thereto by O-ring 64. This rod now will transmit the reciprocating motion to the fuel pump section 66 and the oil pump section 68. In the fuel pump section, the rod 62 is connected to diaphragm pad 70 which will move up and down in the fuel pump section. The perimeter of the pad 70 is connected to the wall of the fuel pump section by a diaphragm 72. The chamber 74 above the diaphragm and pad 72, 70 constitutes a fuel pump chamber having a fuel inlet 76 in which the spring loaded check valve 78 is located. The inlet communicates with the fuel source or tank 80. The outlet of the chamber 74 passes through check valve 82 and then communicates with a surge chamber 84 and conduit 86 leading to the carburetor 20. The chamber 88 under the fuel diaphragm 72 is vented to atmosphere through vent 90. The rod 62 extends past the lower wall 92 of the fuel pump section and is sealed relative thereto by O-ring 94.
The lower end of rod 62 has an oil pumping piston 96 connected thereto through a lost motion connection comprising piston pin 98 projecting through the opening in the lower end of rod 62 with the pin head 100 captured above internal shoulder 102 on the lower end of the rod. The spring 104 is a stiff spring which normally holds the piston in the lowermost position as illustrated. Therefore, the piston reciprocates as rod 62 reciprocates. As the piston moves upwardly, oil will be drawn from the tank or source 106 past the spring loaded check valve 108 into chamber 110. As the piston moves downwardly, the check valve 108 will close and spring loaded check valve 112 will open to allow oil to be delivered through conduit 114 to the junction 116 with the fuel line. It is at this point that the fuel and oil mix are delivered through line 118 to the carburetor 20.
It will be noted that there is an adjustable stop 120 positioned in alignment with the piston 96 but opposite the cross bore between the inlet 108 and outlet 112. If this adjustable stop is moved upwardly sufficiently to restrict movement of the piston 96 as rod 62 comes down, the lost motion between the piston and the rod then comes into play and the spring 104 is compressed while the stroke of the piston is restricted or shortened, thus decreasing the amount of oil delivered during the stroke of the fuel pump which is still making a full stroke.
In the aforesaid co-pending U.S. Pat. application Ser. No. 410,497, the adjustable stop 120 is positioned by means of a cam actuated through linkage connected with the throttle. Thus, when the throttle was in the idle position, the stop would move to restrict delivery and permit the fuel/oil mixture to lean out. When the throttle was moved towards full throttle, the fuel/oil mixture was enriched by retracting the stop and permitting the full stroke of piston 96. That arrangement, however, required the fuel pump to be located where it could be mechanically interconnected through linkage. The present arrangement positions the stop 120 under control of a stroke limiter 30 responsive to the amplitude of the crankcase pressure wave. This means only tubing is needed to interconnect the stroke limiter and engine. As a consequence the fuel pump can be located remote from the throttle linkage and there is more flexibility in location.
As previously indicated, the conduit 26 connected to the crankcase to sense the pressure wave has a branch 28 leading to limiter 30 which comprises a housing having an upper chamber 122 separated from a lower chamber 124 by diaphragm 126 and pad 128. The pad is biased upwardly by spring 130. Positive pressure waves coming into the limiter housing through conduit 28 will unseat the spring loaded check valve 132 and pass into chamber 122 while the negative pressure portion of the waves will unseat the check valve 134 and reduce the pressure in chamber 124 under diaphragm 126. Therefore, a positive to negative pressure gradient is established across the diaphragm from chamber 122 to 124 and will move the pad 128 downwardly against the bias of spring 130. The center of the diaphragm pad is connected to the adjustable stop 120 and positions the stop. It will be appreciated that the greater the pressure differential (as associated with full throttle) the more the pad 128 will be moved downwardly against the force of the spring 130 and, therefore, the greater will be the effective stroke of piston 96 which means more oil delivered in relation to the fuel delivered, thus enriching the mixture.
A small vent or bleed hole 136 passes through the diaphragm pad 128 to prevent the pressure differential being trapped, in effect, across the pad and taking away control. With the bleed hole the pressure will always tend to equalize, but at a slow rate. The small vent is adequate to prevent the pad from locking up.
The compressed spring 130 can have a variable spring rate or a multiplicity of springs can be employed, if desired, to more closely control the position of the adjustable stop relative to the operating condition of the engine. It will be understood the pressure wave of the crankcase pressure is a characteristic of each particular engine design and all two-stroke engines have a characteristic pressure wave. This invention uses the pressure wave to position the stop and control the oil delivery. This arrangement will work in conjunction with other fuel pumps. The oil delivery can be varied in accordance with the amplitude of the pressure wave while the fuel delivery remains constant, thus enabling the fuel/oil ratio to be varied.
It will be apparent that consumption of the fuel/oil mixture is determined by the throttle setting. The fuel and oil pump will stall when consumption is less than the capacity of the pump. Preferably, the point where the fuel and oil mix should be close to the carburetor so the mixture closely follows the operating conditions.
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A two-stroke internal combustion engine of the type having separate fuel and oil pumps delivering their outputs for mixture prior to entering the carburetor, the oil pump having a variable output relative to the fuel pump output, and means responsive to the amplitude of the pressure wave in the engine crankcase to vary the output of the oil pump to optimize the fuel/oil ratio for the operating conditions.
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FIELD OF THE INVENTION
This invention relates generally to electro-optical intrusion alarm systems and more particularly to a universal intrusion alarm capable of forming a surveillance net enclosing an entire room.
BACKGROUND
Radiation sensitive intrusion alarm systems have received substantial interest in recent years as a result of the increase in the number of burglaries committed in the United States and various foreign countries. Such interest has been further enhanced with the advent of significant improvements made in the responsivity of infrared radiation detectors operating in the 8-15 micron wavelength range. Any object having a temperature above absolute zero emits radiation in the infrared wavelength region of the electromagnetic radiation spectrum, and the 8-15 micron wavelength range is of particular interest as a "window" in the well-known transmission spectrum for infrared radiation.
Highly sensitive thermal detectors which are responsive to 8-15 micron wavelength infrared radiation have been developed and generate a usuable electrical output signal in response to changes in levels of infrared radiation received. As a result there have been various designs proposed for electro-optical intrusion alarm systems utilizing these detectors and operative to generate numerous selected fields of view over certain areas under surveillance.
Some of the earlier electro-optical intrusion alarm systems of the above type include those which generate a field of view covering the total desired space (volume) under surveillance. When an intruder penetrates any location within this space, he creates a minute change in the total average radiation seen by the system's field of view, and this change in radiation in related to a temperature differential caused by the intruder's average temperature relative to the average background temperature of the space penetrated. This temperature differential is usually very small, i.e. less than about 1°C., and must be detected by the radiation sensor portion of the electro-optical intrusion alarm system. Since this level of sensitivity required for IR detection is constant, one solution to providing a dependable false alarm-free system with a high signal-to-noise ratio is to reduce the overall noise level in the background radiation.
PRIOR ART
In order to improve the signal-to-noise (S/N) ratio of electro-optical intrusion alarm systems which generate a field of view covering a particular volume of space to be monitored, we discovered at least as early as 1969 that it is possible to utilize a net type of surveillance to reduce background noise levels. Specifically, we discovered that a cone-shaped surveillance net (field-of-view) could be optically focused on an infrared detector in order to monitor intrusion into the volume of space defined by the cone-shaped net. Thus, anyone penetrating the relatively thin walls of the cone shaped net would produce a much greater temperature differential when referenced to the background average temperature of the net than would have been the case if the field-of-view had encompassed the entire volume of the cone.
Although our above net type surveillance intrusion alarm system will operate satisfactory for certain types of intrusion alarm applications, it is not particularly well suited for the highly sensitive total room coverage demanded by certain types of very high security intrusion alarm applications. For example, where large sums of money are stored in a typical bank vault having four walls, a ceiling and a floor, it is sometimes mandatory that an intrusion alarm system be 100 percent effective to provide an alarm indication for the slightest penetration through any portion of any wall, floor or ceiling defining the vault. When using our above described approach for generating cone-shaped surveillance nets, one encounters dead spots if the net is optically generated within the confines of the room.
THE INVENTION
In order to provide total and false alarm-free room surveillance, and in order to simultaneously provide a universal system and method for monitoring the unlawful entry into any room whose walls define a polyhedron, we have discovered a totally unique and novel solution to the above problem of dead spots in our prior art system using cone-shaped surveillance nets. Our present system and method are considered universal in the sense that this invention can be used to provide total and highly sensitive intrusion monitoring in any room whose walls, ceiling and floor define a polyhedron.
To achieve this total and flase alarm-free room surveillance, we have devised an electro-optical intrusion alarm system which includes reflector means for optically generating a plurality of orthogonal fields of view at selected corners of a room. such fields-of-view are defined as the angular measurement of predetermined volumes of space, which in a preferred embodiment of the invention are thin polyhedrons including two closely spaced and substantially coextensive planes. One of these planes includes a wall of the room under surveillance. These orthogonal fields-of-view, which are thin curtain-like polyhedrons having predetermined volumes, actually represent the finite volumes of space along side the walls of the room through which background infrared radiation passes to an orthogonally arranged optical reflector arrangement. Radiation changes within these volumes are reflected from this optical reflector arrangement to one or more thermal detectors which in turn generate a low level - low frequency electrical signal, which signal is converted to an AC signal and amplified in order to be useful as an output alarm signal.
Accordingly, it is an object of the present invention to provide a new and improved electro-optical intrusion alarm system operative to monitor the entry of an intruder through the walls, floor or ceiling of a room.
Another object is to provide an intrusion alarm system of the type described having an improved sensitivity and a high signal-to-noise ratio.
Another object is to provide an intrusion alarm system of the type described which may be constructed using the latest state-of-the-art thermopile detectors which are highly sensitive to minute radiation changes in the 8-15 micron wavelength range of the electromagnetic radiation spectrum.
A feature of the present invention is the provision of a universal method for providing total and false operationproof intrusion surveillance over any room whose walls, floor, ceiling, etc. have planar surfaces.
Another feature of this invention is the provision of a unique orthogonal optical reflector array for generating orthogonal fields-of-view which are curtain-like polyhedrons coextensive with the plane surface defining the room. This array occupies a minimum of space in a selected corner of the room.
Another feature is the provision of a method and system of the type describe which permits the free movement of people within the room under surveillence without triggering the intrusion alarm.
These and other objects and features of the invention will become more readily apparent in the following description of the accompanying drawing.
DRAWINGS
FIG. 1a illustrates, in perspective view, the orthogonal fields-of-view generated by the reflector array of the type described above and used in a preferred embodiment of the present invention.
FIG. 1b is an enlarged view of three orthogonally arranged convex reflectors which are positioned to generate three orthogonal fields-of-view from one corner of a room and each defined by a thin polyhedron coextensive with one planar surface of the room.
FIG. 1c is an enlarged view of three orthogonally arranged concave reflectors which are positioned to generate three orthogonal fields-of-view from one corner of a room and each defined by a thin polyhedron coextensive with one planar surface of the room.
FIG. 2 is a view of one reflecting surface (not to scale) of a reflector array in FIG. 1, and FIG. 2 also illustrates the corresponding curtain-like surveillance and field-of-view generated by such reflecting surface.
FIG. 3 illustrates generally the electronics of our system for frequency converting and amplifying a low level - low frequency IR signal received from the above described orthogonal fields-of-view.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, there is shown a typical four wall room 10, e.g. a bank vault, under surveillance and including a floor and a ceiling, or a total of six planar surfaces. These surfaces must be strictly monitored for intrusion through any location thereon all times. Therefore, in accordance with the present invention, one infrared detector package 12 is positioned as shown in the lower left hand corner of the room, as viewed in FIG. 1, and another identical infrared detector package 14 is positioned in the upper right hand corner of the room. Since the optics of these two detector packages 12 and 14 have three identical fields of view (FOV), only the three fields of view 16, 18 and 20 generated by the detector package 12 are illustrated by the shading in FIG. 1. Thus, the infrared detector package 12 provides complete intrusion surveillance for the near wall, the window wall and the floor of the room 10, whereas the remaining three planar surfaces of the room are covered by the three identical fields of view generated by the optics of the room detector package 14.
Each of the fields of view 16, 18 and 20 generated by the optics of the room detector package 12 is defined by a solid angle which is 90° in one direction and approximately 6° in a perpendicular direction. Thus, each of these fields of view can be defined as the angular measure of the volume of space within the above solid angle, and electromagnetic radiation from this volume of space impinges on a reflective surface which is optically aligned to the above solid angle. Such optical alignment will be described in more detail below.
Therefore, any intruder 22 or other object making the slightest penetration through an opening 24, for example, in a planar surface of the room 10 will produce an instantaneous change in the background radiation received by the detector package 12. This change in infrared radiation is then converted into an electrical signal which is processed and amplified so as to be useful as an intrusion alarm signal.
Referring now to FIGS. 1b and 1c, there are shown, respectively, two different sets of optical reflectors which are each especially suited for mounting in one corner of the room 10 in order to each optically generate three fields of view, such as FOV's 16, 18 and 20. For example, the three highly polished convex reflective surfaces 26, 28 and 30 in FIG. 1b will optically reflect to the IR detector surface 32 all infrared radiation received from the fields of view 16, 18 and 20, respectively. That is to say, the center of the radiation sensitive surface 32 of the thermopile detector 34 is positioned at the focal point 35 for all three reflecting surfaces 26, 28 and 30. Any change in the background radiation within any of the above three fields of view 16, 18 and 20 produces a corresponding radiation responsive output signal voltage from the thermopile detector 34, and this voltage may then be processed in a manner to be described so as to be useful as an intrusion alarm indication signal.
The concave reflectors 36, 38 and 40 in FIG. 1c may be used instead of the convex reflectors in FIG. 1b, and the concave reflectors have a focal point 35' located as indicated in the foreground of FIG. 1c near the left hand wall of the room 10. These concave reflectors 36, 38 and 40 generate fields of view identical or substantially identical with those of the convex reflecting surfaces in FIG. 1b. In a preferred embodiment of the invention, each of these fields of view may be defined as a thin curtain-like polyhedron which is substantially coextensive with and adjacent to a planar surface of the room, and in fact bounded on one side by such surface. Obviously, the 6° angle of the field of view may be varied in order to vary the signal-to-noise (S/N) ratio of the detection system.
Referring now to FIG. 2, there is shown in an enlarged view the generation of the single field of view 20 (see FIG. 1a) by the reflecting surface 30 which is mounted on or closely adjacent to the surface of the floor of the room 10. The reflecting surface 30 is configured and positioned so that a "dA" incremental area 42 of this surface "sees" the radiation emanating from the incremental volume defined by the area of the plane "P" multiplied by the incremental angle "dθ". The contour of the reflecting surface 30 is such that the integration of dA 90° over the area of the surface 30 corresponds to the volumeric integration of P.dθ over the 90° angle of the FOV 20 shown in FIG. 2. This integrated volume, or field of view, has a point of maximum vertical height at point 45 in the near or foreground corner of the room 10, and the contour of the reflecting surface 30 is such that one edge of dA is in vertical alignment with one corner 44 of the room 10. As "dA" is integrated from left to right and 90° over the reflecting surface 30, it passes through the vertical planes 47 and 48 which include the foreground corner 45 of the room and the background corner 49. Portions of the field of view 20 on opposite sides of the plane 47 are symmetrical with respect to this plane.
Referring now to FIG. 3, there is shown an electrooptical system for sensing and processing any changes in infrared radiation received by an infrared detecting surface 32 from any of the above described six fields of view surrounding the room 10. Such changes in radiation may be produced by the intrusion of an object through any field of view (e.g. 18) planar to any surface of the room 10. The corresponding change in radiant power, ΔP, produced by such object and received at a reflecting surface 26, is equal to a constant, K, times the area of the intruded target seen by the field of view, A t , times the third power of the average background temperature, T 3 , times the corresponding intrusion-produced change in temperature ΔT within a given field of view, divided by the 2nd power of distance between the reflecting surface 26 and the intruder, R 2 . That is: ##EQU1## Additionally, the change in output voltage, ΔV, of the thermopile detector 34 is equal to the responsivity, R, of the detector times ΔP, or:
ΔV = R.ΔP (2)
this change in voltage, ΔV, is coupled to a summing amplifier network 56 whose output is in turn connected to drive a high frequency chopper 57. The low level nanovolt signal at the input of the chopper 57 is converted by the chopper to a high frequency chopped signal which is frequency dependent upon the frequency of the driving oscillator 58. The full wave chopper 57 alternately switches the polarity of the signal from detector 34 from positive to negative with respect to ground, and the signal from the chopper 57 is an amplitude modulated square wave which is fed into a carrier amplifier 60.
The carrier amplifier 60 is an AC bandpass amplifier which is designed specifically for boosting the amplitude of the modulated square wave from the chopper 57, and the bandwidth of the amplifier 60 is selected so that very little harmonic content of the square wave from the chopper 57 is lost due to high frequency attenuation. This characteristic of the amplifier 60 in effect preserves the information signal on the chopped square wave from stage 57, and the amplified output signal from the amplifier stage 60 is substantially identical in form, but greater in amplitude, to the signal at the input of the amplifier stage 60.
The output signal of the amplifier stage 60 is fed to a demodulator stage 62 which, in a preferred embodiment of the invention, is a synchronous detector. The synchronous detector 62 is generally well known in the art and functions as an oscillator (58) driven switch necessary to maintain an in phase signal relationship between the signal at the output of the chopper 57 and the demodulated output signal from detector 62. If a Fourier analysis were performed on the output waveform from the demodulator stage 62, one would find that the DC component and the signal component terms of the output signal from the IR detector 34 are completely restored at the stage 62 output.
The output signal from the synchronous detector 62 is fed back through one path 63 to a background compensating network 64, and this network 64 is required when large offset signals are generated by backgrounds, such as a heater, warm walls, etc. These large offset signals will otherwise tend to drive the carrier amplifier 60 into saturation, thereby suppressing the modulation signal applied thereto. The background compensator stage 64 filters out all but the DC component term from the output of the demodulator stage 62, and this DC term either adds to or subtracts from the detector signal (from 32) in the summing network 56, at a very slow rate. This function reduces the total DC component term of the signal from detector 32 (sometimes called offset) towards zero, thereby extending the overall AC dynamic range of the preamplifier stage 60.
The filter network 66 allows the information signal frequencies at the output of stage 62 to pass to the post-amplifier stage 68 with a minimum of attenuation, and also blocks passage of all other unwanted frequencies. These unwanted frequencies are the low frequency and DC component terms generated by background-plus-offset voltage caused by leakage currents within the amplifier stage 60. Additionally, these unwanted terms include high frequencies generated by the high frequency square wave output from the chopper stage 57, including all its harmonic content, and all of the corresponding sideband frequencies from this square wave.
The signal at the output of the filter network 66 is substantially identical in form, but greater in amplitude, to that seen at the output of the thermopile detector 32; but there is no DC component in this amplified signal. After the signal has passed through both the filter network 66 and the post amplifier stage 68, it is fed to the threshold and switching circuit 70. Preferably, the threshold and switching circuit 70 is a modified Schmitt trigger circuit which converts low frequency amplified signals to digital pulses which are suitable for driving digital output circuitry 72. The output driver circuitry 72 is designed, of course, to meet specific requirements and may, for example, include components such as a relay switch, an RF transmitter, a light, or an audio alarm.
Various modifications may be made in the particular reflector design and contour without departing from the scope of this invention.
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An intrusion system detects changes in background radiation received from a plurality of orthogonally arranged fields of view (FOV) which preferably are defined by thin polyhedrons coextensive with the walls of the room. These fields of view are generated by a plurality of orthogonally arranged optical reflectors located in certain corners of the room, and any changes in background radiation within these fields of view are detected by one or more thermopile detectors which are optically aligned with the above optical reflectors. The low level - low frequency output signal voltages form the thermopile detectors are converted to an AC signal and amplified for use as an intrusion alarm signal.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] This invention relates to absorbent articles such as disposable diapers, disposable incontinence pads and disposable feminine hygiene pads that, on their topsheet surface, comprise an anti-microbial agent.
[0003] 2. Description of Related Art
[0004] A desirable property goal of absorbent materials such as disposable diapers, incontinence pads or feminine hygiene pads, is that the urine they absorb does not become a haven or breeding medium for bacteria. The bacteria are undesirable because they catalyze the breakdown of substances in the urine, creating products that cause a strong odor and skin irritation.
[0005] U.S. Pat. No. 4,655,756, describes an absorbent article that has the antibacterial compound, polyhexamethylene biguanide (PHMB), in its nonwoven core material. U.S. Pat. No. 5,993,840 similarly discloses the use of PHMB in the core of a diaper. Additionally, however, it provides for a PHMB-binding anionic polymer in the core in order to retain the PHMB there.
[0006] The aforementioned patents disclose inventions designed to attack bacteria in urine absorbed by the article's core material. The present invention can, prior to or after urination, attack bacteria that resides either on the wearer's skin or on the article topsheet itself.
BRIEF SUMMARY OF THE INVENTION
[0007] In a general aspect, the invention is a composition that comprises a material with an anionic surfactant on its surface and a polymeric biguanide noncovalently bonded to the anionic surfactant.
[0008] In a related aspect, the invention is a composition that comprises a material whose surface is anionic (is negatively charged) and that further comprise polymeric biguanide noncovalently bonded to that anionic surface. Examples of materials that have such an anionic surface include but are not limited to cotton, pulp, and rayon.
[0009] For both of the above aspects of the invention, any anionic surfactant bound to the surface is considered an entity that is different from the surface itself.
[0010] The anionic surface or surfactant to which the polymeric biguanide is bound serves as a reservoir from which the polymeric biguanide is released upon contact of the material with bacteria-populated skin. Sufficient polymeric biguanide is released so as to bind to the bacteria and either kill them or prevent their further growth.
[0011] In preferred embodiments, the polymeric biguanide is limited to a zone on the surface. If used, the anionic surfactant can be similarly limited. In many preferred embodiments, such a zone occupies between 10% and 50% of the surface area.
[0012] Examples of compositions of interest include, but are not limited to those comprising fibers, those that are liquid pervious nonwoven webs (preferably with a weight in the range, 10 to 30 grams per square meter) and those that are liquid pervious apertured films (preferably with a weight in the range 15 to 40 grams per square meter.). Fibers of interest for such compositions include, but are not limited to staple fibers and continuous fibers. Fibers can be part of a carded web (especially staple fibers), spunbond (especially continuous fibers) be thermally or ultrasonically bonded, adhesively bonded, bonded by hydroentangling, or combined in other ways known in the art.
[0013] A related invention is an absorbent article that comprises, as a topsheet, a composition of the invention. As it is the surface intended to contact the skin of the person wearing the article, the bodyside surface of the topsheet will comprise the polymeric biguanide and, if used, the anionic surfactant. Some examples of such absorbent articles are a disposable incontinence pad, a disposable diaper, and a disposable feminine hygiene pad. The article optionally further comprises, in its core, a polymeric biguanide, or both a polymeric biguanide and an anionic surfactant.
[0014] In a variation of the absorbent article, the polymeric biguanide is located on the topside surface of a layer that is just under the article's topsheet. (The topside surface is therefore the one in contact with the topsheet.) Typically such an article comprises the top sheet, an intermediate layer (such as an acquisition layer), an absorbent layer and a backsheet. {Paralleling the compositions of the invention, either the topside surface of the intermediate layer is anionic or an anionic surfactant is bound to the topside surface. Accordingly, the polymeric biguanide is bound to that anionic topside surface or to that anionic surfactant. Although the topside surface of the intermediate layer may not directly contact the skin of the wearer, the fact that the topsheet can be very thin and liquid pervious means that that perspiration from the wearer can mediate interaction between the polymeric biguanide and bacteria on the wearer's skin.
[0015] In particular embodiments, the composition of the invention is produced by a process that comprises (1) pre-treating the composition's surface with the anionic surfactant, and (2) then applying the polymeric biguanide to the surface so that it binds to the anionic surfactant. If the surface is anionic, the first step can be omitted and the polymeric biguanide is applied so that it binds directly to the surface. The aforementioned processes are themselves aspects of the invention and are of particular interest here where the composition is the topsheet or intermediate layer for a disposable article.
[0016] One set of options for applying a polymeric biguanide or anionic surfactant is to use a kiss-on or brush roller. Another is to use a spray or foam comprising the polymeric biguanide. The anionic surfactant may be added as a melt-additive, especially when the composition is a fiber. Additional options for applying the biguanide or surfactant are known in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1A is an exploded perspective view of a disposable diaper.
[0018] FIG. 1B is a planar view of the bodyside surface of the topsheet in FIG. 1A .
DETAILED DESCRIPTION OF THE INVENTION
[heading-0019] Polymeric Biguanides
[0020] One class of preferred polymeric biguanides are linear polymeric biguanides, described in U.S. Pat. Nos. 4,655,756 and 5,993,480, in which the recurring unit is of the formula, or a salt thereof:
wherein X and Y are bridging groups that may be the same or different, such that the number of N to N carbon atoms within X plus the number of N to N carbon atoms within Y is in the range 9 to 17, where the number of N to N carbon atoms within a bridging group is the number of backbone carbon atoms that, in that group, separate the N atoms adjacent to that group. (For example, for hexamethylene, the distance is 6) or the salt thereof with an acid. X any Y preferably comprise polymethylene chains.
[0022] X and Y are, for example, polymethylene chains. Those chains optionally incorporate heteroatoms such as oxygen, sulfur or nitrogen. An example of a chain with such incorporation is ethylene oxyethylene. Furthermore the chains optionally incorporate saturated or unsaturated cyclic nuclei. In those cases, the N to N distance refers to the shortest of the two possible N to N routes along the cyclic moiety.
[0023] A class of preferred polymeric biguanides are polyhexamethylene biguanides of the formula:
Z n
where Z is
and n is from 2 to 40.
PHMB
[0027] PHMB is the most preferred polymeric biguanide. It is highly preferred because, at very low concentrations, it has a broad spectrum of activity against bacteria, fungi and yeasts, particularly those associated with the human body. It is also harmless to the macrobiotic system and is not a skin sensitizer. Therefore, it will not give rise to problems such as skin irritation or rashes when applied to products that directly contact the skin.
[0028] At relatively low concentrations, PHMB is bacteriostatic. At higher concentrations, it is rapidly bacteriocidal. PHMB achieves its negative effect on a bacterium by initially binding to a receptive site on the microbe's surface, and then proceeding to disrupt its cytoplasmic membrane.
[heading-0029] Anionic Surfactant
[0030] The topsheet of the non-woven material is treated with an anionic surfactant that will not be washed away during repeated insults. This surfactant should, in turn, bind the polymeric biguanide sufficiently strongly to prevent most of it from being washed away during normal insults to the absorbent article. On the other hand, the surfactant must bind the polymeric biguanide sufficiently weakly to allow some of it to migrate to and kill microbes.
[0031] The solubility of the anionic surfactant in urine is preferably not greater than 2%, more preferably not greater than 1%, even more preferably not greater than 0.5% and especially not greater than 0.1% by weight. At temperature in the range 20° C. to 37° C.
[0032] Anionic polymers useful for binding polymeric biguanides are disclosed and discussed in U.S. Pat. No. 5,993,840. The anionic polymer can be obtained by polymerization or copolymerization of appropriate monomers. The anionic group may be a phosphonic, phosphoric, sulphonic, or carboxylic group. Carboxylic groups are preferred.
[0033] Possible anionic monomers include, but are not limited to, vinylphosponic acid, styrene-phosphonic acid, 2-acrylamidopropanephosphonic acid, ethylidene-1,1-diphosphonic acid, hydroxyethylacrylate monophosphate, styrene sulphonic acid, 2-acrylamido-2-methylpropanesulphonic acid, sulphoethyl methacrylate, vinylsulphonic acid, methallyl sulphonic acid, propene sulphonic acid and, more preferably, methacrylic and, even more preferably, acrylic acid.
[0034] Preferred anionic polymers are:
[0035] polyacrylic acid and copolymers of acrylic acid with one or more non-ionic monomers;
[0036] poly(maleic acid) and copolymers thereof with one or more non-ionic monomers;
[0037] alginic acid;
[0038] graft polymers of acrylic acid unto starch; and
[0039] graft polymers of acrylic acid unto carboxymethylcellulose.
[0040] Other anionic polymers that can be used are those derived from carboxymethylcellulose, partially oxidized cellulose, sulphoethylcellulose, or phosphorylated cellulose.
[0041] Useful non-ionic monomers include, but are not limited to, those of the formula
[0042] where R 1 is hydrogen or C 1 -C 4 alkyl (an alkyl group of 1 to 4 carbon atoms);
[0043] where R 2 is alkyl (preferably C 1 -C 20 alkyl, more preferably C 1 -C 6 alkyl), aryl (preferably phenyl) or cycloalkyl (preferably cyclohexyl) . For each of said R 2 moieties, R 2 is optionally substituted.
[0044] Preferred nonionic monomers are methyl(meth)acrylate, butyl(meth)acrylate, ethyl(meth)acrylate, 2-ethylhexyl(meth)acrylate, 2-hydroxyethyl(meth)acrylate and acetoacetoxyethyl(meth)acrylate.
[0045] Preferred anionic polymers are polyacrylic acid and copolymers of acrylic acid that have one or more non-ionic monomers, poly(maleic acid) and copolymers of maleic acid and at least one nonionic monomer, alginic acid, graft polymers of acrylic acid onto starch and carboxymethyl cellulose.
[0046] Polyacrylic acid will preferably be in the molecular weight range 1000 to 5,000,000.
[0047] The polymers are, optionally, crosslinked.
[0048] Super absorbent polymers, such as those based on polyacrylates and related polymers are highly preferred.
[0049] The surfactant can, for example, be applied by spraying. Alternatively, it can be applied by dipping the topsheet in a bath of the surfactant.
[heading-0050] Interaction of Polymeric Biguanides with the Surfactant or Anionic Surface
[0051] The polymeric biguanide, especially if it is a mild cationic compound such as PHMB, will interact with the anionic surfactant or surface to form cationic-anionic pairs. The surfactant tethers the polymeric biguanide to the surface, hindering but not completely preventing migration of biguanide away from the topsheet. An anionic surface binds the biguanide directly, similarly hindering its migration. As long as a substantial amount of the polymeric biguanide is present on the topsheet, it will provide a reservoir for polymeric biguanide that can dissociate from the topsheet and bind to the skin bacteria.
[0052] The polymeric biguanide is preferably applied through a “kiss-on” roller or brush roller. Therefore, ion pairs will be formed only at the areas that have direct contact with the roller. Such areas of the absorbent material preferably include the topsheet areas that have direct contact with the skin. The amount of polymeric biguanide applied is preferably between 8 and 19 mg/SM (mg/square meter) . The hydrochloride salt of the polymeric biguanide can be used.
[heading-0053] Topsheet
[0054] The topsheet (coverstock) is preferably liquid pervious, soft and non-irritating to the wearer's skin. A suitable topsheet may be manufactured from a wide range of woven or nonwoven materials. Such materials include, but are not limited to, polymeric material such as apertured formed thermoplastic films, apertured plastic films, and hydro-formed thermoplastic films. If nonwoven, the web may, for example, be one that was spun-bonded, carded, wet-laid, melt-blown, hydro-entangled, or made by a combination of two or more such techniques.
[0055] The invention will be illustrated in more detail with reference to the following Example, but it should be understood that the present invention is not deemed to be limited thereto.
EXAMPLE
Example 1
Method for Producing an Absorbent Material with the Anti-Microbial PHMB on the Surface
[0056] FIG. 1A illustrates a disposable diaper 1 in which a topsheet 3 is used. The topsheet 3 , acquisition layer (intermediate layer) 5 , absorbent layer (core) 7 and back sheet 9 form successive layers. Also evident are attachment tapes 11 , 13 , a tape landing area 15 , a standing leg cuff 17 , and an elastic gatherer 19 . The surface 21 of the topsheet is the bodyside surface; i.e., the side that will come in contact with the skin of a wearer's body. The surface 6 of the acquisition layer is the topside surface of that layer.
[0057] The bodyside surface 21 of the topsheet 3 is shown in FIG. 1B . Prior to assembly of the diaper, a zone 23 of that surface is sprayed with the permanent anionic surfactant, crosslinked polyacrylate, dissolved in water at a concentration of 20% by weight in water so that the zone 23 has a surfactant concentration of about 8-200 g/square meter. The topsheet is dried using a hot air blower.
[0058] PHMB, at a concentration of 0.1 to 1.0% wt/wt in water, is applied to the surfactant-coated zone using a kiss-on or brush roller so as to achieve a concentration of 8-19 mg/SM in water in the zone. The topsheet is then dried in a vacuum.
[0059] While the invention has been described in detail and with reference to specific examples thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
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The disclosure describes compositions, such as absorbent article topsheets or undersheets, that on its bodyside surfaces comprises an anionic surfactant-bound polymeric biguanide or an anionic surface-bound polymeric biguanide that can dissociate from the article so as to attack bacteria on the wearer's skin.
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BACKGROUND OF THE INVENTION
This invention relates to a new and useful improvement in automotive crankcase emission control systems.
Most vehicles under present day emission control regulations employ means for burning or reburning exhaust or crankcase fumes. It is well established that while such present day systems provide a substantial improvement in the discharge of pollutants from the vehicle exhaust, the performance of the vehicle, including miles per gallon from the fuel burned, is seriously lessened.
SUMMARY OF THE INVENTION
According to the present invention and forming a primary objective thereof, a crankcase emission control system is provided that not only amounts to a substantial improvement in removing pollutants from the exhaust system of the vehicle but also causes the vehicle to get better mileage per gallon of fuel.
A more particular object is to provide a crankcase emission control system that adds a filter to the emission control system presently in use, thus filtering out solids and vapors that generally are passed back to the fuel inlet means of the engine.
Another object of the present invention is to provide a system of the type described that utilizes as the filter a conventional spin-on type filter and which system also has provision for incorporating the usual pollution control valve therein.
The invention will be better understood and additional objects and advantages will become apparent from the following description taken in connection with the accompanying drawings which illustrate preferred forms of the device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view partly diagrammatic of a vehicle engine and including the present system incorporated thereon;
FIG. 2 is an enlarged fragmentary sectional view of a portion of the present apparatus;
FIG. 3 is an elevational view of a second embodiment of the invention;
FIG. 4 is an enlarged fragmentary sectional view taken on the line 4--4 of FIG. 3; and
FIG. 5 is a fragmentary sectional view taken on the line 5--5 of FIG. 4.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring first to FIG. 1, the numeral 10 designates a conventional engine having a crankcase 12, a valve cover 14, an intake manifold 16, a carburetor 18, and an exhaust manifold 20. According to present theories, much pollution is caused from crankcase vapors and can be lessened by passing the vapors which have escaped from the crankcase into the valve cover 14 back into the carburetor at or near the intake manifold 16. The vapors from the crankcase and valve cover are thus burned with the fuel mixture. Such systems include a pollution control valve (PCV valve) designated in FIGS. 1 and 2 by the numeral 22. In the systems now in use, the pollution control valve is removably attached to the valve cover as by a flexible grommet and has communication with the intake manifold by suitable flexible conduit.
According to the present invention a filter 24 is included in the conduit extending from the valve cover 14 to the intake manifold 16. Conduit sections are designated by numerals 26a and 26b and are connected to the filter through the medium of a filter support 28. Such support comprises a disc-shaped body member 30 integral with a right angle bracket 32 adapted for attachment in any suitable place in the motor well, such as to the fire wall 34.
With particular reference to FIG. 2, body member 30 has an axial tapped bore 31 threadedly receiving a hollow stud 38 which projects from the lower end of the body member and is of a diameter capable of threadedly receiving a filter 24. The head 40 of the stud 38 has a tapped bore 42 therein for threadedly receiving a fitting 44 of a pollution control valve, the hose section 26b extending from the pollution control valve to the intake manifold. Body member 30 also has a tapped bore 46 offset from center and arranged to receive a fitting 48 of the hose section 26b that extends from the valve cover 14. Fitting of the one end of hose 26a to the valve cover 14 is accomplished by a grommet 50 in the place where a hose or the pollution control valve was formerly mounted. A fitting 52 for the one end of hose section 26b at the intake manifold is already present in view of existing structure. Likewise, the connection of the one end of hose section 26b to the pollution control valve 22 is conventional.
The bottom surface of body member 30 is suitably contoured to adapt to the type of filter 24 that is used. In a conventional spin-on oil filter presently in common use and one that performs well to carry out the instant invention, the filter has a top annular extension 24a arranged to engage firmly against the bottom of the mounting member when the filter is threaded in place, and an annular gasket 24b is provided at an inward point for sealing. Body member 30 may have a bottom annular recess 54 for abutment by the extension 24a. A filter of the type described receives the product to be filtered inwardly from the outside in, and such product after passing through a filter material 24c passes through a perforated hollow center core 24d for discharge through stud 38, pollution control valve, and to the intake manifold 16. The filter has an annular recess 24e in its end surface whereby the inlet product flows around the filter for access to the entire filter.
FIGS. 3, 4 and 5 show an embodiment utilizing the same principles as that shown in FIG. 2 except that the filter support 28' has provision for holding two filters 24, one projecting upwardly and the other projecting downwardly. For this purpose, the body member 30' of this embodiment has a tapped axial bore 31' arranged to threadedly receive a straight hollow stud 38' projecting both above and below the body member for holding the top and bottom filters. The body member is integral with a bracket 32' adapted to be secured to the vehicle, such bracket having an integral projecting stud 60 for engagement in a short radial tapped bore 62 in the body member 30'. Fitting 48 for the one end of conduit section 26a, namely the section extending from the valve cover, is threadedly engaged in a radial tapped bore 64 in the body member 30'. Bore 64 has communication with one of several vertical passageways 66 arranged in an annular pattern around the member 30' and offset from the center of the latter so as to provide an inlet into the filters. These passageways are in communication at the upper and lower sides of the member 30' by the annular recess 24e provided in the filters.
A radial bore 68 extends from a central point in communication with the interior of stud 38', by means of an aperture 70 in said stud, to the exterior of the member 30' where a fitting 44 for the pollution control valve 22 is attached, an outward portion of the bore 68 being tapped to threadedly receive such fitting. Hose 26b extends from the pollution control valve 22 to the intake manifold as in FIG. 1.
According to the invention, the conventional system of circulating the crankcase fumes from the valve cover back into the intake manifold is preserved, as is the use of the pollution control valve. It has been found that by adding a filter in the system that the amount of pollutants discharged from the exhaust is greatly decreased and the mileage per gallon substantially increased. The type of filter used may vary but it has been found that the conventional spin-on oil filter commonly in use provide good results. Any suitable filter that traps solid particles in the fumes as well as some vapors may be used.
It is to be understood that the form of my invention herein shown and described is to be taken as a preferred example of the same and that various changes in the shape, size and arrangement of parts may be resorted to without departing from the spirit of my invention, or the scope of the subjoined claims.
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A filter is included in a conventional emission control system of the type wherein crankcase fumes are fed into the fuel intake manifold for burning. Conventional emission control systems include a pollution control valve, and the present system also incorporates such valve in combination with said filter.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. provisional patent application Ser. No. 61/364,593, filed Jul. 15, 2010, which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] Embodiments of the present invention generally relate to a method and apparatus for parallel context processing techniques for high coding efficiency entropy coding, which may be used in the video coding standard High Efficiency Video Coding (HEVC).
[0004] Description of the Related Art
[0005] Context-Adaptive Binary Arithmetic Coding (CABAC) is one of two entropy engines used by the existing video coding standard AVC. CABAC is a method of entropy coding that provides high coding efficiency. Processing in CABAC engine is highly serial in nature. Consequently, in order to decode high bit rate video bit-streams in real-time, the CABAC engine needs to be run at extremely high frequencies which consumes a significant amount of power and in the worst case may not be feasible.
[0006] Therefore, there is a need for an improved method and/or apparatus for parallel context processing techniques for high coding efficiency entropy coding in HEVC.
SUMMARY OF THE INVENTION
[0007] Embodiments of the present invention relate to a method and apparatus for parallel context processing for example for high coding efficient entropy coding, such as, HEVC. The method comprising retrieving syntax element relating to a block of an image, grouping at least two bins belonging to similar context based on the syntax element, and coding the grouped bins in parallel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] 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.
[0009] FIG. 1 is an embodiment of a CABAC block diagram;
[0010] FIG. 2 is an embodiment of a flow diagram depicting PIPE/V2V coding;
[0011] FIG. 3 is an embodiment of a syntax element partitioning;
[0012] FIG. 4A is an embodiment of a flow diagram depicting a parallelization of context processing for significance map utilizing speculative computing at each bin;
[0013] FIG. 4B is an embodiment of a flow diagram depicting a parallelization of context processing for significance map utilizing speculative computing at a fifth bin;
[0014] FIG. 5 is an embodiment of a flow diagram depicting a method for context processing tree for level coding in AVC;
[0015] FIG. 6 is an embodiment of a flow diagram depicting context processing tree for levels when SIGN is coded in separate bin-plane; and
[0016] FIG. 7 is an embodiment of a proposed approach on order of syntax elements.
DETAILED DESCRIPTION
[0017] FIG. 1 is an embodiment of a CABAC block diagram. As shown in FIG. 1 , the serial nature in CABAC comes from the following three blocks, a binarizer, a context modeler and a binary arithmetic coder. In the binarizer, bins from many syntax elements, such as, coefficient levels and motion vector differences are coded using variable length coding such as unary coding and exp-Golomb coding. Variable length codes are inherently serial in nature. In the context modeler, the serial dependency comes about since the probability used in the context model for coding the next bin is updated depending on the current bin value. If the current bin value is Least Probable Symbol (LPS), the probability is increased and if the current bin value is Most Probable Symbol (MPS), the probability is decreased. Another source of serial dependency is the context index selection process, where the context index of bin may be determined by the value of previously coded bins. In the binary arithmetic coder (BAC), the arithmetic coding uses interval subdivision. The range, value, offset used to determine the interval on [ 0 , 1 ] that uniquely identifies the coded stream of bin values are updated in a serial fashion as and when bins get encoded/decoded.
[0018] In some embodiments of parallel entropy coding tools, the parallelism proposed may be broadly classified into three categories: (1) Bin-level parallelism, which parallelizes the BAC, (2) Syntax element-level parallelism, which parallelizes the BAC, the context modeler, and the binarizer and (3) Slice-level parallelism.
[0019] A N-bins/cycle coding (NBAC) encodes and decodes N-bins/cycle to achieve N-fold improvement in throughput. The contexts for N-bins are calculated through the use of conditional probabilities. In some HEVC embodiment, the binarizer and context modeler were basically the same as in CABAC of AVC. However, coding schemes are determined variable-to-variable length for coding of the bins. There are two flavors of the scheme: (1) PIPE and (2) V2V. The main difference between the two is the context probabilities are quantized to 12 levels in PIPE and to 64 in V2V. In PIPE/V2V coding scheme, the bins are coded using a parallel bin encoding scheme as shown in FIG. 2 . FIG. 2 is an embodiment of a flow diagram depicting PIPE/V2V coding.
[0020] Some embodiments that utilize schemes that interleaves the V2V code words from different partial bitstreams into a single bitstream. As a result, a throughput increase of 6× for PIPE in hardware is possible. Such embodiments usually cause an estimated throughput increase of 3× in BAC stage for PIPE hardware implementation for both the parallel and serial versions of PIPE. Since PIPE uses 12 bitstream buffers and V2V uses 64 bitstream buffers, PIPE is usually utilized more often than V2V from a complexity purpose. However in both cases, there is no estimated overall throughput improvement in the entropy coder due to serial bottlenecks in context processing and binarization.
[0021] The NBAC, PIPE, V2V schemes reduces serial dependency in the BAC block. However, the serial dependency in the context modeler and binarizer still remain. So, the effective throughput increase that can be achieved in entropy coding is limited. Hence, techniques for parallelization of context processing (PCP) may be utilized.
[0022] In syntax element partitioning, syntax elements such as macroblock type, motion vectors, transform coefficients, significant coefficient map etc. are divided into N groups and each group is coded separately. The context selection and adaptation within a group happens in parallel leading to a potential N-fold speed up in context modeler if the various partitions are balanced in terms of the number of bins they process. In practice, the various partitions are not balanced and the throughput improvement is less than a factor of N.
[0023] FIG. 3 is an embodiment of a syntax element partitioning. FIG. 3 shows the block diagram of a system with N syntax partitions. The bin coders can be arithmetic coders or PIPE/V2V coders. If PIPE/V2V coders are used as the bin coders, the serial version of PIPE interleaving codewords maybe preferable for reducing the number of bitstream buffers.
[0024] Syntax element partitioning results showed throughput improvement and BD-Rate. In this embodiment, significance map coding is carried out in AVC CABAC. In such an embodiment, the last significant coefficient flag is transmitted when the related coefficient is determined to be significant. The coefficient is the output of a block after transform and quantization. Also, a coefficient is significant when it has value that is non-zero.
[0025] This technique introduces serial dependency in decoding of significance map. When throughput improvement is needed, speculative computation are performed at every bin. Such computations leads to complex logic, as shown in FIG. 4A . FIG. 4A is an embodiment of a flow diagram depicting a parallelization of context processing for significance map utilizing speculative computing at each bin. Speculative computation at every bin also results in increased power consumption.
[0026] Significance map coding are parallelized by transmitting the last significant coefficient flag once per certain number of bins. For example, FIG. 4B is an embodiment of a flow diagram depicting a parallelization of context processing for significance map utilizing speculative computing at a fifth bin. If all of the significant coefficient flag is zero, then the last significant coefficient flag is not transmitted.
[0027] Such an embodiment reduces the number of last bins that need to be transmitted, but it increases the number of significant bins that need to be transmitted. However, there is about a 5% overall reduction in the number of significance map bins that need to be processed. Our algorithm parallelizes about 21.65% of the bins for largest coding unit (LCTB).
[0028] Table 1 shows the distribution of bins used by different syntax element types as a percent of total bins for a LCTB. The bin distribution was obtained by measuring bins in bitstreams generated, for example, by TMuC-0.1 using cfg files in cfp-fast directory. Shown in Table 1 is the distribution of bins used by different syntax element type as a percent of total bins for a LCU.
[0000]
TABLE 1
Bins used
Average
per
number
syntax
of bins
SigMap
21.65%
SigLast
8.35%
LevelAbs
16.67%
LevelSign
9.92%
[0029] The coefficient coding is usually carried out in AVC CABAC. The context used for the absolute value of the coefficient minus one, known as the coefficient level (1) depends on the position of the bin. Thus, when the binIdx is 0 (i.e. first bin of the coefficient level), then the context is derived by (ctxIdxInc=((numDecodAbsLevelGt1 !=0) ? 0: Min(4, 1+numDecodAbsLevelEq1))); Otherwise, context is divided by (ctxIdxInc=5+Min(4−((ctxBlockCat==3) ? 1:0), numDecodAbsLevelGt1)). Context processing for the first bin in the absolute value of the coefficient minus one (i.e. Coeff Level BinIdx 0 in FIG. 7 ) is different from the other bins in the coefficient level.
[0030] In one embodiment, the encoding Coeff Level BinIdx 0 occurs in a separate bin-plane as shown in the second row of FIG. 7 . The advantage in the context processing, because it can be carried out in parallel to the rest of the context processing i.e. the context processing for all the Coeff Level BinIdx 0, for all the coefficients level in a block, may be carried out in parallel to bin processing of Coeff Level BinIdx 0 before the decoding of the other bins in the coefficient level. This is referred to as Coeff Level BinIdx PCP.
[0031] In AVC, sign information is interleaved along with level information as shown in FIG. 5 . This leads to inefficiency in parallel context processing. FIG. 5 is an embodiment of a flow diagram depicting a method for context processing tree for level coding in AVC. In FIG. 5 , the context processing tree that needs to be pre-calculated at each bin to achieve 4× parallelism in context processing of level in AVC. The context processing that happens at every SIGN node is wasteful since SIGN is coded in bypass mode. Table 3 shows the distribution of level of coefficients obtained by measuring levels in bitstreams generated by, for example, a TMuC-0.1 using cfg files in cfp-fast directory.
[0000]
TABLE 3
Probablity of
Level
occurrence
1
0.76
2
0.15
3
0.05
4
0.02
5
0.01
[0032] Level=1 occurs with the highest probability, so the most probable path in the context processing tree of FIG. 6 is L0(0) SIGN0 L1(0) SIGN1. For this particular path, the context processing efficiency is 50%, meaning half the context processing is wasteful. On the average, for the context processing tree of FIG. 6 and assuming the level distribution of Table 3, the context processing efficiency is 60%. FIG. 6 is an embodiment of a flow diagram depicting context processing tree for levels when SIGN is coded in separate bin-plane. In FIG. 6 , the context processing tree for levels when sign is coded in separate bin-plane. As can be seen in the figure, context processing efficiency is 100%. This is also illustrated in FIG. 7 where all sign bins (i.e. Coeff Sign Bins) are coded on separate bin plans; this is referred to as Coeff Sign PCP.
[0033] In some embodiment, the first two bins in the coefficient level are context coded. The rest of the bins, such as, coefficient sign bins and Golomb-Rice+Exp-Golomb (GR-EG) binarized bins, are bypass coded. As an extension of “Coeff Level BinIdx 0 PCP”, the second bin in the absolute value of the coefficient minus 1 (i.e. Coeff Level BinIdx 1) is also coded in a separate bin-plane. The Coeff Sign Level can be interleaved or be on a separate bin-plane with GR-EG bins.
[0034] FIG. 7 is an embodiment of a proposed approach on order of syntax elements. FIG. 7 illustrates a data ordering based on Coeff Level BinIdx 0 PCP, Coefficient Sign PCP, and Coeff Level BinIdx 1 PCP. Bypass coded bins are Coefficient Sign & GR-EG bins. The first row shows original ordering used in H.264/AVC. The ordering of HEVC (HM-1.0), in which the proposed Coeff Level BinIdx 0 PCP and Coefficient Sign PCP was adopted, is shown in the second row. Here c0 and sign can be placed in partitions that can be coded in parallel with the other bins. The new coefficient level binarization and coding introduced in HM-3.0 is shown in the third row. Finally, the proposed Coeff Level BinIdx 1 PCP is shown in the fourth row. Here c0, c1 and sign+GR-EG bins can be placed in partitions that can be coded in parallel with the other bins. Note that sign and GR-EG bins (i.e. exp-golomb and golomb rice bins of coeff) can be placed in the same partition as all are bypass coded.
[0035] Since bypass coding is simpler than context coding, bypass bins can be coded faster than context coded bins. In particular, many bypass bins can be coded in a cycle which can increase the throughput of the CABAC. With Coeff Level BinIdx 1 PCP all bypass coded bins for coefficients in a given TU are grouped together which increases throughput impact of parallel bypass bins processing.
[0036] Variants of this approach include separating GR-EG+sign bins from the Coeff Level BinIdx 0 and Coeff Level BinIdx 1, but keeping the GR-EG+sign bins interleaved and keeping the Coeff Level BinIdx 0 and Coeff Level BinIdx 1 bins interleaved as shown in proposal #2 in FIG. 11 . This eliminates the additional of loops required to separate the Coeff Level BinIdx 0 from Coeff Level BinIdx 1, and Coefficient Sign from RG-EG bins. Alternatively, proposal #3 in FIG. 7 keeps GR-EG and Coefficient sign bins interleaved, to reduce the loops, and keeps Coeff Level BinIdx 0 and Coeff Level BinIdx 1 in separate partitions. This is due to the fact that the context selection for Coeff Level BinIdx 0 and Coeff Level BinIdx 1 are more complex and keeping the two separate helps to improve parallel processing as described in section Coeff Level BinIdx 0 PCP. This approach can also be applied to other type of syntax elements such as motion vector difference. The bypass bins of the motion vectors difference can be coded together on a separate bin-plane than the context coded bins.
[0037] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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A method and apparatus for parallel context processing for example for high coding efficient entropy coding in HEVC. The method comprising retrieving syntax element relating to a block of an image, grouping at least two bins belonging to similar context based on the syntax element, and coding the grouped bins in parallel.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/369,502, filed Apr. 2, 2002, titled LANDING GEAR AND METHOD OF ASSEMBLY.
BACKGROUND OF THE INVENTION
This invention relates generally to landing gear used in the support of semitrailers and more particularly to gearing configurations of a landing gear.
Landing gear of the present invention has particular application in the support of semitrailers when they are not attached to a tractor. The landing gear conventionally includes a pair of telescoping legs capable of extending to engage the pavement or other supporting surface to hold up the front end of the semitrailer, and of retracting to move up out of the way when the semitrailer is being pulled over the road by a tractor. The extension and retraction is most often carried out by the driver manually turning a crank connected by gearing to a lead screw in the leg. The lead screw interconnects telescoping leg sections of the leg so as to retract a lower leg section into an upper leg section or extend the lower leg section from the upper leg section depending on the direction the screw is rotated.
The semitrailers are very large and heavy by themselves, and further carry large loads. In order to lift such loads when extending the legs, the gearing provides a mechanical advantage in addition to the crank. In providing the mechanical advantage, the rotation of the lead screw is very much retarded in relation to the rotation of the crank. In other words, it will require numerous turns of the crank to achieve a very small linear travel of the lower leg section relative to the upper leg section. The high ratio of turns per inch of travel is acceptable when the legs are actually bearing the load of the trailer because of the accompanying mechanical advantage. Once the load is relieved from the leg, such as when the semitrailer is supported by the tractor, the slow linear movement of the lower leg section becomes an issue because of the long time it takes to get the lower leg section retracted far enough above the ground for safe travel over the road. Likewise, slow extension of the lower leg section into engagement with the pavement is also highly undesirable. It is known to provide for shifting between a low gear and a high gear in the gearing, with the low gear providing the mechanical advantage needed for lifting large loads and high gear providing for more rapid linear movement of the lower leg section (i.e., a lower turns per inch ratio). Co-assigned U.S. Pat. No. 4,187,733 discloses gearing of this type. Generally, a large difference between the turns per inch ratio in low gear versus high gear is desirable.
One way to assist in providing greater lift in low gear is to provide a gear on an idler shaft located between the input shaft (of the crank) and the output shaft connected to the lead screw. This arrangement is typically referred to as a double reduction. An idler shaft requires additional space in the gear box, which is at a premium. In addition, there are two additional openings in the gear box containing bearings for the idler shaft. These openings provide an additional place from which leakage of lubricant becomes more likely over the life of the landing gear.
Conventionally, the gearing has been located in a gear box which is formed separately from the leg. For instance, the gear box may be formed from two halves which are individually stamped and later bolted together. The gears making up the gearing may be installed in one half of the gear box before it is completed. The gear box is welded or otherwise attached to the landing gear leg on the inside or outside of the leg. The input shaft from the crank, and the output shaft which is connected to the lead screw, are held by bearings located in the landing gear leg. The conventional construction requires a number of parts in addition to the landing gear leg and several manufacturing steps to assemble the gearing in the gear box with the input and output shafts and the leg. It is known to incorporate some of the gearing in the leg, but significant manufacturing steps are required to assemble component parts of the gearing together with the input and output shafts.
SUMMARY OF THE INVENTION
Among the several objects and features of the present invention may be noted the provision of landing gear which is of simplified construction; the provision of such landing gear having a compact gear arrangement; the provision of such landing gear which provides additional torque in low gear and augmentation of crank rotation in high gear to increase speed; the provision of such a landing gear which inhibits leakage of lubricant; the provision of such landing gear which has fewer external bearings receiving shafts; the provision of such landing gear which has fewer parts; the provision of such landing gear which is lighter in weight; and the provision of such landing gear which can be efficiently assembled.
Further among the several objects and features of the present invention may be noted the provision of a method of assembling landing gear which can be carried out rapidly and with precision; the provision of such a method which reduces the number of externally exposed shaft bearings to minimize leakage; and the provision of such a method which reduces the number of steps to complete manufacture of the landing gear.
In general, one embodiment of the invention is directed to landing gear for selectively supporting a semitrailer. The landing gear includes a leg having an upper section and a lower section in telescoping arrangement with each other and a lead screw mounted for extending and retracting the upper and lower sections relative to each other upon rotation of the lead screw. The landing gear also includes an input shaft for applying a torque to the lead screw to drive rotation thereof, the input shaft being rotatable about a first rotation axis and movable in translation along the first rotation axis for shifting between a first position for low gear operation and a second position for high gear operation. The landing gear also includes an output shaft including an output gear for transmitting torque to the lead screw, the output shaft being mounted for rotation about a second rotation axis and being generally axially aligned with the input shaft. The landing gear also includes a gearing subassembly configured so that for each rotation of the input shaft, the output shaft rotates less than one rotation for low gear operation and interconnecting the generally axially aligned input and output shafts in the second position so that for each rotation of the input shaft, the output shaft rotates more than one rotation, whereby the gearing subassembly augments lift when the input shaft is in the first position and augments speed in the second position.
The invention is also directed to landing gear for selectively supporting a semitrailer. The landing gear includes a leg having an upper section and a lower section in telescoping arrangement with each other and a lead screw mounted for extending and retracting the upper and lower sections relative to each other upon rotation of the lead screw. The landing gear also includes an input shaft rotatable about a first rotation axis and an output shaft rotatable about a second rotation axis and connected for driving rotation of the lead screw. The landing gear further includes an idler shaft rotatable about a third rotation axis and gearing associated with the input shaft, output shaft, idler gear and lead screw for operatively connecting input shaft to the lead screw for driving rotation thereof. The landing gear also includes a bearing member located within the upper section of the leg and including a bearing element bearing the idler shaft for rotation, the bearing member being supported by the upper section at a location above the location of the bearing element.
Another embodiment of the invention is directed to landing gear for selectively supporting a semitrailer. The landing gear includes a leg having an upper section and a lower section in telescoping arrangement with each other and a lead screw mounted for extending and retracting the upper and lower sections relative to each other upon rotation of the lead screw. The landing gear also includes an input shaft rotatable about a first rotation axis and movable in translation along the first rotation axis for shifting between a first position for low gear operation and a second position for high gear operation and an output shaft mounted for rotation about a second rotation axis. The landing gear further includes a first idler shaft mounted for rotation about a first idler shaft axis spaced from the axis of rotation of the input shaft and a second idler shaft mounted for rotation about a second idler shaft axis spaced from the axis of rotation of the input shaft. The input shaft and the first idler shaft are arranged such that in the first position torque from the input shaft is transmitted through the first idler shaft to the lead screw and the output shaft and the input shaft and the second idler shaft are arranged such that in the second position torque from the input shaft is transmitted through the second idler shaft to the output shaft and lead screw.
Another embodiment of the invention is directed to landing gear for selectively supporting a semitrailer. The landing gear includes a leg having an upper section and a lower section in telescoping arrangement with each other. The upper section has opposing walls, a first of the walls having a slot therein at an upper end. The landing gear also includes a lead screw mounted for extending and retracting the upper and lower sections relative to each other upon rotation of the lead screw and an input shaft rotatable about a first rotation axis and connected in operation to the lead screw for driving rotation thereof. The input shaft extends into the upper section of the leg through the slot in the first wall. The landing gear further includes a cover plate attached to the upper section generally over the slot, the cover plate including a bearing receiving the input shaft there through.
Another embodiment of the invention is directed to a method of assembling a landing gear leg. The method includes the steps of mounting at least one shaft on a bearing located in a bearing member and inserting the bearing member mounting the shaft into an upper section of the landing gear leg.
Another embodiment of the invention is directed to a subassembly for use in manufacturing a landing gear leg. The subassembly includes a bearing member adapted to be mounted on the leg in an open top thereof and a shaft mounted on the bearing member for rotation. The subassembly also includes gearing associated with the shaft for use in transmitting rotation, whereby the shaft and gearing are supported for rotation independently of mounting in the leg.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of a semitrailer unhitched from its truck tractor, and having landing gear thereon supporting the front end of the semitrailer;
FIG. 2 is an enlarged perspective view of a landing gear leg of the landing gear depicted in FIG. 1 ;
FIG. 3 is a front side elevation of the landing gear leg of FIG. 2 ;
FIG. 4 is a right side elevation of the landing gear leg of FIG. 2 ;
FIG. 5 is an exploded perspective view of the landing gear leg of FIG. 2 capable of receiving a gearing subassembly for both conventional and reverse mounted legs;
FIG. 6 is a side elevation of a mounting plate of the landing gear leg of FIG. 2 ;
FIG. 7 is a side elevation of an upper portion of the landing gear leg;
FIG. 8 is a plan view of an upper section of the landing gear leg;
FIG. 9 is a bottom side perspective of a top cover and associated idler shaft and gearing of a single idler landing gear leg according to one embodiment of the invention;
FIG. 10 is an inverted view of the top cover and idler shaft of FIG. 9 with the parts exploded to illustrate assembly;
FIG. 11 is a schematic fragmentary cross section of the single idler landing gear leg of FIG. 9 with the input shaft in the low gear position;
FIG. 12 is a schematic fragmentary cross section of the single idler landing gear leg of FIG. 9 with the input shaft in the high gear position;
FIG. 13A is an end view of the idler shaft of the single idler landing gear of FIG. 9 ;
FIG. 13B is a sectional view of the idler shaft taken along line 13 B— 13 B of FIG. 13A ;
FIG. 14 is a bottom side perspective of a top cover of the single idler landing gear leg;
FIG. 15 is an inverted perspective view of the top cover of FIG. 14 with the parts exploded to illustrate assembly;
FIG. 16 is a schematic, fragmentary cross section of another version of the single idler landing gear leg having an idler shaft supported from the side internally of the leg;
FIG. 17 is a bottom side perspective of a top cover and associated dual idler shafts and gearing according to one embodiment of the invention;
FIG. 18 is an inverted perspective view of the top cover and dual idler shafts of FIG. 17 with the parts exploded to illustrate assembly;
FIG. 19 is a schematic, fragmentary side elevation of a dual idler landing gear leg with a wall of the leg and other selected parts broken away to reveal construction with the input shaft in the high gear position;
FIG. 20 is a schematic, fragmentary side elevation of a dual idler landing gear leg with a wall of the leg and other selected parts broken away to reveal construction with the input shaft in the low gear position;
FIG. 21 is an enlarged fragmentary side elevation of the dual idler landing gear;
FIG. 22A is an end view of the low idler shaft of the dual idler landing gear;
FIG. 22B is a sectional view of the low idler shaft taken along line 22 B— 22 B of FIG. 22A ;
FIG. 23A is an end view of the high idler shaft of the dual idler landing gear;
FIG. 23B is a sectional view of the high idler shaft taken along line 23 B— 23 B of FIG. 23A ;
FIG. 24 is a bottom side perspective of the top cover of the dual idler landing gear leg;
FIG. 25 is an exploded perspective of the top cover of FIG. 24 ;
FIG. 26 is a fragmentary front elevation of a single idler landing gear leg having components substantially identical to the dual idler landing gear leg of FIGS. 20 and 21 ; and
FIG. 27 is a fragmentary side elevation of the single idler landing gear leg with a wall of the leg and other selected parts broken away to reveal construction.
Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates landing gear, indicated generally at 10 , for the support of semitrailers when not attached to a tractor. The landing gear 10 typically includes a pair of legs 11 (only one leg is shown) located near respective front corners of a semitrailer 12 . Each leg 11 is capable of extending to engage the pavement S or other supporting surface to hold up the front end of the semitrailer as is well understood in the art. A shoe 14 of the landing gear 10 is pivotally mounted on the leg 11 for engaging the pavement S. The legs 11 are also capable of retracting to move up out of the way when the semitrailer 12 is being pulled over the road by a tractor (not shown). A crank handle 16 is used to extend and contract the length of the leg 1 , as will be described below. The following description is confined to one of the legs 11 . The other leg (not shown) has a similar construction, but if it is connected to gearing of the illustrated leg such as by an output shaft extending underneath the front of the semitrailer 12 , the other leg need not have some of the gearing present in the illustrated leg. Such constructions are well understood by those of ordinary skill in the art and will not be further described herein.
Referring to FIGS. 2–5 , the landing gear leg 11 includes a lower leg section 13 ( FIG. 5 ) telescopingly received in an upper leg section 15 . The lower leg section 13 is a steel square tube. The upper leg section 15 is preferably a square tube made of steel or other like material. The upper leg section 15 has internal dimensions larger than that of the lower leg section 13 so that the lower leg section is telescopingly received in the upper leg section.
The lower and upper leg sections 13 , 15 could also have other cross sectional shapes, such as rectangular, round or the like. In an alternate version, the upper leg section is a steel channel having an open front side extending the length of the upper leg section. A mounting plate 17 for attaching the leg 11 to the trailer 12 is attached by bolts and/or welding to the upper leg section 15 . Holes 17 A in the mounting plate 17 may receive fasteners (not shown) for attaching the leg 11 to the trailer 12 . The leg 11 can be attached to the trailer in either a “conventional mount” and “reverse mount”. These labels will be understood by those of ordinary skill in the art and will not be discussed further.
FIG. 5 illustrates that the upper leg section 15 has two U-shaped cutouts 18 , 20 extending axially downward from the upper end of the upper leg section on opposite sides of the upper leg section. In the final assembly, the cutouts 18 and 20 are closed by an outside cover plate 19 and an inside cover plate 21 , respectively. For illustrative purposes, with the conventionally mounted leg 11 , the “outside” cover plate 19 faces out to the side of the semitrailer and the “inside” coverplate 21 faces in toward the center of the semitrailer. The upper leg section 15 is formed with two pockets 22 extending outward from the upper leg section on opposite sides of the upper leg section. The pockets 22 are formed on the sides of the upper leg section that do not have the cutouts 18 , 20 . The pockets 22 are sized to accommodate an idler gear as will be described below.
The lower and upper leg sections 13 , 15 are connected together by a lead screw 23 (only the very upper portion of which is illustrated in FIG. 5 ) for extension and retraction of the lower leg section 13 relative to the upper leg section 15 upon rotation of the lead screw. The lead screw 23 has a bevel gear 25 mounted on its upper end for use in driving the lead screw as will be described. The landing gear leg 11 includes an input shaft 27 received through the outside cover plate 19 into the leg and an output shaft 31 received through the inside cover plate 21 of the leg. The input shaft 27 and output shaft 31 are connected together a subassembly 32 further including gearing as will be described below. More specifically, the gearing subassembly 32 is preferably constructed and arranged to fit substantially within the cross sectional area of the upper leg section 15 . In one embodiment, the output shaft 31 would extend to the aforementioned other leg (not shown) of the landing gear to drive the rotation of the lead screw in that leg. The crank handle 16 ( FIG. 1 ) is preferably attached to the outer end of the input shaft 27 for manually applying torque to rotate the input shaft.
Assembly of the landing gear leg 11 may performed by dropping the top cover 47 and associated components of the subassembly 32 onto the open top of the upper leg section 15 . Thus, in one preferred embodiment, the gearing components of the subassembly, such as the idler shafts, the output gear, the pinion gear and the large diameter input gear, as will be described below, are all received within the upper leg section 15 . The input shaft 27 passes through the cutout 18 on the outside of the upper leg section 15 and the output shaft 31 passes through the cutout 20 on the inside of the upper leg section. Cover plate bolts extend through holes in respective cover plates 19 , 21 and into the top cover 47 to secure the subassembly 32 to the leg 11 . The cover plates 19 , 21 may also be welded to the upper section 15 and/or a gasket (not shown) maybe provided between the cover plate ( 19 , 21 ) and upper section.
Preferably, the leg 11 is constructed selectively for either conventional mounting on a semitrailer or reverse mounting by turning the subassembly 32 to the upper section 15 through 180 degrees. Nothing else about the construction of the leg changes, which simplifies manufacturing. It maybe seen that the upper end of the upper leg section 15 has the opposite laterally outwardly formed pockets 22 . In addition, the front side of the upper leg section 15 has an outwardly formed portion 24 . The pockets 22 provide space for the gears of the idler shafts (not shown) without regard to the orientation of the subassembly 32 . The outwardly formed portion 24 keeps the distance from a center of the upper section 15 to the respective cutouts 18 , 20 equal. Thus, a beveled pinion gear member (described below with reference to FIG. 9 ) in the subassembly 32 will mesh with the bevel gear 25 at the top of the lead screw 23 no matter which direction the top cover subassembly is oriented. FIG. 5 shows the top cover subassembly 32 oriented for both conventional mount and for reverse mount. In either orientation, the subassembly 32 can be dropped into the open top of the upper leg section 15 for assembling the leg 11 .
FIG. 6 illustrates a mounting plate 17 ′ used with an upper leg portion (not shown) shaped as a channel and is configured to cover the open front side of the upper leg portion. FIGS. 7 and 8 illustrate a modified version of an upper section 15 ″ of a landing gear leg having the shape of a square tube. The upper section 15 ″ has a mounting plate 17 ″ attached thereto. The upper end of the upper section 15 ″ is belled outwardly to form pockets 22 ″ and outwardly formed portions 24 ″. The pockets 22 ″ and outwardly formed portions 24 ″ extend over a substantial portion of the width of their respective side walls. Otherwise, the construction of the upper section 15 ″ is substantially the same as upper section 15 . The upper leg section 15 at its upper end is symmetrical about a central plane P.
FIGS. 9–16 illustrate a subassembly, generally designated at 32 , and parts thereof separately and in combination with the leg 11 . Referring to FIGS. 9 and 10 , the subassembly 32 comprises a single idler shaft 45 ( FIG. 13 ) for mechanically connecting the input shaft 27 with the output shaft 31 . The input shaft 27 is received through a bearing 29 in the outside cover plate 19 into the leg 11 and the output shaft 31 is received through a bearing 33 in the inside cover plate 21 of the leg. The top cover 47 has been removed from FIG. 9 for clarity.
The inner end of the input shaft 27 has a reduced diameter and is received and borne in an axial opening of an output gear 35 of the output shaft 31 for free rotation relative to the output gear and for axial movement relative to the output gear. Alternately, the output shaft has a reduced diameter end portion (not shown) which is received in an axial opening in the input shaft, or the shafts could be supported independently of each other. Thus, the input and output shafts 27 , 31 are coaxal. The bearing 29 supporting the input shaft 27 in the outside cover plate 19 permits the input shaft to both rotate and move axially relative to the bearing. As to axial movement, a ball and spring mechanism (not shown) is provided to engage the bearing 29 to releasably lock the input shaft 27 in two axial positions, corresponding to low gear ( FIG. 11 ) and high gear ( FIG. 12 ), respectively.
The input shaft 27 carries a pinion gear 37 which is pinned to the reduced diameter portion of the input shaft for conjoint rotation with the input shaft. It is contemplated that the pinion gear 37 could be formed as one piece with the input shaft 27 . The pinion gear 37 has a small diameter, and has a first set of gear teeth 38 and a second set of gear teeth 40 . The input shaft 27 also mounts a large diameter input gear 39 for free rotation relative to the input shaft, except as will be described, but which is held from movement along the axis of the input shaft relative to the upper leg section 15 . A central, internally toothed opening 42 of the input gear 39 has a diameter which is larger than the input shaft 27 for receiving a part of the pinion gear 37 into the central opening. The large diameter input gear 39 includes a flat central portion 46 and an angled outer portion 48 . This construction permits the large diameter gear 39 to fit closely against the outside cover plate 19 and between the outside cover plate and the bevel gear 25 of the lead screw 23 . The annular outer portion 48 of the large diameter gear 39 angles outwardly and has teeth formed therein for meshing with another gear as will be described.
The output gear 35 is pinned to the output shaft 31 for conjoint rotation. The output gear 35 includes first gear member 41 which receives input torque to drive the gear and a second beveled pinion gear member 43 which is meshed with the bevel gear 25 of the lead screw 23 . The first gear member 41 is substantially planar and fits close against the inside cover plate 21 and between the bevel gear 25 and the cover plate. As illustrated, the output gear 35 is formed as a single piece of tubular material. However, it may be formed from multiple pieces which are separated and secured to a common tube, or directly to the output shaft 31 .
Driving connection of the input shaft 27 with the output gear 35 is achieved by way of an idler shaft 45 having three idler gears formed as one piece with the shaft. It would be possible to form the gears separately from the shaft and connect them to the shaft. As shown in FIGS. 11 and 12 , the idler shaft 45 is supported for rotation within the upper leg section 15 by a top cover 47 . In certain statements of the present invention, the top cover 47 may be considered to be a “bearing member”. The top cover will be described more fully hereinafter. A first idler gear 49 has the smallest diameter of the gears on the idler shaft and is permanently meshed with the large diameter input gear 39 . A second idler gear 51 has the largest diameter and is located generally in the middle of the idler shaft 45 for selective engagement with the teeth 40 of the pinion gear 37 of the input shaft 27 . A third idler gear 53 located at the far left end of the idler shaft 45 has a diameter between that of the first and second idler gears and is permanently meshed with the first gear member 41 of the output gear 35 .
Referring to FIGS. 14 and 15 , a top cover 47 of the single idler landing gear leg 11 is formed to rotatably mount the idler shaft 45 . Preferably, it is not necessary to have additional openings in the exterior of the leg 11 through which rotating shafts are received, which are prime locations for leaking lubricant. The top cover 47 is made either partially or entirely of a polymeric material such as nylon. However, it is contemplated that the top cover 47 may be made of other suitable materials, such as a ductile iron casting or aluminum casting, without departing from the scope of the present invention. It is believed no separate bearings will be necessary if the top cover 47 is made of nylon or a like material. In one version, side flange 70 of the top cover 47 has openings 72 therein for receiving bolts or screws to secure the cover plate 19 (see FIG. 10 ) to the top cover. The top cover has a first outwardly formed pocket 74 extending from a top surface 75 thereof. The pocket 74 provides space for receiving the second idler gear 51 (see FIG. 10 ). The top cover 47 also has a second outwardly formed pocket 76 extending from the top surface 75 for receiving the third idler gear 53 . Side flange 78 of the top cover 47 has openings (not shown) therein for receiving bolts or screws to secure the cover plate 21 (see FIG. 10 ) to the top cover.
Referring now to FIG. 15 , the top cover 47 includes a first yoke 81 which receives a section of the idler shaft 45 between the first idler gear 49 and the second idler gear 51 , and a second yoke 83 which receives a section of the idler shaft between the second idler gear and the third idler gear 53 . The first and second yokes 81 , 83 each have a lower portion 81 A, 83 A which can be separated from an upper portion 81 B, 83 B to place the idler shaft 45 in the top cover 47 . Bolts 84 may be used to connect the lower portions 81 A, 83 A to respective upper portions 81 B, 83 B. The gearing subassembly 32 , top cover 47 , outside cover plate 19 , inside cover plate 21 , input shaft 27 , and output shaft 31 may be subassembled and dropped into the upper leg section 15 as shown in FIG. 5 .
Referring again to FIGS. 11 and 12 , the operation of the landing gear is as follows. Assuming the lower leg section 13 ( FIG. 2 ) is retracted into the upper leg section 15 and is to be extended, the driver first moves the input shaft 27 axially outwardly to the position shown in FIG. 12 . In this position, the pinion gear 37 is partially received in the central opening 42 of the large diameter input gear 39 . The use of a small pinion gear 37 is adopted from co-assigned U.S. Pat. No. 4,187,733, the disclosure of which is incorporated by reference. The first set of teeth 38 on the right side of the pinion gear 37 mesh with the internal teeth of the large diameter gear 39 so that the large diameter gear is now fixed for conjoint rotation with the input shaft 27 . Thus, the engagement of the large diameter gear 39 with the first idler gear 49 is a driving engagement. As is understood by those of ordinary skill in the art, the idler shaft 45 will be rotated more rapidly than the input shaft 27 . The torque is transmitted by the idler shaft 45 to the third gear 53 meshed with the first gear member 41 of the output gear 35 for driving the output gear at a rotational rate which is greater than that of the input shaft 27 . For example and not by way of limitation, if the ratio of teeth of the larger diameter gear 39 to that of the first idler gear 49 is 31T/7T and the ratio of teeth on the second idler gear 53 to the first output gear member 41 is 13T/25T, the output shaft rotates 2.3 times faster than the input shaft. The ratio of the turns of the crank handle 16 (see FIG. 1 ) per inch of travel of the lower leg section 13 for this version is 1.97. In this way, the lower leg section 13 can be more rapidly extended from the upper leg section 15 for bringing the leg into contact with the pavement S.
Once the leg 11 contacts the pavement, it will be necessary to increase the mechanical advantage provided by the gearing to lift the semitrailer 12 ( FIG. 1 ) off of the fifth wheel of the tractor (not shown). To do this, the driver moves the input shaft 27 axially inwardly so that the pinion gear 37 moves out of the central opening 42 of the large diameter input gear 39 and into engagement with the teeth of the second idler gear 51 (as shown in FIG. 11 ). The large diameter input gear 39 , although still meshed with the first gear 49 of the idler shaft 45 does not transmit any torque from the input shaft 27 and does not rotate conjointly with the input shaft. The second set of teeth 40 on the left side of the pinion gear 37 mesh with the teeth of the second idler gear 51 . It will be readily apparent that rotation of the input shaft 27 will be substantially reduced by the second idler gear 51 , producing an accompanying increase in torque. The higher torque is transmitted by the third idler gear 53 to the first gear member 41 of the output gear 35 , achieving a further (or “double”) reduction. Now rotation of the input shaft 27 produces extension of the lower leg section 13 at a slower rate, but with greater lift to raise the semitrailer 12 and its load.
FIG. 16 illustrates another version of the single idler landing gear leg 111 , where corresponding parts are indicated by the same reference numeral, but with the prefix “1”. An idler shaft 145 is supported by bushings associated with outside and inside cover plates 119 , 121 rather than being supported by the top cover. In this embodiment, the top cover 147 is not used to support the idler shaft 145 . Otherwise, the construction is substantially identical to FIG. 9 and will not be further described herein. Referring again to FIG. 16 , it may be seen that the idler shaft 145 has a reduced diameter stub 185 at the right end thereof and an enlarged diameter portion 187 at its left end. The stub 185 is journaled in a bushing 189 which is fitted into an opening formed in the outside cover plate 121 for rotation of the idler shaft 145 . The bushing 189 blocks the opening to assist in sealing the leg 11 . A short axle 191 is received through an opening in the inside cover plate 121 and into a recess in the enlarged diameter portion 187 of the idler shaft to mount the idler shaft 145 for rotation. The axle 191 is sealably secured to the inside cover plate 121 , such as by welding. The fitted bushing 189 and the short axle 191 mount the idler shaft 145 for rotation between the outside and inside cover plates 119 , 121 . Thus, there is no moving part extending through the outside and inside cover plates 119 , 121 . Thus, although the idler shaft 145 is supported from the sides of the leg 11 , it does not extend through the sides. Accordingly, a prime site for the leakage of lubricant (through a rotating shaft bearing) is eliminated.
Some examples of possible high gear and low gear ratios for the single idler leg 11 are listed below in turns of the crank handle 16 per inch of travel of the leg.
Low Gear - 29.2
Low Gear - 32.8
Low Gear - 35.1
High Gear - 1.8
High Gear - 1.97
High Gear - 3.3
Low Gear - 38
Low Gear - 41.8
Low Gear - 35.1
High Gear - 1.8
High Gear - 1.97
High Gear - 4.5
Low Gear - 35.1
High Gear - 3.9
FIGS. 17–25 collectively show a landing gear leg 211 and components thereof, of another embodiment. Corresponding parts are indicated by the same reference numeral as for the landing gear leg 11 , but with the prefix “2”. FIGS. 17 and 18 illustrate a gearing subassembly 232 and a top cover 247 of the dual idler shaft landing gear leg 211 . The subassembly comprises a dedicated low gear idler shaft 257 ( FIGS. 22A and 22B ) and a separate, dedicated high gear idler shaft 263 ( FIGS. 23A and 23B ) for mechanically connecting an input shaft 227 with an output shaft 231 . The input shaft 227 is received through a bearing 229 in an outside cover plate 219 into the leg 211 and the output shaft 231 is received through a bearing 233 in an inside cover plate 221 of the leg. A top cover 247 is formed to rotatably mount both the low gear idler shaft 257 and the high gear idler shaft 263 in the dual idler landing gear leg 211 . Preferably, it is not necessary to have additional openings in the exterior of the leg 211 through which rotating shafts are received, and which are prime locations for leaking lubricant.
FIGS. 19 and 20 illustrates that the input shaft 227 and output shaft 231 are co-axial and a reduced diameter inner end of the input shaft is received and borne within the output shaft. Alternately, an output shaft has a reduced diameter end portion which is received in an axial opening in the input shaft (not shown). The bearing 229 supporting the input shaft 227 in the outside cover plate 219 permits the input shaft to both rotate and move axially relative to the bearing. As to axial movement, a ball and spring mechanism (not shown) is provided to engage the bearing 229 to releasably lock the input shaft 227 in two axial positions, corresponding to high gear and low gear, respectively. The subassembly 232 is shown in the high gear position in FIG. 19 and in the low gear position in FIG. 20 .
It is noted that a pinion gear 237 is formed as one piece with the input shaft 227 and an output gear 235 is formed as one piece with the output shaft 231 . It will be appreciated that the pinion gear 237 and output gear 235 may be formed separately from their respective shafts ( 227 , 231 ). The pinion gear 237 contains a first set of teeth 238 and a second set of teeth 240 . A large diameter input gear 239 is somewhat smaller than the large diameter gear 39 of the first embodiment and is entirely planar, but is similarly mounted for free rotation on the input shaft 227 except when engaged by the first set of teeth 238 of the pinion gear 237 . The output gear 235 differs from the single idler output gear configuration by having a third, small diameter gear member 244 . More specifically, the dual idler landing gear leg includes a low gear idler shaft 257 including a large diameter first gear 259 engageable by the pinion gear 237 for driving the rotation of the low gear idler shaft, and a second small diameter gear 261 permanently meshed with the first gear member 241 of the output gear 235 . A separate high gear idler shaft 263 includes a first high gear idler gear 265 permanently meshed with the large diameter input gear 239 , and a second high gear idler gear 267 permanently meshed with the third gear member 244 of the output gear 235 . Accordingly, it is not necessary to balance speed in high gear against torque in low gear. The separate, dedicated idler shafts 257 , 263 decouple these design features.
As shown in FIG. 21 , the axis A 1 of the low gear idler shaft 257 and the axis A 2 of the high gear idler shaft 263 are offset on opposite sides of a vertical plane P including the common axis of rotation A 3 of the input and output shafts 227 , 231 . Preferably, the offset is as small as necessary to permit the gears of both idler shafts 257 , 263 to mesh with the coaxially arranged gears ( 235 , 237 , 239 ) of the input and output shafts 227 , 231 .
The operation of the dual idler landing gear leg 211 is similar to the operation of the embodiment of the single idler landing gear 11 shown in FIG. 5 , except that different idler shafts 257 , 263 are used for low and high gear. In high gear, the first set of teeth 238 of the pinion gear 237 is partially received in the large diameter input gear 239 so that the large diameter gear rotates conjointly with the input shaft 227 ( FIG. 19 ). It will be appreciated that the high gear idler shaft 263 rotates faster than the input shaft 227 . For example, with 19 teeth on the large diameter input gear 239 and 9 teeth on the high gear idler gear 265 , the idler shaft 263 rotates 2.11 times as fast as the input shaft 227 . The rotational speed is again increased by the second high gear idler gear 267 meshed with the third gear member 244 of the output gear. The low gear idler shaft 257 turns but does not transfer any torque in this configuration. For low speed, high torque operation the input shaft 227 is moved axially to the left so that the large diameter input gear 239 is disengaged and the second set of teeth 240 on the other end of the pinion gear 237 mesh with the first low gear idler gear 259 ( FIG. 20 ). The input shaft torque is now transferred by the low gear idler shaft 257 to the output gear by way of the second low gear idler gear 261 and the first gear member 241 of the output gear 235 . A substantial reduction is achieved both from the input shaft 227 to the low gear idler shaft 257 and from the low gear idler shaft to the output gear 235 by virtue of the relative sides of the meshed gears.
Preferably, the numerical values given in the range have units of turns of the crank per inch of travel of the leg are between 1.02 and 4.5 in high gear and 26 and 44 in low gear. However, one skilled in the art will understand that any combination of low and high ratios is possible. Preferably, the dual idler leg 211 provides good lift in low gear (e.g., 35 turns per inch), and an option for high gear. For example, the high gear could be either 1.02 or 4.5, with minimal change of gears and other components necessary to provide the desired high gear ratio.
As set forth above with respect to the single idler embodiment, the top cover 247 is preferably made of a polymeric material such as nylon. However, it may be made of other suitable materials, such as a ductile iron casting or aluminum casting, without departing from the scope of the present invention. It is believed no separate bearings will be necessary if the top cover 247 is made of nylon or a like material. The input and output shafts 227 , 231 are also supported by the top cover 247 in a first yoke 269 depending from the top cover. A second yoke 271 is provided for supporting one end of the low gear idler shaft 257 and a third yoke 273 is provided to support one end of the high gear idler shaft 263 . FIGS. 24 and 25 illustrate the top cover 247 of the double idler landing gear leg 211 which mounts the idler shafts 257 , 263 for rotation. It may be seen that each yoke 269 , 271 , 273 (broadly, “bearing member”) includes a respective removable lower portion 269 A, 271 A, 273 A which is attached to an upper portion 269 B, 271 B, 273 B by a respective pair of bolts. It is also envisioned that the top cover 247 and yokes 269 , 271 , 273 may be made as a single, unitary piece. In that event, the idler shafts 257 , 263 would be made in two pieces (not shown) to permit their insertion into holes in the yokes 269 , 271 , 273 . After insertion the two pieces of the idler shaft would be connected together. In the illustrated embodiments, the first yoke 269 has three holes, including a first hole 275 A which receives the output shaft 231 , a second hole 275 B which receives the low gear idler shaft 257 and a third hole 275 C which receives the high gear idler shaft 263 . The second yoke 271 has a single hole 277 for another portion of the low gear idler shaft 257 and the third yoke 273 similarly has a single hole 279 for receiving another portion of the high gear idler shaft 263 . The output shaft 231 is received in the first hole 275 A of the first yoke 269 and is supportingly engaged by the first yoke.
To place the idler shafts 257 , 263 in the first, second and third yokes ( 269 , 271 , 273 ), the lower portions ( 269 A, 271 A, 273 A) of the yokes are removed, opening up the second and third holes 275 B, 275 C of the first yoke and the holes 277 , 279 of the second and third yokes. The low gear idler shaft 257 is placed on the top cover 247 (which is preferably inverted for assembly) so that a section of the shaft adjacent to the first low gear idler gear 259 is received in the exposed portion of the second hole 275 B of the upper portion 269 B of the first yoke 269 still associated with the top cover. At the same time, a section of the low gear idler shaft 257 nearer the second low gear idler gear 261 is received in the portion of the hole 277 in the upper portion 271 A of the second yoke 271 which is still associated with the top cover 247 . Similarly, the high gear idler shaft 263 is placed so that a section of the shaft adjacent to the first high gear idler gear 265 is received in the exposed portion of the hole 279 of the upper portion of the third yoke 273 still associated with the top cover 247 . At the same time, a section of the high gear idler shaft 263 nearer the second high gear idler gear 267 is received in the exposed portion of the third hole 275 C in the upper portion 269 B of the first yoke 269 .
The idler shafts 257 , 263 are secured in place by bolting the lower portions 269 A, 271 A, 273 A to the respective upper portions 269 B, 271 B, 273 B, thereby encircling the idler shaft sections. In this way, the idler shafts 257 , 263 are mounted entirely by the top cover 247 . The outside cover plate 219 may be preassembled with the input shaft 227 and the inside cover plate 221 may likewise be preassembled with the output shaft 231 . The input and output shafts (and associated cover plates) can be brought together with the top cover 247 as shown in FIG. 18 . The output shaft 231 is received through the first hole 275 A in the first yoke 269 and the reduced diameter portion of the input shaft 227 is inserted into the output shaft. Bolts are passed through the cover plates 219 , 221 and into the top cover 247 . This completes the subassembly 232 which includes all of the gearing of the landing gear leg 211 except for the bevel gear 225 attached to the top of the lead screw (not shown but essentially the same as the screw 23 of FIG. 5 ). It is further contemplated that the single idler leg 11 may use a top cover substantially similar to the top cover 247 used by the dual idler leg 211 and leave one of the yokes 271 , 273 unused, as described below. The subassembly 232 so formed may be dropped into the open top of the leg 211 in manufacture. The cover plates 219 , 221 are secured to the leg 211 to assemble the subassembly 232 with the upper section 215 of the leg.
FIGS. 26 and 27 illustrate another version of the single idler landing gear leg 211 ′ that uses a top cover 247 ′ having yokes 269 ′, 271 ′ and 273 ′ substantially identical to the top cover described above with respect to the dual idler landing gear leg 211 . Thus, the same top cover and leg sections can be used to manufacture both single and dual idler landing gear legs. In the version illustrated in FIGS. 27 and 28 , the input and output shafts 227 ′, 231 ′ are also supported by the top cover 247 ′ in the first yoke 269 ′ depending from the top cover. Either the second yoke 271 ′ or the third yoke 273 ′ receives and supports the idler shaft 245 ′. The other yoke 273 ′ or 271 ′ is not used by the subassembly 232 ′. The operation of this version would be substantially similar to the operation of the single idler leg 11 described above. With this version, both a single idler subassembly 232 ′ and the dual idler subassembly 232 would use a common top cover to facilitate manufacture.
When introducing elements of the present invention or the preferred embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained. As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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Landing gear for selectively supporting a semitrailer and a method of assembly of the landing gear is provided. The landing gear includes a leg having an upper section and a lower section telescopingly received in the upper section. A lead screw extends and retracts the upper and lower sections relative to each other upon rotation thereof. An input shaft applies a torque to the lead screw to drive rotation thereof, the input shaft being rotatable about a rotation axis and movable in translation along the rotation axis for shifting between a first position for low gear operation and a second position for high gear operation. An output shaft, axially aligned with the input shaft, has an output gear for transmitting torque to the lead screw. A gearing subassembly is received in the upper leg section and is configured to augment lift when the input shaft is in the first position and augment speed in the second position.
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BACKGROUND OF THE INVENTION
[0001] 1 Technical Field of the Invention
[0002] The present invention relates to a steering apparatus for a vehicle that orients road wheels in response to operator input in which the road wheels are not mechanically coupled to the steering wheel.
[0003] 2. Background and Summary of the Present Invention
[0004] A typical automotive vehicle is steered by transmitting the rotation of a steering wheel to a steering mechanism, which directs road wheels in a corresponding fashion. Generally, the steering wheel is located inside the vehicle passenger compartment, and the road wheels are located at the front of the vehicle. Thus, a suitable steering mechanism is necessary to couple the steering wheel and the road wheels.
[0005] A representative steering mechanism is a rack-and-pinion type steering mechanism. In a rack-and-pinion steering mechanism, the rotational motion of the steering wheel is communicated through a steering shaft to a pinion gear at its distal end. The pinion gear is engaged with a rack gear disposed laterally between the road wheels, which in turn are coupled to the rack gear by tie rods. In this manner, rotation of the steering wheel is translated into the lateral movement of the rack gear, which causes the road wheels to pivot in the desired direction. In general, mechanical steering mechanisms are power-assisted by hydraulic or electrical assist units.
[0006] Mechanical steering mechanisms such as described above have a number of limitations. As the steering wheel and the steering mechanism are mechanically coupled in some fashion, the position of the steering wheel is limited within the vehicle passenger compartment. Moreover, the size and weight of the coupling members limits the layout and performance of the vehicle.
[0007] In order to overcome such limitations, it has been proposed to utilize a steering system in which the steering wheel is not mechanically coupled to the road wheels and the road wheels and steering movement is achieved by an electrically controlled motor, for example, a steer-by-wire system. In a steer-by-wire system, a steering actuator operates in response to detected values of various steering parameters, such as steering wheel angle and vehicle speed. The detected values are communicated electronically to the steering actuator from sensors, whereby the steering actuator orients the road wheels in the desired direction.
[0008] Steer-by-wire systems solve a number of problems presented above. In addition, there are a number of other advantages innate to steer-by-wire systems that were not apparent in its mechanically coupled counterpart. For example, a steer-by-wire steering system can be integrated into other electronically controlled systems to increase the efficiency and performance of the vehicle.
[0009] Although a steer-by-wire system presents distinct advantages, it also presents a number of problems. Since there is no direct mechanical coupling between the operator and the road wheels, it is not necessary for the orientation of the steering wheel to correspond to the orientation of the road wheels. For example, it is possible that the steering wheel could be directed in a left-turn orientation while the road wheels are directed in a right-turn orientation. Such a discrepancy may arise when the steer-by-wire system is powered-down, as is the case when the vehicle is turned off, and the steering wheel is turned without a corresponding pivoting of the road wheels.
[0010] Consequently, there is a need in the art for an improved steer-by-wire system that is adapted to correct for misalignment between the steering wheel and the road wheel, and which corrects the misalignment automatically. Furthermore, the steer-by-wire system should be able to correct for misalignment in an efficient and timely manner, such that the steering wheel travels a minimum angular distance from an initial position to the corrected position.
[0011] Accordingly, the present invention provides an improved steer-by-wire system comprising a road wheel angle sensor, a steering wheel angle sensor, and a torque feedback actuator. The aforementioned components are coupled to a controller that is adapted to calculate a corrected steering wheel angle based upon the relative angular positions of the road wheels and the steering wheel as measured by the respective sensors. The controller then controls the torque feedback generator to rotate the steering wheel into a corrected position such that the torque feedback generator rotates the steering wheel a minimum angle. During the initialization, the rotational motion of the steering wheel is also controlled so that the rotation is smooth and in an acceptable low speed to ensure the safety of the driver. By checking the smoothness and the progression of the rotational motion, the controller will detect any resistance to the correction that is greater than the anticipated rotational friction. Such resistance includes interference from the vehicle driver. In response to any resistance, the controller is further adapted to issue a warning signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 is a schematic block diagram of the steer-by-wire system of the present invention.
[0013] [0013]FIG. 2 is a flow chart describing the method of the present invention.
[0014] [0014]FIG. 3 is a graphical representation of the relationship between true steering wheel angle and steering wheel angle calculated by a first steering wheel angle sensor.
[0015] [0015]FIG. 4 is a graphical representation of the relationship between true steering wheel angle and steering wheel angle calculated by a second steering wheel angle sensor.
[0016] [0016]FIG. 5 is a graphical representation of the relationship between true steering wheel angle and steering wheel angle calculated by a third steering wheel angle sensor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] In accordance with a preferred embodiment of the present invention, FIG. 1 depicts a schematic block diagram of a steer-by-wire system 10 for use in a motor vehicle. The steer-by-wire system includes a steering wheel 12 rotatable about a shaft 14 . The steering wheel 12 is mechanically coupled to a torque actuator 18 through the shaft 14 . The torque actuator 18 is further electrically connected to a controller 20 , which controls the magnitude and the direction of a reaction torque in the steering wheel 12 as is the case in a typical steer-by-wire system. The system of the present invention also includes at least one steering wheel angle sensor 16 detecting a steering wheel angle. The detected steering wheel angle is transmitted to the controller 20 , which is also adapted to receive an input value corresponding to a road wheel angle 22 . The road wheel angle is preferably determined by one or more road wheel angle sensors (not shown) disposed near the road wheels of the vehicle (not shown).
[0018] During normal operation, the steer-wire-system 10 of the present invention simulates the feel of steering a mechanical steering system in the steering wheel 12 . This simulated feel is the effect of torque generated by the torque actuator 18 . The torque actuator 18 is controlled by the controller 20 to cause a torque in the shaft 14 and the steering wheel 12 for communicating steering information to a vehicle operator. The steer-by-wire system 10 of the present invention is further adapted to efficiently correct any variation between the detected steering wheel angle and the detected road wheel angle upon starting the vehicle.
[0019] [0019]FIG. 2 is a flow chart depicting the operation of the steer-by-wire system of the present invention. In step S 100 , the steer-by-wire system is powered-up, preferably simultaneous with the electrical components of the vehicle, such as just prior to ignition in an internal combustion vehicle. Alternatively, the steer-by-wire system may be powered-up at any time such that the following steps may be completed prior to driving. In step S 102 , the initialization of the steering wheel is started.
[0020] In step S 104 , the road wheel angle (RWA) is read and transmitted to the controller 20 . In step S 106 , the correct steering wheel angle (CSWA) is calculated based upon a default steering ratio (DSR). The DSR is a value that is predetermined in the steer-by-wire system 10 such that the steer-by-wire system closely approximates a mechanical steering system. Likewise, a mechanical steering system would have a DSR value determined by the mechanical components of the system. In the steer-by-wire system 10 of the present invention, the DSR may be altered during vehicle operation. In terms of the RWA and DSR, the CWSA is determined as follows:
CSWA=RWA*DSR. (1)
[0021] The CSWA value is retained by the controller 20 for comparison with the actual steering wheel angle.
[0022] In step S 108 , the controller 20 receives the steering wheel angle (SWA) measurement from the at least one steering wheel angle sensor 16 . The controller 20 then compares the CSWA to the SWA, and, if they are not identical, the controller 20 calculates a corrective adjustment to the SWA such that the steering wheel 12 will be rotated the shortest angular distance. The details of the later calculation will be discussed more thoroughly below.
[0023] In step S 110 , the controller 20 controls the torque actuator 18 to rotate the steering wheel 12 such that it is in the CSWA position. In step S 112 , the steer-by-wire initialization is complete, and the steer-by-wire system may begin its normal mode of operation.
[0024] Returning now to step S 108 , the present invention is adapted for use in vehicles having different types of steering wheel angle sensors 16 . Consequently, the calculation of the shortest angular distance for correcting the SWA will depend upon the type and combination of steering wheel angle sensors 16 employed in the steer-by-wire system 10 . The present invention contemplates at least three types of steering wheel angle sensors 16 . A first type of steering wheel angle sensor is a multi-turn absolute angular position sensor, hereby denoted a type 1 sensor. A second type of steering wheel angle is a single-turn absolute angular position sensor, hereby denoted a type 2 sensor. A third type of steering wheel angle sensor is an incremental angular position sensor, hereby denoted a type 3 sensor. Each of the foregoing sensors generates a distinct steering wheel angle value, hereby denoted SWA1, SWA2, and SWA3, respectively.
[0025] The steering wheel angle values, SWA1, SWA2, and SWA3, are related to the actual SWA through mathematical relationships that are employed by the controller 20 in calculating the proper steering wheel angle.
[0026] [0026]FIG. 3 is a graphical representation of the relationship between the actual SWA and the SWA1 as calculated by the type 1 sensor. As shown, a type 1 sensor generates a steering wheel angle value that is identical to the actual SWA over the range of steering wheel angles. That is, for a type 1 sensor,
SWA=SWA1. (2)
[0027] The measurements of the type 1 sensor are restricted to the total angular displacement of the steering wheel 12 . That is, if the steering wheel 12 is confined to rotation between −450° and +450°, then the SWA1 measurement will be confined to the same range.
[0028] [0028]FIG. 4 is a graphical representation of the relationship between the actual SWA and the SWA2 as calculated by the type2 sensor. As shown, a type2 sensor generates a steering wheel angle value that is periodic every 360°. Consequently, the SWA2 value is only indicative of the actual SWA is calibrated based upon the number of 360° periods the steering wheel 12 has been rotated. That is, for a type 2 sensor,
SWA=SWA 2+ N* 360°, (3)
[0029] where the integer N is defined as a number of turns or full rotations of the steering wheel 12 .
[0030] [0030]FIG. 5 is a graphical representation of the relationship between the actual SWA and the SWA3 as calculated by the type 3 sensor. The type 3 sensor does not calculate an absolute steering wheel angle. Rather, a type 3 sensor will measure the relative angular displacement between a current angular position, SWA(t1), and an initial angular position, SWA i (t0). That is, a type 3 sensor measures a change in steering wheel angle between an initial, start-up position, and a subsequent steering position. FIG. 5 depicts an initial state of a type 3 sensor in the case that the steer-by-wire system 10 is powered-up when the steering wheel 12 is in a −30° orientation. As such, the type 3 steering wheel angle sensor is measuring a steering wheel angle that is shifted by −30° along the SWA axis of FIG. 5.
[0031] As a result, a type 3 sensor requires an additional input corresponding to the initial absolute angular position to be useful in the present application. If the absolute angular position is known at an initial time, t0, then at a subsequent time t1 the following relationship holds:
SWA ( t 1)= SWA 3( t 1)− SWA 3( t 0)+ SWA i ( t 0),
[0032] where t1>t0, and SWA i (t0) is the absolute angular position of the steering wheel at an initial time, t0. Despite the limitations presented by a type 3 sensor, they are more durable and accurate than both type 1 and type 2 sensors. The present invention preferably contemplates the use of a type 3 sensor. However, in order to determine an initial absolute angular position rendering a type 3 sensor useful, it is preferable to combine a type 3 sensor with one of a type 1 sensor or a type 2 sensor.
[0033] There are four combinations that are suitable for the steering wheel angle sensor 16 . A type 1 sensor or a type 2 sensor may be used alone, with certain modifications. Additionally, either a type 1 sensor or a type 2 sensor may be used in conjunction with a type 3 sensor. In the latter configurations, the type 1 sensor or type 2 sensor would be used solely for the initialization procedure described in FIG. 2, and the type 3 sensor would be used during normal vehicle operation.
[0034] In the first configuration, the type 1 sensor is adapted to calculate an absolute steering wheel angle. Therefore, the controller 20 can adjust the position of the steering wheel 12 by causing SWA1 to be equal to the CSWA. Note that as described, the type 1 sensor does not enable the controller 20 to execute the adjustment of the steering wheel along a shortest angular path, because the use of a type 1 sensor necessarily prohibits a shortest angular path, i.e. all angles are absolute. Thus, in the first configuration, step S 110 shown in FIG. 2 is irrelevant to the initialization of the steer-by-wire system 10 .
[0035] In the second configuration, the type 2 sensor is adapted to calculate a periodic angular position. As noted in Equation (3), in order to properly initialize the steer-by-wire system, the initial turn number, N, must be known. The controller 20 can adjust the position of the steering wheel 12 by causing SWA2 to be equal to the CSWA. In order to satisfy the shortest angular path condition of step S 110 , the controller 20 must minimize the following arithmetical expression:
CSWA− ( SWA 2+ N* 360°)=minimum, (5)
[0036] where N is a turn number. Equation (5) can be minimized by solving the following expression:
N min =Round(( CSWA−SWA 2)/360°), (6)
[0037] where the function Round (x) rounds x to the nearest integer. When a value for N min is determined, the actual steering wheel angle is given by the following equation:
SWA=SWA 2+ N min *360°. (7)
[0038] For example, if Nm,n is zero, then the actual steering wheel angle is equal to the steering wheel angle measured by the type 2 sensor.
[0039] In the third configuration, the type 1 sensor is used in conjunction with the type 3 sensor. Therefore, Equation (4) is modified as follows:
SWA ( t 1)= SWA 3( t 1)− SWA 3( t 0)+ SWA 1 i ( t 0),
[0040] where SWA1 i (t0) is the absolute initial steering wheel angle position at initial time, t0. As in the first configuration, there is no shortest angular path for the controller 20 to determine, so step S 110 is bypassed. In the third configuration, the type 1 sensor is actuated solely for the initialization process, and it is shut down at step S 112 corresponding to the end of the initialization process.
[0041] In the fourth configuration, the type 2 sensor is used in conjunction with the type 3 sensor. Accordingly, at the initial time, t0, the controller determines initial values and determines N min and SWA as follows.
N min =Round(( CSWA ( t 0)− SWA 2( t 0))/360°),
[0042] and
SWA 2 i ( t 0)= SWA 2( t 0)+ N min *360°.
[0043] Using Equation (10), Equation (4) is modified as follows:
SWA ( t 1)= SWA 3( t 1)−SWA3( t 0)+SWA2 i ( t 0),
[0044] where SWA2 i (t0) is the initially-corrected determination of the shortest path in accordance with Equations (4) and (10). As in the third configuration, the type 2 sensor is actuated solely for the initialization process, and it is shut down at step S 112 corresponding to the end of the initialization process. As described, each of the foregoing configurations of steering wheel angle sensors is employable as reference 16 in FIG. 1.
[0045] Returning to FIG. 2, in step S 110 the controller 20 controls the torque actuator 18 to rotate the steering wheel 12 to a correct steering wheel angle. In doing so, the torque actuator 18 exerts a corrective torque on the shaft 14 that is translated to the steering wheel 12 .
[0046] In a preferred embodiment, the controller 20 is further adapted for checking the smoothness and progression of the rotational motion of the steering wheel 12 in order to detect an opposition to the corrective torque. For example, if the torque actuator 18 is rotating the steering wheel 12 during the initialization phase and the driver exerts an opposing torque, then the controller 20 will detect the opposition. Additionally, if the controller 20 detects an opposing torque, then it will issue a warning signal to the driver to cease opposing the initialization process.
[0047] It should be apparent to those skilled in the art that the above-described embodiments are merely illustrative of but a few of the many possible specific embodiments of the present invention. Numerous and various other arrangements can be readily devised by those skilled in the art without departing from the spirit and scope of the invention as defined in the following claims.
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A system for initializing a steering wheel in a steer-by-wire vehicle includes a steering wheel, a torque feedback actuator, a steering wheel angle sensor, and a controller. The controller is adapted to calculate a corrected steering wheel angle based upon the relative angular positions of the road wheels and the steering wheel as measured by the respective sensors. The controller then controls the torque feedback generator to rotate the steering wheel into a corrected position such that the torque feedback generator rotates the steering wheel a minimum angle. The controller issues a warning signal in response to any resistance to the correction, including interference from the vehicle driver.
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TECHNICAL FIELD
[0001] The present invention relates to an ophthalmic composition comprising geranylgeranylacetone.
BACKGROUND ART
[0002] Teprenone (Eisai Co., Ltd.) is a mixture of (5E,9E,13E)-geranylgeranylacetone (hereinafter sometimes referred to as “all-trans form”) and (5Z,9E,13E)-geranylgeranylacetone (hereinafter sometimes referred to as “5Z-mono-cis form”) at a weight ratio of 3:2. Teprenone is widely used as an oral therapeutic agent for gastric ulcer.
[0003] The use of teprenone in the ophthalmic field has been suggested. For example, Patent Literature 1 teaches the use of teprenone as an active ingredient of a prophylactic or therapeutic agent for dry eye, eye strain, or eye dryness.
[0004] Patent Literature 2 discloses a clear eye drop consisting of teprenone, a phospholipid, a synthetic surfactant, and water.
[0005] However, the stability of geranylgeranylacetone in the ophthalmic compositions described in Patent Literature 1 and 2 is not practically sufficient.
[0006] Generally, in order to improve the thermal and light stabilities of an active ingredient in an ophthalmic composition, a borate buffering agent is used (Patent Literature 3 to 6).
CITATION LIST
Patent Literature
[0007] Patent Literature 1: JP-8-133967 A
[0008] Patent Literature 2: JP-2000-319170 A
[0009] Patent Literature 3: Patent No. 2929274
[0010] Patent Literature 4: Patent No. 3146218
[0011] Patent Literature 5: JP-2006-151969 A
[0012] Patent Literature 6: JP-2008-94780 A
SUMMARY OF INVENTION
Technical Problem
[0013] An object of the present invention is to provide an ophthalmic composition comprising geranylgeranylacetone having a practically sufficient stability.
Solution to Problem
[0014] The inventors conducted extensive research in order to solve the above problem and unexpectedly found that the addition of a phosphate buffering agent to an ophthalmic composition comprising geranylgeranylacetone (hereinafter sometimes referred to as “GGA”) improves the thermal and light stabilities of GGA and reduces white turbidity of the ophthalmic composition stored at low temperature. The inventors also found that the addition of a phosphate buffering agent to an ophthalmic composition being held by an ophthalmic container and comprising GGA effectively reduces adsorption of GGA to the wall of the ophthalmic container and a contact lens.
[0015] The present invention has been completed based on the above findings and provides an ophthalmic composition as described below.
[0016] (1) An ophthalmic composition comprising geranylgeranylacetone and a phosphate buffering agent.
[0017] (2) The ophthalmic composition according to the above (1), whose pH is from 6 to 8.
[0018] (3) The ophthalmic composition according to the above (1) or (2), wherein the phosphate buffering agent concentration expressed in terms of a corresponding anhydride is 0.001 to 10% by weight relative to the total amount of the composition.
[0019] (4) The ophthalmic composition according to any of the above (1) to (3), wherein the phosphate buffering agent is at least one selected from the group consisting of phosphoric acid and an alkali metal phosphate.
[0020] (5) The ophthalmic composition according to any of the above (1) to (4), wherein the geranylgeranylacetone content is 0.00001 to 10% by weight relative to the total amount of the composition.
[0021] (6) A method for reducing the loss of the geranylgeranylacetone content of an ophthalmic composition, the method comprising the step of adding a phosphate buffering agent to an ophthalmic composition being held by an ophthalmic container and comprising geranylgeranylacetone, thereby reducing the loss of the geranylgeranylacetone content of the ophthalmic composition.
[0022] (7) A method for reducing white turbidity due to geranylgeranylacetone during storage at low temperature, the method comprising the step of adding a phosphate buffering agent to an ophthalmic composition comprising geranylgeranylacetone, thereby reducing white turbidity due to geranylgeranylacetone during storage at low temperature.
[0023] (8) A method for reducing adsorption of geranylgeranylacetone to a contact lens, the method comprising the step of adding a phosphate buffering agent to an ophthalmic composition comprising geranylgeranylacetone, thereby reducing adsorption of geranylgeranylacetone to a contact lens.
[0024] (9) A method for stabilizing geranylgeranylacetone, the method comprising the step of adding a phosphate buffering agent to an ophthalmic composition comprising geranylgeranylacetone, thereby stabilizing geranylgeranylacetone.
[0025] (10) A method for reducing adsorption of geranylgeranylacetone to a wall of an ophthalmic container, the method comprising the step of adding a phosphate buffering agent to an ophthalmic composition being held by an ophthalmic container and comprising geranylgeranylacetone, thereby reducing adsorption of geranylgeranylacetone to a wall of the ophthalmic container.
[0026] (11) Use of a combination of geranylgeranylacetone and a phosphate buffering agent for the production of an ophthalmic composition.
[0027] (12) Use, as an ophthalmic composition, of a composition comprising geranylgeranylacetone and a phosphate buffering agent.
Advantageous Effects of Invention
[0028] Generally, the GGA content of an ophthalmic composition tends to be reduced during storage. In contrast, the ophthalmic composition of the present invention has an advantage that the loss of the GGA content during long-term storage is very little. The loss of the GGA content of the ophthalmic composition of the present invention varies depending on the material of an ophthalmic container and hence a container material of some kind allows an added phosphate buffering agent to reduce adsorption of GGA to the inner wall of an ophthalmic container. The ophthalmic composition of the present invention also has an advantage that the GGA in the composition is very stable to light and heat.
[0029] Generally, an ophthalmic composition comprising GGA tends to become white turbid when stored at low temperature. Consequently, during commercial distribution to or during storage in cold areas, such an ophthalmic composition becomes white turbid, which reduces its commercial value. In contrast, the ophthalmic composition of the present invention hardly becomes white turbid even when stored at low temperature. Therefore, the ophthalmic composition of the present invention can be commercially distributed to any area and thus its commercial value is high.
[0030] Generally, GGA tends to be adsorbed to a contact lens. Adsorption of a component of an ophthalmic composition to a contact lens reduces the effect given by the component and wearing the contact lens contaminated by the adsorption may cause blurred vision or damage the eye. These problems will not occur with the use of the ophthalmic composition of the present invention.
DESCRIPTION OF EMBODIMENTS
[0031] The present invention will be described in detail below. The ophthalmic composition of the present invention is an ophthalmic composition comprising GGA and a phosphate buffering agent.
Geranylgeranylacetone
(1) Types of Geometric Isomers
[0032] GGA has eight geometric isomers. Specifically, the eight geometric isomers are:
(5E,9E,13E)-6,10,14,18-tetramethyl-5,9,13,17-nonadecatetrae n-2-one (5E,9E,13E GGA) (all-trans form), (5Z,9E,13E)-6,10,14,18-tetramethyl-5,9,13,17-nonadecatetrae n-2-one (5Z,9E,13E GGA) (5Z-mono-cis form), (5Z,9Z,13E)-6,10,14,18-tetramethyl-5,9,13,17-nonadecatetrae n-2-one (5Z,9Z,13E GGA) (13E-mono-trans form), (5Z,9Z,13Z)-6,10,14,18-tetramethyl-5,9,13,17-nonadecatetrae n-2-one (5Z,9Z,13Z GGA) (all-cis form), (5E,9Z,13E)-6,10,14,18-tetramethyl-5,9,13,17-nonadecatetrae n-2-one (5E,9Z,13E GGA) (9Z-mono-cis form), (5E,9Z,13Z)-6,10,14,18-tetramethyl-5,9,13,17-nonadecatetrae n-2-one (5E,9Z,13Z GGA) (5E-mono-trans form), (5E,9E,13Z)-6,10,14,18-tetramethyl-5,9,13,17-nonadecatetrae n-2-one (5E,9E,13Z GGA) (13Z-mono-cis form), and (5Z, 9E,13Z) -6,10,14,18-tetramethyl-5,9,13,17-nonadecatetrae n-2-one (SZ,9E,13Z GGA) (9E-mono-trans form).
[0042] These GGAs can be used alone or in any combination of two or more thereof according to the present invention. In cases where two or more of the GGAs are combined, the mixing ratio is not particularly limited.
[0043] Among the above GGAs, preferred are the all-trans form, the mono-cis forms (especially the 5Z-mono-cis form) and a mixture of the all-trans form and one of the mono-cis forms.
[0044] In cases where the GGA of the present invention is a mixture of the all-trans form and one of the mono-cis forms (especially the 5Z-mono-cis form), the all-trans form content of the mixture is preferably 80% by weight or more, more preferably 82% by weight or more, further more preferably 84% by weight or more, further more preferably 86% by weight or more, further more preferably 88% by weight or more, further more preferably 90% by weight or more, further more preferably 92% by weight or more, further more preferably 94% by weight or more, further more preferably 96% by weight, further more preferably 98% by weight or more. Especially preferably, the GGA consists of the all-trans form. When the all-trans form is in the above ranges, white turbidity at low temperature is reduced.
[0045] Also preferred GGA is a mixture of the all-trans form and one of the mono-cis forms (especially the 5Z-mono-cis form) with a very high mono-cis form (especially the 5Z-mono-cis form) ratio.
(2) All-Trans Form and 5Z-mono-cis Form
[0046] (5E, 9E,13E) -geranylgeranylacetone (the all-trans form) is a compound represented by the following structural formula:
[0000]
[0047] The all-trans form can be purchased from, for example, Rionlon Development Co., Ltd.
[0048] The all-trans form can also be obtained through separating the all-trans form and the 5Z-mono-cis form of a marketed teprenone (Eisai Co., Ltd., Wako Pure Chemical Industries, Ltd., Yoshindo Inc., etc.) by, for example, silica gel chromatography using a mobile phase of n-hexane/ethyl acetate (9:1). The separation of the all-trans form and the 5Z-mono-cis form of a marketed teprenone can also be commissioned to, for example, KNC Laboratories Co., Ltd.
[0049] (5Z,9E,13E)-geranylgeranylacetone (the 5Z-mono-cis form) can also be obtained by the separation from a marketed teprenone.
[0050] The 5Z-mono-cis form is a compound represented by the following structural formula:
[0000]
[0051] The all-trans form can also be synthesized in accordance with a method described in, for example, Bull. Korean Chem. Soc., 2009, Vol. 30, No. 9, 215-217. This literature describes, for example, the method shown by the following synthesis scheme:
[0000]
[0052] Specifically, in the above reaction formula, geranyllinalool 1 is mixed with Compound 2 and aluminum isopropoxide, and the mixture is gradually heated to 130° C. to allow the reaction to occur. After the completion of the reaction, the residue Compound 2 is removed and the reaction mixture is diluted with 5% sodium carbonate so that the residue aluminum propoxide is quenched. In this way, the all-trans form can be obtained. The obtained all-trans form is subsequently purified by, for example, silica gel chromatography using dichloromethane as an eluent.
(3) Mixtures of All-Trans Form and 5Z-mono-cis Form
[0053] Mixtures of the all-trans form and the 5Z-mono-cis form can be obtained by adding the all-trans form or the 5Z-mono-cis form to a marketed teprenone.
GGA Content
[0054] The GGA content is preferably 0.00001% by weight or more, more preferably 0.0001% by weight or more, further more preferably 0.001% by weight or more, relative to the total amount of the composition. The GGA content may be 0.01% by weight or more, 0.1% by weight or more, or 1% by weight or more. The GGA in the above ranges is sufficient to exert its pharmacological action.
[0055] The GGA content of the ophthalmic composition is preferably 10% by weight or less, more preferably 5% by weight or less, further more preferably 3% by weight or less, relative to the total amount of the composition. The ophthalmic composition comprising GGA in the above ranges allows clearer vision and hardly causes blurred vision.
[0056] The GGA content of the ophthalmic composition is, for example, about 0.00001 to 10% by weight, about 0.00001 to 5% by weight, about 0.00001 to 3% by weight, about 0.0001 to 10% by weight, about 0.0001 to 5% by weight, about 0.0001 to 3% by weight, about 0.001 to 10% by weight, about 0.001 to 5% by weight, about 0.001 to 3% by weight, about 0.01 to 10% by weight, about 0.01 to 5% by weight, about 0.01 to 3% by weight, about 0.1 to 10% by weight, about 0.1 to 5% by weight, about 0.1 to 3% by weight, about 1 to 10% by weight, about 1 to 5% by weight, or about 1 to 3% by weight, relative to the total amount of the composition.
Phosphate Buffering Agent
[0057] Phosphate buffering agents can be used alone or in combination of two or more thereof.
[0058] The phosphate buffering agent is not particularly limited and examples thereof include phosphoric acid; alkali metal phosphates such as disodium hydrogen phosphate, sodium dihydrogen phosphate, trisodium phosphate, dipotassium hydrogen phosphate, potassium dihydrogen phosphate, and tripotassium phosphate; alkaline earth metal phosphates such as calcium phosphate, calcium hydrogen phosphate, calcium dihydrogen phosphate, monomagnesium phosphate, dimagnesium phosphate (magnesium hydrogen phosphate), and trimagnesium phosphate; and ammonium phosphates such as diammonium hydrogen phosphate and ammonium dihydrogen phosphate. The phosphate buffering agent may be an anhydride or hydrate.
[0059] Among the above, preferably at least one selected from the group consisting of phosphoric acid and alkali metal phosphates is used, and more preferably at least one selected from the group consisting of phosphoric acid and sodium phosphates is used.
[0060] Preferred combinations of phosphate buffering agents are, for example, a combination of phosphoric acid, disodium hydrogen phosphate, sodium dihydrogen phosphate, and trisodium phosphate; a combination of phosphoric acid, disodium hydrogen phosphate, and sodium dihydrogen phosphate; a combination of phosphoric acid, disodium hydrogen phosphate, and trisodium phosphate; a combination of phosphoric acid, sodium dihydrogen phosphate, and trisodium phosphate; a combination of disodium hydrogen phosphate, sodium dihydrogen phosphate, and trisodium phosphate; a combination of phosphoric acid and disodium hydrogen phosphate; a combination of phosphoric acid and sodium dihydrogen phosphate; a combination of phosphoric acid and trisodium phosphate; a combination of disodium hydrogen phosphate and sodium dihydrogen phosphate; a combination of disodium hydrogen phosphate and trisodium phosphate; and a combination of sodium dihydrogen phosphate and trisodium phosphate.
[0061] Among these, preferred are a combination of phosphoric acid, disodium hydrogen phosphate, and sodium dihydrogen phosphate; a combination of phosphoric acid and disodium hydrogen phosphate; a combination of phosphoric acid and sodium dihydrogen phosphate; and a combination of disodium hydrogen phosphate and sodium dihydrogen phosphate. More preferred is a combination of disodium hydrogen phosphate and sodium dihydrogen phosphate.
[0062] The phosphate buffering agent content expressed in terms of a corresponding anhydride is preferably 0.001% by weight or more, more preferably 0.005% by weight or more, further more preferably 0.01% by weight or more, further more preferably 0.05% by weight or more, relative to the total amount of the composition. The phosphate buffering agent in the above ranges is sufficient to exhibit the effects of stabilizing GGA, reducing white turbidity at low temperature, and reducing adsorption of GGA to a container wall or a contact lens.
[0063] The phosphate buffering agent content expressed in terms of a corresponding anhydride is preferably 10% by weight or less, more preferably 7% by weight or less, further more preferably 5% by weight or less, further more preferably 3% by weight or less, relative to the total amount of the composition. When GGA is in the above ranges, the ophthalmic composition exhibits reduced eye irritancy.
[0064] The phosphate buffering agent content expressed in terms of a corresponding anhydride is, for example, about 0.001 to 10% by weight, about 0.001 to 7% by weight, about 0.001 to 5% by weight, about 0.001 to 3% by weight, about 0.005 to 10% by weight, about 0.005 to 7% by weight, about 0.005 to 5% by weight, about 0.005 to 3% by weight, about 0.01 to 10% by weight, about 0.01 to 7% by weight, about 0.01 to 5% by weight, about 0.01 to 3% by weight, about 0.05 to 10% by weight, about 0.05 to 7% by weight, about 0.05 to 5% by weight, or about 0.05 to 3% by weight, relative to the total amount of the ophthalmic composition.
[0065] The phosphate buffering agent content expressed in terms of a corresponding anhydride is preferably 0.0005 parts by weight or more, more preferably 0.001 parts by weight or more, further more preferably 0.005 parts by weight or more, further more preferably 0.01 parts by weight or more, relative to 1 part by weight of GGA. The phosphate buffering agent in the above ranges is sufficient to exhibit the effects of stabilizing GGA, reducing white turbidity at low temperature, and reducing adsorption of GGA to a container wall or a contact lens.
[0066] The phosphate buffering agent content expressed in terms of a corresponding anhydride is preferably 5000 parts by weight or less, more preferably 1000 parts by weight or less, further more preferably 500 parts by weight or less, further more preferably 200 parts by weight or less, relative to 1 part by weight of GGA. When the phosphate buffering agent is in the above ranges, the ophthalmic composition exhibits reduced eye irritancy.
[0067] The phosphate buffering agent content expressed in terms of a corresponding anhydride is, for example, about 0.0005 to 5000 parts by weight, about 0.0005 to 1000 parts by weight, about 0.0005 to 500 parts by weight, about 0.0005 to 200 parts by weight, about 0.001 to 5000 parts by weight, about 0.001 to 1000 parts by weight, about 0.001 to 500 parts by weight, about 0.001 to 200 parts by weight, about 0.005 to 5000 parts by weight, about 0.005 to 1000 parts by weight, about 0.005 to 500 parts by weight, about 0.005 to 200 parts by weight, about 0.01 to 5000 parts by weight, about 0.01 to 1000 parts by weight, about 0.01 to 500 parts by weight, or about 0.01 to 200 parts by weight, relative to 1 part by weight of GGA.
Preparations
[0068] The form of the ophthalmic composition may be a liquid, a fluid, a gel or a semi-solid. Generally, components in a liquid or fluid composition tend to be adsorbed to a container wall. Hence, the present invention is suitably applied to a liquid or fluid ophthalmic composition. In addition, GGA in an aqueous composition tends to be adsorbed to a container wall and thus the present invention is also suitably applied to an aqueous composition.
[0069] The type of the ophthalmic composition is not particularly limited. Examples thereof include an eye drop, an eye wash, a contact lens-wearing solution, a contact lens solution (e.g., a washing solution, a storage solution, a sterilizing solution, a multipurpose solution, a package solution, etc.), a preservative for a harvested ocular tissue (a cornea etc.) for transplantation, an irrigating solution for surgery, an ophthalmic ointment (e.g., a water-soluble ophthalmic ointment, an oil-soluble ophthalmic ointment, etc.), an intraocular injection (e.g., an intravitreal injection), etc. Among these, preferred are an eye drop, an eye wash, an ophthalmic ointment and an intraocular injection.
[0070] Preparation methods for an ophthalmic preparation are well known. An ophthalmic preparation can be prepared by mixing GGA with a pharmaceutically acceptable base or carrier, and as needed a pharmaceutically acceptable additive for an ophthalmic preparation and another active ingredient (a physiologically or pharmacologically active component).
<Bases or Carriers>
[0071] Examples of the base or carrier include water; an aqueous solvent such as a polar solvent; a polyalcohol; a vegetable oil; and an oily base. Examples of the base or carrier for an intraocular injection include water for injection and physiological saline.
[0072] These bases or carriers can be used alone or in combination of two or more thereof.
<Additives>
[0073] Examples of the additive include a surfactant, a flavor or cooling agent, an antiseptic, a bactericide or antibacterial agent, a pH adjusting agent, a tonicity agent, a chelating agent, another buffering agent, a stabilizer, an antioxidant, and a thickening agent. An intraocular injection may contain a solubilizing agent, a suspending agent, a tonicity agent, a buffering agent, a soothing agent, a stabilizer, and an antiseptic.
[0074] These additives can be used alone or in combination of two or more thereof.
[0075] The additives will be exemplified below.
[0076] Surfactants: for example, nonionic surfactants such as polyoxyethylene (hereinafter sometimes referred to as “POE”)-polyoxypropylene (hereinafter sometimes referred to as “POP”) block copolymers (e.g., poloxamer 407, poloxamer 235, poloxamer 188), ethylenediamine POE-POP block copolymer adducts (e.g., poloxamine), POE sorbitan fatty acid esters (e.g., polysorbate 20, polysorbate 60, polysorbate 80 (TO-10 etc.)), POE hydrogenated castor oils (e.g., POE (60) hydrogenated castor oil (HCO-60 etc.)), POE castor oils, POE alkyl ethers (e.g., polyoxyethylene (9) lauryl ether, polyoxyethylene (20) polyoxypropylene (4) cetyl ether), and polyoxyl stearate;
amphoteric surfactants such as glycine-type amphoteric surfactants (e.g., alkyl diaminoethyl glycine, alkyl polyaminoethyl glycine), betaine-type amphoteric surfactants (e.g., lauryldimethylaminoacetic betaine, imidazolinium betaine); cationic surfactants such as alkyl quaternary ammonium salts (e.g., benzalkonium chloride, benzethonium chloride); etc.
[0079] The numbers in the parentheses represent the molar number of added POE or POP.
[0080] Flavors or cooling agents: for example, camphor, borneol, terpenes (these may be in the d-form, l-form, or dl-form); essential oils such as mentha water, eucalyptus oil, bergamot oil, anethole, eugenol, geraniol, menthol, limonene, mentha oil, peppermint oil, rose oil, etc.
[0081] Antiseptics, bactericides, or antibacterial agents: for example, polidronium chloride, alkyldiaminoethylglycine hydrochloride, sodium benzoate, ethanol, benzalkonium chloride, benzethonium chloride, chlorhexidine gluconate, chlorobutanol, sorbic acid, potassium sorbate, sodium dehydroacetate, methyl paraoxybenzoate, ethyl paraoxybenzoate, propyl paraoxybenzoate, butyl paraoxybenzoate, oxyquinoline sulfate, phenethyl alcohol, benzyl alcohol, biguanide compounds (in particular, polyhexamethylene biguanide or its hydrochloride etc.), Glokill (Rhodia Ltd.), etc.
[0082] pH adjusting agents: for example, hydrochloric acid, sodium hydroxide, potassium hydroxide, calcium hydroxide, magnesium hydroxide, triethanolamine, monoethanolamine, diisopropanolamine, sulfuric acid, phosphoric acid, etc.
[0083] Tonicity agents: for example, sodium bisulfite, sodium sulfite, potassium chloride, calcium chloride, sodium chloride, magnesium chloride, potassium acetate, sodium acetate, sodium bicarbonate, sodium carbonate, sodium thiosulfate, magnesium sulfate, disodium hydrogen phosphate, sodium dihydrogen phosphate, potassium dihydrogen phosphate, glycerin, propylene glycol, etc.
[0084] Chelating agents: for example, ascorbic acid, edetic acid tetrasodium, sodium edetate, citric acid, etc.
[0085] Other buffering agents: for example, phosphate buffering agents; citrate buffering agents such as citric acid and sodium citrate; acetate buffering agents such as acetic acid, potassium acetate, and sodium acetate; carbonate buffering agents such as sodium bicarbonate and sodium carbonate; borate buffering agents such as boric acid and borax; amino acid buffering agents such as taurine, aspartic acid and its salts (e.g., potassium salts etc.), and ε-aminocaproic acid; etc.
[0086] These buffering agents can be added in an amount that does not affect the effect of the phosphate buffering agent.
[0087] Stabilizers: for example, trometamol, sodium formaldehyde sulfoxylate (rongalit), tocopherol, sodium pyrosulfite, monoethanolamine, aluminum monostearate, glyceryl monostearate, etc.
[0088] Antioxidants: for example, water-soluble antioxidants such as ascorbic acid, ascorbic acid derivatives (ascorbic acid-2-sulfate disodium salts, sodium ascorbate, ascorbic acid-2-magnesium phosphate, ascorbic acid-2-sodium phosphate, etc.), sodium bisulfite, sodium sulfite, sodium thiosulfate, etc.
[0089] The antioxidant may be a fat-soluble antioxidant. The addition of a fat-soluble antioxidant to the ophthalmic composition of the present invention reduces adsorption of the ophthalmic composition to a container wall, thereby further effectively reducing the loss of the GGA content of the composition. The addition of a fat-soluble antioxidant also reduces adsorption of GGA to a contact lens and improves the thermal and light stabilities of GGA.
[0090] Examples of the fat-soluble antioxidant include butyl group-containing phenols such as butylhydroxytoluene (BHT) and butylhydroxyanisole (BHA); nordihydroguaiaretic acid (NDGA); ascorbic acid esters such as ascorbyl palmitate, ascorbyl stearate, ascorbyl aminopropyl phosphate, ascorbyl tocopherol phosphate, ascorbic acid triphosphate, and ascorbyl palmitate phosphate; tocopherols such as α-tocopherol, β-tocopherol, γ-tocopherol, and δ-tocopherol; tocopherol derivatives such as tocopherol acetate, tocopherol nicotinate, and tocopherol succinate; gallic acid esters such as ethyl gallate, propyl gallate, octyl gallate, and dodecyl gallate; propyl gallate; 3-butyl-4-hydroxyquinolin-2-one; vegetable oils such as soybean oil, rapeseed oil, olive oil, and sesame oil; carotenoids such as lutein and astaxanthin; polyphenols such as anthocyanins, catechin, tannin, and curcumin; the vitamin A group including retinol, retinol esters (retinol acetate, retinol propionate, retinol butyrate, retinol octylate, retinol laurate, retinol stearate, retinol myristate, retinol oleate, retinol linolenate, retinol linoleate, retinol palmitate, etc.), retinal, retinal esters (retinal acetate, retinal propionate, retinal palmitate, etc.), retinoic acid, retinoic acid esters (methyl retinoate, ethyl retinoate, retinol retinoate, tocopheryl retinoate, etc.), dehydro forms of retinol, dehydro forms of retinal, dehydro forms of retinoic acid, provitamin A (α-carotene, β-carotene, γ-carotene, δ-carotene, lycopene, zeaxanthin, β-cryptoxanthin, echinenone, etc.), and vitamin A; CoQ10, etc. These compounds are marketed.
[0091] Among these, preferred are butyl group-containing phenols, NDGA, ascorbic acid esters, tocopherols, tocopherol derivatives, gallic acid esters, propyl gallate, and 3-butyl-4-hydroxyquinolin-2-one, vegetable oils, and the vitamin A group. Among these, preferred are butyl group-containing phenols, tocopherols, tocopherol derivatives, vegetable oils, and the vitamin A group, more preferred are butyl group-containing phenols, vegetable oils, retinol, and retinol esters, and further more preferred are BHT, BHA, sesame oil, and retinol palmitate.
[0092] These fat-soluble antioxidants can be used alone or in combination of two or more thereof.
[0093] The fat-soluble antioxidant content of the ophthalmic composition is preferably 0.00001% by weight or more, more preferably 0.00005% by weight or more, further more preferably 0.0001% by weight or more, further more preferably 0.0005% by weight or more, relative to the total amount of the ophthalmic composition. The fat-soluble antioxidant in the above ranges is sufficient to exhibit the effects of reducing adsorption of GGA to a container wall (thereby reducing the loss of the GGA content), reducing adsorption of GGA to a contact lens, and improving the thermal and light stabilities of GGA.
[0094] The fat-soluble antioxidant content of the ophthalmic composition is preferably 10% by weight or less, more preferably 5% by weight or less, further more preferably 2% by weight or less, further more preferably 1% by weight or less, relative to the total amount of the composition. When the fat-soluble antioxidant is in the above ranges, the ophthalmic composition exhibits reduced eye irritancy.
[0095] The fat-soluble antioxidant content of the ophthalmic composition is, for example, about 0.00001 to 10% by weight, about 0.00001 to 5% by weight, about 0.00001 to 2% by weight, about 0.00001 to 1% by weight, about 0.00005 to 10% by weight, about 0.00005 to 5% by weight, about 0.00005 to 2% by weight, about 0.00005 to 1% by weight, about 0.0001 to 10% by weight, about 0.0001 to 5% by weight, about 0.0001 to 2% by weight, about 0.0001 to 1% by weight, about 0.0005 to 10% by weight, about 0.0005 to 5% by weight, about 0.0005 to 2% by weight, or about 0.0005 to 1% by weight, relative to the total amount of the ophthalmic composition.
[0096] The fat-soluble antioxidant content of the ophthalmic composition is preferably 0.0001 parts by weight or more, more preferably 0.001 parts by weight or more, further more preferably 0.005 parts by weight or more, further more preferably 0.01 parts by weight or more, relative to 1 part by weight of GGA. The fat-soluble antioxidant in the above ranges is sufficient to exhibit the effects of reducing adsorption of GGA to a container wall (thereby reducing the loss of the GGA content), reducing adsorption of GGA to a contact lens, and improving the thermal and light stabilities of GGA.
[0097] The fat-soluble antioxidant content of the ophthalmic composition is preferably 100 parts by weight or less, more preferably 50 parts by weight or less, furthermore preferably 10 parts by weight or less, further more preferably 5 parts by weight or less, relative to 1 part by weight of GGA. When the fat-soluble antioxidant is in the above ranges, the ophthalmic composition exhibits reduced eye irritancy.
[0098] The fat-soluble antioxidant content of the ophthalmic composition is, for example, about 0.0001 to 100 parts by weight, about 0.0001 to 50 parts by weight, about 0.0001 to 10 parts by weight, about 0.0001 to 5 parts by weight, about 0.001 to 100 parts by weight, about 0.001 to 50 parts by weight, about 0.001 to 10 parts by weight, about 0.001 to 5 parts by weight, about 0.005 to 100 parts by weight, about 0.005 to 50 parts by weight, about 0.005 to 10 parts by weight, about 0.005 to 5 parts by weight, about 0.01 to 100 parts by weight, about 0.01 to 50 parts by weight, about 0.01 to 10 parts by weight, or about 0.01 to 5 parts by weight, relative to 1 part by weight of GGA.
[0099] Thickening agents: for example, guar gum; hydroxypropyl guar gum; high molecular cellulose compounds such as methylcellulose, ethylcellulose, hydroxypropyl methylcellulose, hydroxyethyl cellulose, and carboxymethyl cellulose sodium; gum arabic; karaya gum; xanthan gum; agar-agar; alginic acid; α-cyclodextrin; dextrin; dextran; heparin; heparinoid; heparin sulfate; heparan sulfate; hyaluronic acid; hyaluronates (sodium salts etc.); sodium chondroitin sulfate; starch; chitin and its derivatives; chitosan and its derivatives; carrageenan; sorbitol; high molecular polyvinyl compounds such as polyvinylpyrrolidone, polyvinyl alcohol, and polyvinyl methacrylate; carboxy vinyl polymers such as alkali metal polyacrylates (sodium salts, potassium salts, etc.), amine polyacrylates (monoethanolamine salts, diethanolamine salts, triethanolamine salts, etc.), and ammonium polyacrylates; casein; gelatin; collagen; pectin; elastin; ceramide; liquid paraffin; glycerin; polyethylene glycol; macrogol; polyethyleneimine alginates (sodium salts etc.); alginate esters (propylene glycol esters etc.); powdered tragacanth; triisopropanolamine; etc.
<Other Pharmacologically or Physiologically Active Components>
[0100] Pharmacologically or physiologically active components other than GGA can be used alone or in combination of two or more thereof.
[0101] Examples of the pharmacologically or physiologically active components include prophylactic or therapeutic components for a retinal disease, nerve growth factors, decongestants, drugs for restoring extraocular muscle function, anti-inflammatory drugs or astringent drugs, antihistaminics or antiallergics, vitamins, amino acids, antibacterial drugs or bactericides, sugars, high molecular compounds, celluloses or their derivatives, local anesthetics, etc. These components will be exemplified below.
[0102] Prophylactic or therapeutic components for a retinal disease: for example, prostaglandin F2α derivatives such as prost drugs (latanoprost, travoprost, tafluprost, etc.), prostamide drugs (bimatoprost etc.) and prostone drugs (isopropyl unoprostone); sympatholytic drugs such as β-blockers (timolol maleate, gel-forming timolol, carteolol hydrochloride, gel-forming carteolol, etc.), β1-blockers (betaxolol hydrochloride etc.), αβ-blockers (levobunolol hydrochloride, nipradilol, bunazosin hydrochloride, etc.) and α2 blockers (brimonidine tartrate); parasympathomimetic drugs such as pilocarpine hydrochloride and distigmine bromide; sympathomimetic drugs such as epinephrine, epinephrine hydrogen tartrate and dipivefrin hydrochloride; carbonic anhydrase inhibitors such as dorzolamide hydrochloride and brinzolamide; specific inhibitors to ROCK (Rho-associated coiled coil forming protein kinase) such as SNJ-1656 and K-115; calcium antagonists such as lomerizine hydrochloride; EP2 agonists such as DE-117; adenosine A2a receptor agonists such as OPA-6566; therapeutic agents for age-related macular degeneration such as VEGF aptamers (pegaptanib sodium) and VEGF inhibitors (ranibizumab, bevacizumab); etc.
[0103] Nerve growth factors: for example, nerve growth factor (NGF), brain-derived nerve growth factor (BDNF), glial cell line-derived neurotrophic factor (GDNF), etc.
[0104] Since nutritional factors including nerve growth factors are contained in serum, it is possible to add serum from a patient to a preparation for the patient.
[0105] Decongestants: for example, α-adrenergic agonists such as epinephrine, epinephrine hydrochloride, ephedrine hydrochloride, oxymetazoline hydrochloride, tetrahydrozoline hydrochloride, naphazoline hydrochloride, phenylephrine hydrochloride, methylephedrine hydrochloride, epinephrine hydrogen tartrate, naphazoline nitrate, etc. These maybe in the d-form, l-form, or dl-form.
[0106] Drugs for restoring extraocular muscle function: for example, cholinesterase inhibitors having an active center similar to that of acetylcholine, such as neostigmine methylsulfate, tropicamide, helenien, atropine sulfate, etc.
[0107] Anti-inflammatory drugs or astringent drugs: for example, zinc sulfate, zinc lactate, allantoin, ε-aminocaproic acid, indomethacin, lysozyme chloride, silver nitrate, pranoprofen, azulene sulfonate sodium, dipotassium glycyrrhizinate, diammonium glycyrrhizinate, diclofenac sodium, bromfenac sodium, berberine chloride, berberine sulfate, etc.
[0108] Antihistaminics or antiallergics: for example, acitazanolast, diphenhydramine or its salts (hydrochloride etc.), chlorpheniramine maleate, ketotifen fumarate, levocabastine or its salts (hydrochloride etc.), amlexanox, ibudilast, tazanolast, tranilast, oxatomide, suplatast or its salts (tosilate etc.), sodium cromoglicate, pemirolast potassium, etc.
[0109] Vitamins: for example, retinol acetate, retinol palmitate, pyridoxine hydrochloride, flavin adenine dinucleotide sodium, pyridoxal phosphate, cyanocobalamin, panthenol, calcium pantothenate, sodium pantothenate, ascorbic acid, tocopherol acetate, tocopherol nicotinate, tocopherol succinate, tocopherol calcium succinate, ubiquinone derivatives, etc.
[0110] Amino acids: for example, aminoethylsulfonic acid (taurine), glutamic acid, creatinine, sodium aspartate, potassium aspartate, magnesium aspartate, magnesium potassium aspartate, sodium glutamate, magnesium glutamate, ε-aminocaproic acid, glycine, alanine, arginine, lysine, γ-aminobutyric acid, γ-aminovaleric acid, sodium chondroitin sulfate, etc. These may be in the d-form, l-form, or dl-form.
[0111] Antibacterial drugs or bactericides: for example, alkylpolyaminoethylglycine, chloramphenicol, sulfamethoxazole, sulfisoxazole, sulfamethoxazole sodium, sulfisoxazole diethanolamine, sulfisoxazole monoethanolamine, sulfisomezole sodium, sulfisomidine sodium, ofloxacin, norfloxacin, levofloxacin, lomefloxacin hydrochloride, acyclovir, etc.
[0112] Sugars: for example, monosaccharides, disaccharide, in particular, glucose, maltose, trehalose, sucrose, cyclodextrin, xylitol, sorbitol, mannitol, etc.
[0113] High molecular compounds: for example, alginic acid, sodium is alginate, dextrin, dextran, pectin, hyaluronic acid, chondroitin sulfate, (completely or partially saponified) polyvinyl alcohol, polyvinylpyrrolidone, carboxy vinyl polymers, macrogol, pharmaceutically acceptable salts thereof, etc.
[0114] Celluloses or their derivatives: for example, ethylcellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose, methylcellulose, carboxymethyl cellulose, carboxymethylcellulose sodium, carboxyethyl cellulose, nitrocellulose, etc.
[0115] Local anesthetics: for example, chlorobutanol, procaine hydrochloride, lidocaine hydrochloride, etc.
[0000] pH
[0116] The pH of the ophthalmic preparation is preferably 4 or higher, more preferably 5.5 or higher, further more preferably 6 or higher, further more preferably 6.5 or higher. The preparation having a pH value in the above ranges is excellent in the thermal and light stabilities of GGA.
[0117] The pH of the ophthalmic preparation is preferably 9 or lower, more preferably 8.5 or lower, further more preferably 8 or lower, further more preferably 7.5 or lower. The ophthalmic preparation having a pH value in the above ranges exhibits reduced eye irritancy.
Usage
[0118] The usage of the ophthalmic composition of the present invention varies depending on its dosage form and the route of administration is appropriately selected in accordance with the dosage form.
[0119] For example, when the composition of the present invention is an eye drop, the eye drop comprising GGA in the above concentration ranges is instilled, for example, about 1 to 5 times a day, preferably about 1 to 3 times a day, in an amount of about 1 to 2 drops each time.
[0120] When the composition of the present invention is an eye wash, eye washing is performed, for example, about 1 to 10 times a day, preferably about 1 to 5 times a day, each time using about to 20 mL of the eye wash comprising GGA in the above concentration ranges.
[0121] When the composition of the present invention is an ophthalmic ointment, the ophthalmic ointment comprising GGA in the above concentration ranges is applied to the eye, for example, about 1 to 5 times a day, preferably about 1 to 3 times a day, in an amount of about 0.001 to 5 g each time.
[0122] When the composition of the present invention is an intraocular injection, the intraocular injection comprising GGA in the above concentration ranges is injected, for example, about 1 to 3 times per day to 14 days, preferably once per day to 14 days, in an amount of about 0.005 to 1 mL each time.
[0123] When the composition of the present invention is a contact lens solution (a washing solution, a storage solution, a sterilizing solution, a multipurpose solution, package solution, etc.), a preservative for a harvested ocular tissue (a cornea etc.) for transplantation, or an irrigating solution for surgery, such a composition comprising GGA in the above concentration ranges is used in a usual dosage and regimen of such a type of preparation.
[0124] When the composition of the present invention is a sustained-release contact lens preparation, the contact lens comprising GGA in the above amount is replaced with a fresh one, for example, about 1 to 3 times per day to 14 days, preferably once per day to 14 days.
[0125] When the composition of the present invention is a sustained-release intraocular implant, about 1 to 14 days after the implantation of the implant comprising GGA in the above amount, a fresh one is implanted as needed.
[0126] The administration period varies depending on the type and stage of the disease, the age, weight, and sex of the patient, the route of administration, etc., and can be selected as appropriate, for example, from the range from about one day to 30 years. When the retinal protective action exhibited by the ophthalmic composition of the present invention suppresses the progress of a retinal disease, the administration can be further continued.
Others
[0127] The present invention includes a method for reducing the loss of the GGA content of an ophthalmic composition, the method comprising adding a phosphate buffering agent to an ophthalmic composition being held by an ophthalmic container and comprising GGA,
a method for reducing adsorption of GGA to a wall of an ophthalmic container, the method comprising adding a phosphate buffering agent to an ophthalmic composition being held by an ophthalmic container and comprising GGA, a method for reducing white turbidity due to GGA during storage at low temperature, the method comprising adding a phosphate buffering agent to an ophthalmic composition comprising GGA, a method for reducing adsorption of GGA to a contact lens, the method comprising adding a phosphate buffering agent to an ophthalmic composition comprising GGA, and a method for stabilizing GGA, the method comprising adding a phosphate buffering agent to an ophthalmic composition comprising GGA.
[0131] In these methods of the present invention, the components, dosage, properties, dosage form, etc. of the ophthalmic composition are as described for the ophthalmic composition of the present invention.
[0132] The material of the ophthalmic container is not particularly limited as long as the material is usually used for an ophthalmic container. Examples of the ophthalmic container include an ophthalmic container whose surface in contact with the ophthalmic composition is at least partially or wholly made of at least one material selected from the group consisting of a polyolefin, an acrylic acid resin, a terephthalic acid ester, a 2,6-naphthalene dicarboxylic acid ester, a polycarbonate, a polymethylterpene, a fluorine resin, a polyvinyl chloride, a polyamide, an ABS resin, an AS resin, a polyacetal, a modified polyphenylene ether, a polyarylate, a polysulfone, a polyimide, a cellulose acetate, a hydrocarbon optionally substituted with a halogen atom, a polystyrene, a polybutylene succinate, an aluminum and a glass.
[0133] Examples of the polyolefin include polyethylenes (including high density polyethylene, low density polyethylene, ultra low densitypolyethylene, linear low densitypolyethylene, ultra high molecular weight polyethylene, etc.), polypropylenes (including isotactic polypropylene, syndiotactic polypropylene, atactic polypropylene, etc.), ethylene-propylene copolymers, etc.
[0134] Examples of the acrylic acid resin include acrylic acid esters such as methyl acrylate, methacrylic acid esters such as methyl methacrylate, cyclohexyl methacrylate and t-butyl cyclohexyl methacrylate, etc.
[0135] Examples of the terephthalic acid ester include polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, etc.
[0136] Examples of the 2,6-naphthalene dicarboxylic acid ester include polyethylene naphthalate, polybutylene naphthalate, etc.
[0137] Examples of the fluorine resin include fluorine-substituted polyethylenes (polytetrafluoroethylene, polychlorotrifluoroethylene, etc.), polyvinylidene fluoride, polyvinyl fluoride, perfluoroalkoxy fluorine resins, tetrafluoroethylene-hexafluoropropylene copolymers, ethylene-tetrafluoroethylene copolymers, ethylene-chlorotrifluoroethylene copolymers, etc.
[0138] Examples of the polyamide include nylon etc.
[0139] Examples of the polyacetal include polyacetals consisting of oxymethylene units, polyacetals containing oxyethylene units, etc.
[0140] Examples of the modified polyphenylene ether include polystyrene-modified polyphenylene ether etc.
[0141] Examples of the polyarylate include amorphous polyarylate etc.
[0142] Examples of the polyimide include aromatic polyimides such as the one obtained by polymerizing pyromellitic dianhydride and 4,4′-diaminodiphenyl ether.
[0143] Examples of the cellulose acetate include cellulose diacetate, cellulose triacetate, etc.
[0144] Examples of the hydrocarbon optionally substituted with a halogen atom include hydrocarbons such as methane, ethane, propane, butane, ethylene, propylene, 1-butene, 2-butene and 1,3-butadiene; hydrocarbons substituted with a fluorine atom; hydrocarbons substituted with a chlorine atom; hydrocarbons substituted with a bromine atom; hydrocarbons substituted with an iodine atom; etc.
EXAMPLES
[0145] The present invention will be described in more detail below with reference to Examples, but the present invention is not limited thereto.
(1) Preparation of Geranylgeranylacetone
[0146] Marketed teprenone (all-trans form:5Z-mono-cis form=6:4 (weight ratio)) (Wako Pure Chemical Industries, Ltd.) was purchased and the all-trans form was separated and purified by silica gel chromatography.
[0147] The above preparative purification was carried out using silica gel (PSQ60B, Fuji Silysia Chemical Ltd.) filled in a glass tube and a mobile phase of n-hexane/ethyl acetate (9:1). After the separation, each fraction was concentrated and dried under reduced pressure and the degree of purification and structure of the all-trans form were determined by GC and 1 H-NMR (solvent: deuterated chloroform; internal standard: tetramethylsilane) (about 20% yield).
<GC Measurement Conditions>
[0000]
Column: DB-1 (J&W Scientific, 0.53 mm×30 m, film thickness of 1.5 μm)
Column temperature: elevated at a rate of 5° C./minute from 200° C. to 300° C. (10 minutes)
Vaporizing chamber temperature: 280° C.
Detector temperature: 280° C.
Carrier gas: helium
Hydrogen pressure: 60 kPa
Air pressure: 50 kPa
[0155] Makeup gas pressure: 75 kPa (nitrogen gas)
Total flow: 41 mL/min Column flow: 6.52 mL/min Linear velocity: 58.3 cm/sec Split ratio: 5:1 Injection volume: 1 μL of 0.1 g/100 mL sample (in ethanol)
(2) Measurement Method for GGA Concentration
[0161] In accordance with the measurement conditions for the elution test described in PFSB/ELD Notification No. 0412007 “teprenone 100 mg/g fine granule”, the GGA concentration of each eye drop was determined from the area value of the 5Z-mono-cis form (Ac) and the area value of the all-trans form (At) using Japanese pharmacopoeia “teprenone reference standard (all-trans form:5Z-mono-cis form=about 6:4 (weight ratio), Pharmaceutical and Medical Device Regulatory Science Society of Japan)” or teprenone (Wako Pure Chemical Industries) as a reference standard under the HPLC measurement conditions described below. For the eye drop containing teprenone (all-trans form:5Z-mono-cis form=3:2 (weight ratio)), the GGA content was calculated by summing the amounts of the all-trans form and the 5Z-mono-cis form.
<HPLC Measurement Conditions>
[0000]
Detector: ultraviolet absorption spectrometer (measurement wavelength: 210 nm)
Column: YMC-Pack ODS-A (inner diameter: 4.6 mm, length: 15 cm, particle diameter: 3 μm)
Column temperature: 30° C.
Mobile phase: 90% acetonitrile solution
Flow rate: 1.2 to 1.3 mL/min (the 5Z-mono-cis form and the all-trans form are eluted in this order.)
Injection volume: 5 μL of 0.05 g/100 mL sample
(3) Light Stability Test
[0168] Eye drops containing the marketed teprenone or GGA consisting of the all-trans form purified by the above method were prepared as follows. The constitutions of the eye drops are shown in Tables 1 and 2 below.
[0169] Specifically, to a surfactant (polysorbate 80, POE castor oil, etc.) warmed to 65° C., teprenone or the all-trans form, and optionally BHT, were added and dissolved under stirring in a hot water bath at 65° C. for 2 minutes. Water at 65° C. was added and each buffer was added under stirring to give a homogeneous solution. The pH and osmotic pressure were adjusted with hydrochloric acid and/or sodium hydroxide. This resulting solution was filtered through a membrane filter with a pore size of 0.2 μm (bottle top filter, Thermo Fisher Scientific) to give a clear sterile eye drop. Before the preparation of the sterile is eye drops, it was confirmed by HPLC described later that adsorption of GGA to instruments etc., which leads to the loss of the GGA content, did not occur during the preparation procedure.
[0170] A polyethylene terephthalate container (8 mL) (the container for Rohto Dryaid EX, Rohto Pharmaceutical) was completely filled with each of the prepared eye drops in an aseptic manner. Each eye drop was subjected to light irradiation under the following conditions. Teprenone or the all-trans form content in each sample was quantified immediately after the production and after the irradiation and the residual ratio (%) was calculated.
Irradiation equipment: LTL-200A-15WCD (Nagano Science) Light source: D-65 lamp Total irradiation: 1,300,000 lx·h (4000 lx×325 hours) Temperature and humidity: 25° C. and 60% RH Direction of light irradiation: the light was irradiated from the top to the container left to stand in the upright position on the spinning disk of the equipment.
[0175] The results are shown in Tables 1 and 2.
(4) Thermal Stability Test
[0176] Eye drops having the constitutions shown in Table 2 below were prepared and filtered in the same manner as in the preparation method described above. Each of the eye drops was filled into the polyethylene terephthalate container (8 mL) described above or a 10 mL clear glass container (Nichiden-Rika Glass) in an aseptic manner. For these eye drops, the stability test was performed by leaving the containers to stand in the upright position at 40° C., 50° C. or 60° C. for 10 days or 20 days. The teprenone or all-trans form content (g/100 mL) in each of the eye drops was quantified under the HPLC conditions described above immediately after the production and after being left to stand for a predetermined period of time, and the residual ratio (%) was calculated.
[0177] The results are shown in Table 2.
[0000]
TABLE 1
Comparative
g/100 mL
Example 1
Example 2
Example 3
Example 1
All-trans form
0.005
0.005
0.005
0.005
Sodium dihydrogen
2.000
1.400
0.300
—
phosphate dihydrate
Disodium hydrogen
0.400
1.400
3.200
—
phosphate
dodecahydrate
Boric acid
—
—
—
1.400
Borax
—
—
—
0.300
POE castor oil
0.002
0.002
0.002
0.002
Polysorbate 80
0.050
0.050
0.050
0.050
Hydrochloric acid
q.s.
q.s.
q.s.
q.s.
Sodium hydroxide
q.s.
q.s.
q.s.
q.s.
Purified water
q.s.
q.s.
q.s.
q.s.
pH
5.7
6.5
7.5
7.5
Osmotic pressure
270
260
260
240
mOsm
Residual
1,300,000
89.4
89.1
90.5
86.1
ratio (%)
lx · h
[0000]
TABLE 2
Comparative
Comparative
g/100 mL
Example 4
Example 5
Example 6
Example 7
Example 8
Example 9
Example 2
Example 3
All-trans form
0.050
0.050
0.050
—
—
—
0.050
—
All-trans form:
—
—
—
0.050
0.050
0.050
—
0.050
5Z-mono-cis form
weight ratio(6:4)
Sodium dihydrogen
2.000
1.400
0.300
2.000
1.400
0.300
—
—
phosphate dihydrate
Disodium hydrogen
0.400
1.400
3.200
0.400
1.400
3.200
—
—
phosphate
dodecahydrate
Boric acid
—
—
—
—
—
—
1.400
1.400
Borax
—
—
—
—
—
—
0.300
0.300
POE castor oil
0.020
0.020
0.020
0.020
0.020
0.020
0.020
0.020
Polysorbate 80
0.500
0.500
0.500
0.500
0.500
0.500
0.500
0.500
Hydrochloric acid
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
Sodium hydroxide
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
Purified water
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
pH
5.7
6.5
7.5
5.7
6.5
7.5
7.5
7.5
Osmotic pressure
270
260
260
270
260
260
240
240
mOsm
Storage conditions
Residual ratio (%)
1,300,000 lx · h
PET
91.3
91.9
92.8
90.6
91.8
91.9
89.0
88.4
40° C. 20 days
Glass
99.9
99.7
100.1
99.5
99.9
99.6
—
—
PET
98.4
98.0
99.5
97.3
98.3
99.1
96.7
97.1
50° C. 20 days
Glass
97.9
99.0
99.3
96.5
97.5
98.9
—
—
PET
91.9
94.3
99.6
90.2
94.6
99.4
72.4
83.4
60° C. 10 days
Glass
97.9
101.3
101.7
96.0
100.5
98.3
—
—
PET
84.8
90.7
97.2
85.6
91.8
96.9
72.5
81.5
60° C. 20 days
PET
67.3
81.1
91.2
67.4
81.6
89.2
48.5
59.3
[0178] As is apparent from Tables 1 and 2, the thermal and light stabilities of GGA were higher in the eye drops containing the phosphate buffering agents than in the eye drops containing the borate buffering agents.
(5) White Turbidity Reduction Test at Low Temperature
[0179] To a surfactant (polysorbate 80) warmed to 65° C., teprenone and the all-trans form were separately added and dissolved under stirring in a hot water bath at 65° C. for 2 minutes. Water at 65° C. was added and each buffer was added under stirring to give a homogeneous solution. The pH and osmotic pressure were adjusted with hydrochloric acid and/or sodium hydroxide. This resulting solution was filtered through a membrane filter with a pore size of 0.2 μm (bottle top filter, Thermo Fisher Scientific) to give an eye drop. Thus eye drops having the constitutions shown in Tables 3 and 4 were prepared.
[0180] A 10 mL clear glass container (Nichiden-Rika Glass) was completely filled with each of the eye drops (so that no air space remained). After sealing of the container, the eye drops were stored in the upright position at 4° C. Immediately after the preparation and after stored at 4° C. for three days or 14 days, 0.2 mL of each eye drop was transferred to wells of a 96-well plate (flat bottom, polystyrene) with a glass graduated pipette, and the absorbance was measured at 660 nm with a microplate reader (VersaMax, Molecular Devices) (temperature in the chamber: 20 to 25° C.). As referred to in JIS K0101 (Testing methods for industrial water, measurement of turbidity by light transmission), the absorbance at 660 nm of each sample was used as the indicator for white turbidity (the degree of turbidity).
[0181] The test procedure was carried out quickly. Before the test procedure was carried out, it was confirmed that the loss of the GGA content did not occur during the storage at 4° C. or the measurement of absorbance.
[0182] The results are shown in Tables 3 and 4.
[0000]
TABLE 3
Example
Example
Example
Example
Example
Example
Comparative
Comparative
g/100 mL
10
11
12
13
14
15
Example 4
Example 5
All-trans form
0.050
0.050
0.050
—
—
—
0.050
—
All-trans form:
—
—
—
0.050
0.050
0.050
—
0.050
5Z-mono-cis form
weight ratio (6:4)
Sodium dihydrogen
2.000
1.400
0.300
2.000
1.400
0.300
—
—
phosphate dihydrate
Disodium hydrogen
0.400
1.400
3.200
0.400
1.400
3.200
—
—
phosphate
dodecahydrate
Boric acid
—
—
—
—
—
—
1.400
1.400
Borax
—
—
—
—
—
—
0.300
0.300
Polysorbate 80
0.250
0.250
0.250
0.250
0.250
0.250
0.250
0.250
Hydrochloric acid
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
Sodium hydroxide
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
Purified water
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
pH
5.7
6.5
7.5
5.7
6.5
7.5
7.5
7.5
Osmotic pressure
270
260
260
270
260
260
240
240
mOsm
4° C. 3 days 660 nm
0.0762
0.0734
0.0717
0.1250
0.1164
0.1056
0.1826
0.2302
The absorbance (660 nm) of water as a control was 0.0353.
[0000]
TABLE 4
Example
Example
Example
Example
Comparative
Comparative
g/100 mL
16
17
18
19
Example 6
Example 7
All-trans form
0.050
0.050
—
—
0.050
—
All-trans form:
—
—
0.050
0.050
—
0.050
5Z-mono-cis form
weight ratio (6:4)
Sodium dihydrogen
2.000
0.300
2.000
0.300
—
—
phosphate dihydrate
Disodium hydrogen
0.400
3.200
0.400
3.200
—
—
phosphate
dodecahydrate
Boric acid
—
—
—
—
1.400
1.400
Borax
—
—
—
—
0.300
0.300
Polysorbate 80
0.350
0.350
0.350
0.350
0.350
0.350
Hydrochloric acid
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
Sodium hydroxide
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
Purified water
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
pH
5.7
7.5
5.7
7.5
7.5
7.5
Osmotic pressure
270
260
270
260
240
240
mOsm
4° C. 14 days 660 nm
0.0400
0.0417
0.0709
0.0690
0.1080
0.2358
[0183] The absorbance (660 nm) of water as a control was 0.0374.
[0184] As is apparent from Tables 3 and 4, white turbidity after storage at 4° C. was more reduced in the eye drops containing the phosphate buffering agents than in the eye drops containing the borate buffering agents.
[0185] As shown in Table 2, the residual ratio of GGA varied depending on the type of the container holding the eye drop. This explains that the use of a container of some type reduces adsorption of GGA to the container wall and such reduction allows the phosphate buffering agent to suppress the decrease in the residual ratio of GGA.
(6) Test for Reduction in Adsorption to Contact Lenses
[0186] To a surfactant (polysorbate 80 and optionally POE castor oil) warmed to 65° C., teprenone or the all-trans form, and optionally BHT, were added and dissolved under stirring in a hot water bath at 65° C. for 2 minutes. Water at 65° C. was added and each buffer was added under stirring to give a homogeneous solution. The pH and osmotic pressure were adjusted with hydrochloric acid and/or sodium hydroxide. This resulting solution was filtered through a membrane filter with a pore size of 0.2 μm (bottle top filter, Thermo Fisher Scientific) to give an eye drop. Thus eye drops having the constitutions shown in Table 5 below were prepared. These eye drops were separately filled into a 4 mL clear glass container (Nichiden-Rika Glass).
[0187] One soft contact lens (hereinafter SCL): ACUVUE OASIS (Johnson & Johnson, approval number: 21800BZY10252000, base curve: 8.4 mm, diameter: 14.0 mm, power: −3.00 D) or ACUVUE ADVANCE (Johnson & Johnson, approval number: 21800BZY10251000, base curve: 8.3 mm, diameter: 14.0 mm, power: −3.00 D) was immersed in 4 mL of each eye drop (immersion solution) and left to stand in the upright position at 25° C., 60% RH for 8 hours, 14 hours or 24 hours. Each SCL had been initialized before use through immersion in 10 mL of physiological saline (Otsuka Normal Saline) overnight after being taken out from the package solution.
[0188] For 4 mL of the eye drop without immersion of SCL (blank solution), the same procedure as those for the eye drops with immersion of SCL (immersion solution) was performed. The amount of teprenone or the all-trans form was quantified by HPLC for each of the blank solution and the immersion solution, and the difference in the amounts between the blank solution and the immersion solution was used to calculate the amount of adsorption to SCL (μg/lens) (n=2).
[0000] Amount of adsorption (μg/lens)=[amount of teprenone or all-trans form in blank solution (g/100 mL)−amount of teprenone or all-trans form in immersion solution (g/100 mL)]/100×4×1000×1000
[0189] The results for ACUVUE OASIS and ACUVUE ADVANCE are shown in Tables 5 and 6, respectively.
[0000]
TABLE 5
Example
Example
Example
Example
Comparative
Comparative
g/100 mL
20
21
22
23
Example 8
Example 9
All-trans form
0.05
0.05
—
—
0.05
—
All-trans form:
—
—
0.05
0.05
—
0.05
5Z-mono-cis form
weight ratio (6:4)
Sodium dihydrogen
2.00
0.30
2.00
0.30
—
—
phosphate dihydrate
Disodium hydrogen
0.40
3.20
0.40
3.20
—
—
phosphate
dodecahydrate
Boric acid
—
—
—
—
1.40
1.40
Borax
—
—
—
—
0.30
0.30
Polysorbate 80
0.25
0.25
0.25
0.25
0.25
0.25
Hydrochloric acid
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
Sodium hydroxide
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
Purified water
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
pH
5.7
7.5
5.7
7.5
7.5
7.5
Osmotic pressure
270
260
270
260
240
240
mOsm
Adsorption amount
152.8
146.4
137.4
148.6
222.4
208.8
(μg/lens)
Immersion
132.8
156.3
143.1
159.1
219.7
207.8
for 14 hours
[0000]
TABLE 6
Comparative
Comparative
Example
Example
Example
Example
Example
Example
g/100 mL
24
25
26
27
10
11
All-trans form
0.05
0.05
—
—
0.05
—
All-trans form:
—
—
0.05
0.05
—
0.05
5Z-mono-cis form
weight ratio (6:4)
Sodium dihydrogen
2.00
0.30
2.00
0.30
—
—
phosphate dihydrate
Disodium hydrogen
0.40
3.20
0.40
3.20
—
—
phosphate
dodecahydrate
Boric acid
—
—
—
—
1.400
1.400
Borax
—
—
—
—
0.300
0.300
POE castor oil
0.02
0.02
0.02
0.02
0.02
0.02
Polysorbate 80
0.50
0.50
0.50
0.50
0.50
0.50
Dibutylhydroxytoluene
0.005
0.005
0.005
0.005
0.005
0.005
Hydrochloric acid
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
Sodium hydroxide
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
Purified water
q.s.
q.s.
q.s.
q.s.
q.s.
q.s.
pH
5.7
7.5
5.7
7.5
7.5
7.5
Osmotic pressure
270
260
270
260
240
240
mOsm
Adsorption amount
85.3
71.2
84.1
83.7
112.4
120.1
(μg/lens)
Immersion for
89.7
85.3
96.1
85.5
111.0
133.9
8 hours
Adsorption amount
229.1
209.5
251.9
243.3
287.1
328.4
(μg/lens)
Immersion for
212.9
213.6
254.6
235.5
298.1
345.8
24 hours
[0190] As is apparent from Tables 5 and 6, the adsorption of GGA to contact lenses was smaller in the eye drops containing the phosphate buffering agents than in the eye drops containing the borate buffering agents.
INDUSTRIAL APPLICABILITY
[0191] The ophthalmic composition of the present invention is excellent in the stability of GGA and adsorption of GGA in the composition to a container wall and a contact lens is remarkably reduced, and therefore the ophthalmic composition is very useful in practice.
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An ophthalmic composition comprising geranylgeranylacetone and a phosphate buffering agent has an advantage that the loss of the geranylgeranylacetone content during long-term storage is very little. This is because of reduced adsorption of geranylgeranylacetone to a wall of an ophthalmic container. The ophthalmic composition comprising geranylgeranylacetone and a phosphate buffering agent also has an advantage that adsorption of geranylgeranylacetone to a contact lens is little. Further, the ophthalmic composition comprising geranylgeranylacetone and a phosphate buffering agent hardly becomes white turbid even when stored at low temperature.
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FIELD OF THE INVENTION
[0001] The present invention relates to carpet seam tape and methods for joining carpet.
BACKGROUND
[0002] When installing carpet, it is common for the room in which the carpet is being installed to have at least one dimension (length or width) that is greater than the length of a standard roll of carpet (which is typically twelve feet). In such a case, a single unitary segment of carpet from a roll cannot cover the entire floor of the room, and two or more segments must be pieced together. When two or more segments are pieced together, an edge of one segment is abutted against an edge of another segment, and these edges are joined (“seamed”) together using seam tape.
[0003] FIGS. 1 and 2 illustrate top and cross-sectional views, respectively, of prior art seam tape. Prior art seam tape 10 comprises an elongated base layer 12 , scrim 14 , and an adhesive 16 (the adhesive is omitted from FIG. 1 for clarity). The base layer typically comprises paper or other relatively inelastic material. The scrim typically comprises woven threads and provides strength and additional inelasticity to the seam tape. The adhesive typically comprises a hot-melt thermoplastic adhesive applied to a large portion of the base layer. The scrim is embedded within the adhesive.
[0004] When joining carpet edges together, the edge of one carpet segment is positioned to abut the edge of the other carpet segment. The seam tape is positioned under the abutting edges, and the adhesive is activated by applying heat to the top surface of the carpet above the seam tape. The heat melts the adhesive and the melted adhesive bonds to the underside of both carpet segments as the adhesive cures.
[0005] After the carpet segments are positioned to cover the entire floor and the seams are joined using seam tape, the carpet is stretched at the outer edges and the outer edges are secured to the floor using tack strips. The stretching tightens the carpet to remove any slack and wrinkles FIG. 3 illustrates what happens when the carpet is stretched in a direction transverse to the carpet seam (indicated by the arrows in FIG. 3 ). The top image of FIG. 3 illustrates the unstretched carpet. As the carpet is stretched and the two carpet segments 18 A, 18 B are pulled away from each other, the inelasticity of the seam tape 10 causes the seam to lift off the floor, resulting in an unsightly bulge in the carpet (illustrated in the bottom image of FIG. 3 ). This is called seam “peaking” or “profiling” and is highly undesirable.
BRIEF SUMMARY
[0006] In one embodiment of the invention, a method for joining two carpet segments, each carpet segment having an underside and at least one edge, comprises abutting one edge of one carpet segment with one edge of the other carpet segment; positioning a length of seam tape under the abutting edges, the seam tape comprising an elongated base layer being resilient in a transverse direction; and an adhesive applied to the base layer; and activating the adhesive to secure the seam tape to the undersides of both carpet segments.
[0007] In another embodiment of the invention, a method for joining two carpet segments, each carpet segment having an underside and at least one edge, comprises abutting one edge of one carpet segment with one edge of the other carpet segment; positioning a length of seam tape under the abutting edges, the seam tape comprising an elongated base layer comprising fabric; and an adhesive applied to the base layer; and activating the adhesive to secure the seam tape to the undersides of both carpet segments.
[0008] In another embodiment of the invention, a method for joining two carpet segments, each carpet segment having an underside and at least one edge, comprises abutting one edge of one carpet segment with one edge of the other carpet segment; positioning a length of seam tape under the abutting edges, the seam tape comprising an elongated base layer; and an adhesive applied to the base layer; and activating the adhesive to secure the seam tape to the undersides of both carpet segments. In this embodiment, the seam tape does not comprise a scrim.
[0009] In any of the above methods, the adhesive may comprise a hot-melt thermoplastic adhesive, and the base layer may comprise fabric, such as cotton and elastane or denim and elastane. In any of the above methods, the adhesive may comprise (a) a unitary mass of adhesive, (b) a plurality of beads of adhesive, or (c) a plurality of spots of adhesive.
[0010] In another embodiment of the invention, carpet seam tape for joining two carpet segments comprises an elongated base layer being resilient in a transverse direction; and an adhesive applied to the base layer.
[0011] In another embodiment of the invention, carpet seam tape for joining two carpet segments comprises an elongated base layer comprising fabric; and an adhesive applied to the base layer.
[0012] In another embodiment of the invention, carpet seam tape for joining two carpet segments comprises an elongated base layer; and an adhesive applied to the base layer. However, the seam tape does not comprise a scrim.
[0013] In any of the above carpet seam tapes, the adhesive may comprise a hot-melt thermoplastic adhesive, and the base layer may comprise fabric, such as cotton and elastane or denim and elastane. In any of the above methods, the adhesive may comprise (a) a unitary mass of adhesive, (b) a plurality of beads of adhesive, or (c) a plurality of spots of adhesive.
[0014] In another embodiment of the invention, a carpet system comprises two carpet segments; and carpet seam tape affixed to and joining the two carpet segments. The carpet seam tape comprises an elongated base layer being resilient in a transverse direction; and an adhesive applied to the base layer.
[0015] In another embodiment of the invention, a carpet system comprises two carpet segments; and carpet seam tape affixed to and joining the two carpet segments. The carpet seam tape comprises an elongated base layer comprising fabric; and an adhesive applied to the base layer.
[0016] In another embodiment of the invention, a carpet system comprises two carpet segments; and carpet seam tape affixed to and joining the two carpet segments. The carpet seam tape comprises an elongated base layer; and an adhesive applied to the base layer. However, the seam tape does not comprise a scrim.
[0017] In any of the above carpet systems, the adhesive may comprise a hot-melt thermoplastic adhesive, and the base layer may comprise fabric, such as cotton and elastane or denim and elastane. In any of the above methods, the adhesive may comprise (a) a unitary mass of adhesive, (b) a plurality of beads of adhesive, or (c) a plurality of spots of adhesive.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0018] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
[0019] FIG. 1 is a top view of prior art seam tape;
[0020] FIG. 2 is a cross-sectional view of the prior art seam tape of FIG. 1 along the indicated line;
[0021] FIG. 3 illustrates carpet segments joined using the prior art seam tape of FIG. 1 ;
[0022] FIG. 4 is a top view of seam tape, in accordance with an embodiment of the present invention;
[0023] FIG. 5 is a cross-sectional view of the seam tape of FIG. 4 ;
[0024] FIG. 6 illustrates carpet segments joined using the seam tape of FIG. 4 ;
[0025] FIG. 7 is a top view of seam tape, in accordance with an alternative embodiment of the present invention; and
[0026] FIG. 8 is a cross-sectional view of the seam tape of FIG. 7 .
DETAILED DESCRIPTION
[0027] Embodiments of the invention provide the ability to securely join carpet segments while preventing seam peaking when the joined carpet is stretched. Referring now to FIGS. 4 and 5 , top and cross-sectional views are illustrated, respectively, of seam tape in accordance with an embodiment of the present invention. The seam tape 30 of embodiments of the invention comprises an elongated base layer 32 and an adhesive 36 applied to the base layer. Notably, the seam tape does not comprise a scrim. The elongated base layer may comprise any suitable material that is resilient (stretches and rebounds) in a transverse (perpendicular to the longitudinal axis) direction. For example, the elongated base layer may comprise a textile or fabric (including combinations of different textiles or fabrics), rubber, polymer (including combinations of different polymers), and combinations thereof. In one embodiment of the invention, the elongated base layer comprises a fabric that combines cotton (such as denim) and elastane (such as Lycra or Spandex). For example, the fabric that is used to make “stretch jeans” may be used for the base layer. Such a fabric may be, for example, 98% denim and 2% elastane or 95% denim and 5% elastane, although different amounts of denim and elastane may be used. Optionally, one or more additional materials may be combined with the cotton and elastane. For example, the elongated base layer may comprise a fabric that combines polyester with the cotton and elastane, such as a combination of 78% cotton denim, 18% polyester, and 4% elastane. The fabric may be dyed or undyed. The adhesive typically comprises a hot-melt thermoplastic adhesive.
[0028] The material selected for the elongated base layer should be as resilient as the carpet to which the seam tape is to be secured, such as to not impede the carpet from stretching. However, it may also be desirable for the material to not be significantly more resilient than the carpet. Such a material should provide enough stretch to the seam tape to reduce the likelihood of seam peaking, but not so much stretch as to allow a gap to be visible at the seam. As different types of carpets may have different amounts of resiliency, it may be desirable to have different types of seam tapes, each with a different amount of resiliency to match a different type of carpet. Alternatively, it may be desirable to have a single type of seam tape that has sufficient resiliency to be used with a wide variety of different types of carpet.
[0029] For purposes of this application, the terms “textile” and “fabric” are used interchangeably to refer to a flexible woven material comprising a network of natural or artificial fibers (often referred to as thread or yarn). Textiles are formed by weaving, knitting, crocheting, knotting, or pressing fibers together. For purposes of this application, the terms “textile” and “fabric” specifically exclude paper.
[0030] FIG. 6 illustrates what happens when carpet that is joined using carpet seam tape 30 of embodiments of the invention is stretched in a direction transverse to the carpet seam (indicated by the arrows in FIG. 6 ). As the two carpet segments 38 A, 38 B are pulled away from each other, the elasticity of the seam tape 30 prevents the seam from lifting off the floor, thereby preventing seam peaking It does this by allowing the stretch to “reach” the seam. That is, the portions of the carpet that are affixed to the seam tape (of embodiments of the invention) are able to stretch (along with the seam tape). In contrast, the prior art seam tape does not allow the portions of the carpet that are affixed to the prior art seam tape to stretch (because the prior art seam tape does not stretch).
[0031] Referring now to FIGS. 7 and 8 , top and cross-sectional views are illustrated, respectively, of seam tape in accordance with an alternative embodiment of the present invention. The seam tape 50 of alternative embodiments of the invention comprises an elongated base layer 52 and an adhesive 56 applied to the base layer. As above, seam tape 50 does not comprise a scrim. Rather than a unitary mass of adhesive applied to the base layer, seam tape 50 comprises a plurality of “beads” of glue. The beads of glue are illustrated as being substantially parallel to the longitudinal axis of the seam tape and to each other, but other configurations may be used. The beads are illustrated as being continuous, but may be non-continuous beads or may even comprise individual “dots” or “spots” of adhesive. Such a non-unitary application of adhesive to the base layer may be desirable where a non-flexible (or insufficiently flexible) adhesive is used. Some types of adhesives, once cured, may be less flexible than other types of adhesives. For example, high melt glue is less flexible, once cured, than low melt glue. Using a non-unitary application of adhesive to the base layer when a less flexible adhesive is used prevents (or at least reduces) the adhesive from restricting the tape (and therefore the carpet) from stretching.
[0032] While four beads of adhesive are illustrated in FIGS. 7 and 8 , the amount of adhesive in each bead and the spacing and number of the beads may vary, depending on the type of adhesive, the type of carpet, etc. It is desirable that the amount of adhesive and the spacing of the beads be selected such that the beads remain separate and do not run together when the seam tape is heated and the adhesive is melted. Since the use of such beads is typically limited to glues that are relatively less flexible, ensuring that the beads remain separate after melting helps maintain the continued resiliency of the seam tape.
[0033] The carpet seam tape of embodiments of the invention offers many improvements over prior art seam tape. The carpet seam tape of embodiments of the invention lays flat despite stretching of the carpet because the elasticity of the seam tape allows the carpet to stretch. The carpet seam tape of embodiments of the invention is easier to manufacture and less expensive due at least to the lack of a scrim. The carpet seam tape of embodiments of the invention provides a bond that is better capable of withstanding repeated steam cleaning due to its use of fabric rather than paper as the base layer.
[0034] When the carpet seam tape of embodiments of the invention is used to seam carpet, the edges of the carpet should be “seam sealed” as per standard carpet seaming practices established by the Carpet and Rug Institute. This seam sealing step further reduces the likelihood of peaking It is anticipated that all other standard seaming techniques will work when the carpet seam tape of embodiments of the invention is used to seam carpet, and therefore should be used.
[0035] In addition to joining carpet segments during installation of carpet, the carpet seam tape of embodiments of the invention may be used in a carpet mill to join the ends of carpet rolls to form larger carpet rolls.
[0036] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0037] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
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A method for joining two carpet segments, each carpet segment having an underside and at least one edge. The method comprises abutting one edge of one carpet segment with one edge of the other carpet segment; positioning a length of seam tape under the abutting edges, and activating the adhesive to secure the seam tape to the undersides of both carpet segments. The seam tape comprises an elongated base layer that is resilient in a transverse direction and an adhesive applied to the base layer. The adhesive may comprise a hot-melt thermoplastic adhesive. The base layer may comprise a resilient textile or fabric, such as cotton denim and elastane.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. Ser. No. 08/056,966, filed Apr. 29, 1993, now abandoned which is a continuation of Ser. No. 07/880,400, filed May 8, 1992, now abandoned.
FIELD OF THE INVENTION
This application relates to hybrid cell lines (lymphocyte hybridomas) for the production of monoclonal antibodies to human leukemia inhibitory factor, to such homogeneous monospecific antibodies, and to the use of such antibodies for diagnostic and therapeutic purposes.
BACKGROUND OF THE INVENTION
Leukemia inhibitory factor (LIF) is a polypeptide with a broad range of biological effects. LIF was initially purified from mouse cells and identified on the basis of its ability to induce differentiation in and suppress the proliferation of the murine monocytic leukemia cell line M1. Tomida, et al., J. Biol. Chem. 259:10978-10982 (1984); Tomida, et al., FEBS Lett. 178:291-296 (1984). Human LIF (hLIF) subsequently was shown to have comparable effects on human HL60 and U937 cells, particularly when acting in collaboration with GM-CSF or G-CSF colony stimulating factors. Maekawa, et al. Leukemia 3:270-276 (1989).
LIF has been shown to exhibit a variety of biological activities and effects on different cell types. For example, it has been shown to stimulate osteoblast proliferation and new bone formation, Metcalf, et al., Proc. Nat. Acad. Sci., 86:5948-5952 (1989), as well as bone resorption, Abe, et al., Proc. Nat. Acad. Sci. 83:5958-5962 (1986); Reid, et al., Endocrinology 126:1416-1420 (1990), stimulate liver cells to produce acute phase plasma proteins, Baumann, et al., J. Immunol. 143:1163-1167 (1989), inhibit lipoprotein lipase, Mori, et al., Biochem. Biophys. Res. Commun. 160:1085-1092 (1989), stimulate neuronal differentiation and survival, Murphy, et al., Proc. Nat. Acad. Sci. 88:3498-3501 (1991), Yamamori, et al., Science 246:1412-1416 (1989), and inhibit vascular endothelial cell growth, Ferrara, et al., Proc. Nat. Acad. Sci. 89:698-702 (1992). Receptors for LIF have been found on monocyte-macrophages, osteoblasts, placental trophoblasts, and liver parenchymal cells. Hilton, et al., J. Cell. Biochem. 46:21-26 (1991); Allan, et al., J. Cell. Physiol. 145:110-119 (1990); Hilton, et al., Proc. Nat. Acad. Sci. 85:5971-5975 (1988).
Depending upon its particular activity or effect, LIF has been referred to by various names, including differentiation-inducing factor (DIF, D-factor), hepatocyte-stimulating factor (HSF-II, HSF-III), melanoma-derived LPL inhibitor (MLPLI), and cholinergic neuronal differentiation factor (CDF). Hilton, et al., J. Cell. Biochem. 46:21-26 (1991).
Genomic and cDNA clones encoding murine, rat, and human LIF have been isolated. Gearing, et al., EMBO J. 6:3995-4002 (1987); Yamamori, et al., Science 246:1412-1416 (1989); Gough, et al., Proc. Nat. Acad. Sci. 85:2623-2627 (1988).
Antibodies to hLIF are expected to have valuable diagnostic and therapeutic applications, such as in assaying for the presence of hLIF in clinical specimens, and in regulating the biological effects of hLIF and the interaction of hLIF with its receptors and other ligands. In particular, monoclonal antibodies (mAbs) detecting unique epitopes of hLIF would be of great value in understanding and regulating the diverse biological activities of hLIF. Neutralizing mAbs specific for hLIF that inhibit one or more of the biological activities or effects of hLIF have great potential as therapeutic agents useful in the treatment of conditions wherein the presence of hLIF causes or contributes to undesirable pathological effects, such as cachexia, dysregulated calcium metabolism, or excessive bone resorption (such as may be associated with osteoporosis).
Several polyclonal antibodies have been described that react with LIF. Tomida, et al., FEBS Letters 151:281-285 (1983) immunized rabbits with partially purified D-factor from mouse cells, and obtained antibodies capable of neutralizing the activity of mouse D-factor, and to a lesser extent, rat and hamster D-factors, in several assays. Baumann, et al., J. Immunol. 143:1163-1167 (1989) reported that rabbit polyclonal antibodies against hepatocyte-stimulating factor III (HSF-III) neutralized the activity of hLIF on hepatic cells.
There is a need for high affinity monoclonal antibodies to hLIF that are capable of effective inhibition of the biological activities of hLIF. It would be particularly desirable to provide monoclonal antibodies that are effective inhibitors of hLIF binding to its receptors, but which do not interfere with the binding of other factors, such as interleukin 1 (IL-1), interleukin 3 (IL-3), interleukin 6 (IL-6), tumor necrosis factor-α (TNF-α), granulocyte CSF (G-CSF), granulocyte-macrophage-colony stimulating factor (GM-CSF), and Oncostatin M.
SUMMARY OF THE INVENTION
The present invention is based on successful research involving the production and extensive characterization of monoclonal antibodies to hLIF. Accordingly, the present invention is directed to monoclonal antibodies, and derivatives thereof, which are capable of recognizing unique epitopes on hLIF and/or which exhibit high affinity for hLIF. The invention is further directed to monoclonal antibodies capable of inhibiting one or more of the biological activities of hLIF.
In one aspect, the invention concerns an anti-hLIF monoclonal antibody that is capable of inhibiting the mitogenic effect of hLIF on leukemic cells, and that does not cross-react with IL-1, IL-3, IL-6, TNF-α, G-CSF, or GM-CSF.
In another aspect, the invention concerns isolated nucleic acid encoding such antibodies, and hybridoma or recombinant cells producing such antibodies.
In a further aspect, the invention concerns the therapeutic or diagnostic use of such antibodies. The monoclonal antibodies of the invention are useful as therapeutic agents, either by themselves or in conjunction with (chemo)therapeutic agents, to treat diseases or conditions that are aggravated by hLIF. The monoclonal antibodies of the invention also are useful in diagnostic and analytical assays for determining the presence of hLIF in clinical specimens.
These and further aspects will be apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the binding (antigenic) specificity of anti-hLIF mAb D25.1.4 as determined by ELISA.
FIGS. 2A and 2B shows a comparison of the binding of anti-hLIF monoclonal antibodies to recombinant human LIF (rHuLIF) and recombinant murine LIF (rMuLIF) as determined by ELISA.
FIG. 3 shows the binding of horse radish peroxidase conjugated anti-hLIF monoclonal antibodies (HRP-mAbs) to hLIF in the presence and absence of 100-fold molar excess of unlabeled anti-hLIF monoclonal antibody (D3.14.1, D4.16.9, D25.1.4, or D62.3.2) or irrelevant control antibody (anti-hVEGF mAb A3.13.1).
FIG. 4 shows the effect of anti-hLIF monoclonal antibody (D3.14.1, D4.16.9, D25.1.4, or D62.3.2) or irrelevant control antibody (anti-hVEGF mAb A3.13.1) on hLIF inhibition of M1-T22 murine myeloid leukemic cell growth. Results are expressed as a percentage reduction (neutralization) of such hLIF activity as compared to a control assay in which hLIF inhibition of M1-T22 murine myeloid leukemic cell growth was determined in the absence of antibody.
FIGS. 5A-5F shows fluorescence activated cell sorting (FACS) analysis of intracellular Ca 2+ levels in Jurkat human T-cells exposed to hLIF alone (no Ab), or hLIF pre-incubated with anti-hLIF monoclonal antibody (D3.14.1, D4.16.9, D25.1.4, or D62.3.2) or irrelevant control antibody (anti-hVEGF mAb A3.13.1). The assay was carried out over three minutes time; hLIF alone or the pre-incubated mixtures of hLIF and antibody were added one minute after the start of the FACS analysis (in the first panel (no Ab), for example, the time of addition of hLIF is indicated by the downward pointing arrow).
FIG. 6 shows the binding of 125 I-hLIP to hLIF receptors on M1-T22 cells in the presence of unlabeled anti-hLIF monoclonal antibody (D3.14.1, D4.16.9, D25.1.4, or D62.3.2) or irrelevant control antibody (anti-hVEGF mAb 3.13.1). The amount of anti-hLIF monoclonal antibody added was either 50×, 10×, or 1× the molar amount of hLIF in the assay. NSC= 125 I-hLIF bound to M1-T22 cells in the presence of 1000-fold molar excess of unlabeled hLIF (a measure of non-specific binding). TC= 125 I-hLIF bound to M1-T22 cells in the absence of antibody (a measure of maximal binding).
FIG. 7 shows the results of an ELISA for detection of various concentrations of hLIF, using mAb4.16.9 as a capture antibody and mAb 3.14.1 as a detection antibody.
DETAILED DESCRIPTION OF THE INVENTION
A. Definitions and General Methods
The term "monoclonal antibody" as used herein refers to a substantially homogeneous population of antibodies, i.e., the individual antibodies comprising the population are identical in specificity and affinity except for possible naturally occurring mutations that may be present in minor amounts. Note that a monoclonal antibody composition may contain more than one monoclonal antibody.
The monoclonal antibodies included within the scope of the invention include hybrid and recombinant antibodies (for example, "humanized" antibodies) regardless of species of origin or immunoglobulin class or subclass designation, as well as antibody fragments (for example, Fab, F(ab') 2 , and Fv), so long as they have the novel and unobvious characteristics of the antibodies described herein, in preferred embodiments being antibodies that are capable of binding to substantially the same epitope as one recognized by a monoclonal antibody produced by any one of the D3.14.1, D4.16.9, D25.1.4, or D62.3.2 hybridomas described herein, and/or that have affinity for that epitope which is greater than or equal to the affinity of a monoclonal antibody produced by any one of such hybridomas.
Thus, the modifier "monoclonal" indicates the character of the antibody as a substantially homogeneous population of antibodies, and is not to be construed as requiring production of the antibody by any particular method. For example, the monoclonal antibodies of the invention my be made using the hybridoma method first described by Kohler & Milsrein, Nature 256:495-497 (1975), or may be made by recombinant DNA methods. For example, see Cabilly, et al., U.S. Pat. No. 4,816,567; or Mage a Lamoyi, in Monoclonal Antibody Production Techniques and Applications, pp.79-97 (Marcel Dekker, Inc., New York, 1987).
In the hybridoma method, a mouse or other appropriate host animal is immunized with hLIF by subcutaneous, intraperitoneal, or intramuscular routes to elicit lymphocytes that produce or are capable of producing antibodies that will specifically bind to the protein used for immunization. Alternatively, lymphocytes may be immunized in vitro. Lymphocytes then are fused with myeloma cells using a suitable fusing agent, such as polyethylene glycol, to form a hybridoma cell. Goding, Monoclonal Antibodies: Principles and Practice, pp.59-103 (Academic Press, 1986).
The hybridoma cells thus prepared are seeded and grown in a suitable culture medium that preferably contains one or more substances that inhibit the growth or survival of the unfused, parental myeloma cells. For example, if the parental myeloma cells lack the enzyme hypoxanthine guanine phosphoribosyl transferass (HGPRT or HPRT), the culture medium for the hybridomas typically will include hypoxanthine, aminopterin, and thymidine (HAT medium), which substances prevent the growth of HGPRT-deficient cells.
Preferred myeloma cells are those that fuse efficiently, support stable high level expression of antibody by the selected antibody-producing cells, and are sensitive to a medium such as HAT medium. Among these, preferred myeloma cell lines are murine myeloma lines, such as P3-NS-1-Ag-4-1, Kohler, et al., Eur. J. Immunol 6:292-295 (1976), X63-Ag8.653, Kearney, et al., J. Immunol. 123:1548-1550 (1979), SP2/0-Ag/4, Sltulman, et al., Nature 276:269-270 (1978), or P 3 X63Ag8U 1 Yelton et al., Curr. Top. Microbiol. Immunol. 81:1-7 (1978). Human myeloma and mouse-human heteromyeloma cell lines also have been described for the production of human monoclonal antibodies. Kozbor, J. Immunol. 133:3001-3005 (1984). Brodeur, et al., Monoclonal Antibody Production Techniques and Applications, pp. 51-63 (Marcel Dekker, Inc., New York, 1987).
Culture medium in which hybridoma cells are growing is conveniently assayed for production of monoclonal antibodies directed against hLIF. Preferably, the binding specificity of antibodies is determined by immunoprecipitation or by an in vitro binding assay, such as radioinimmunoassay (RIA) or enzyme-linked immunoabsorbent assay (ELISA), or by fluorescence activated cell sorting (FACS). The monoclonal antibodies of the invention are those that preferentially bind to soluble or cell bound hLIF and which are neutralizing, as explained herein. The specificity of binding of the monoclonal antibodies of the invention is determined by reaction of the antibodies with factors other than hLIF, with the objective being the identification of antibodies that do not bind to any factors other than hLIF, especially IL-1, IL-3, IL-6, G-CSF, GM-CSF, or Oncostatin M. A monoclonal antibody that preferentially binds to soluble or cell bound hLIF generally will exhibit at least the same degree of specificity of binding as a monoclonal antibody produced by any one of the D3.14.1, D4.16.9, D25.1.4, or D62.3.2 hybridomas described herein.
In a preferred embodiment of the invention, the monoclonal antibody will have an affinity which is greater than about 10 9 liters/mole and preferably is equal to or greater than about 10 10 liters/mole, as determined, for example, by the Scatchard analysis of Munson, et al., Anal. Biochem. 107:220-239 (1980).
The term "neutralizing antibody" as used herein refers to a monoclonal antibody that is capable of substantially inhibiting or eliminating a biological activity of hLIF.
After hybridoma cells are identified that produce neutralizing antibodies of the desired specificity and affinity, the clones typically are subcloned by limiting dilution procedures and grown by standard methods. Goding, Monoclonal Antibodies: Principles and Practice, pp.59-104 (Academic Press, 1986). Suitable culture media for this purpose include, for example, Dulbecco's Modified Eagle's Medium or RPMI-1640 medium. In addition, the hybridoma cells may be grown in vivo as ascites tumors in an animal.
The monoclonal antibodies secreted by the selected hybridoma cells are suitably purified from cell culture medium or ascites fluid by conventional immunoglobulin purification procedures such as, for example, protein A-SEPHAROSE hydroxylapatite chromatography, gel electrophoresis, dialysis, or affinity chromatography.
DNA encoding the monoclonal antibodies of the invention is readily isolated and sequenced using conventional procedures (for example, by using oligonucleotide probes that are capable of binding specifically to genes encoding the heavy and light chains of murine antibodies). The hybridoma cells of the invention serve as a preferred source of such DNA. Once isolated, the DNA is ligated into expression or cloning vectors, which are then transfected into host cells such as simian COS cells, Chinese hamster ovary (CHO) cells, or myeloma cells that do not otherwise produce immunoglobulin protein. The transformant cells are cultured to obtain the synthesis of monoclonal antibodies in the recombinant host cell culture.
The DNA optionally is modified in order to change the character of the immunoglobulin produced by its expression. Immunoglobulin variants are well known. For example, chimeric antibodies are made by substituting the coding sequence for human heavy and light chain constant domains in place of the homologous murine sequences. Cabilly, et al., U.S. Pat. No. 4,816,567 et al.; Morrison, et al., Proc. Nat. Acad. Sci. 81:6851-6855 (1984). In addition, the Fc domain chosen is any of IgA, IgG-1, -2, -3 or -4. The Fc domain optionally is capable of effector functions such as complement binding.
Humanized forms of the murine antibodies are made by substituting the complementarity determining regions of the mouse antibody into a human framework domain, as described, for example, in U.S. patent application Ser. No. 07/715,272 now abandoned. In some embodiments, selected murine framework residues also are substituted into the human recipient immunoglobulin.
Fusions of the antibodies of this invention and cytotoxic moieties are made, for example, by ligating to the antibody coding sequence all or part of the coding sequence for a cytotoxic non-immunoglobulin polypeptide. Such non-immunoglobulin polypeptides include polypeptide toxins such as ricin, diphtheria toxin, or Pseudomonas exotoxin. Also, the conjugates can be prepared by in vitro methods. For example, immunotoxins may be constructed using a disulfide exchange reaction or by forming a thioether bond between the antibody and the toxin polypeptide. Examples of suitable reagents for this purpose include iminothiolate and methyl-4-mercaptobutyrimidate. Suitable fusion partners for the antibodies of this invention include viral sequences, cellular receptors such as the T-cell receptor, cytokines such as TNF, interferons, or interleukins, and other biologically or immunologically active polypeptides. Typically such non-immunoglobulin fusion polypeptides are substituted for the constant domains of an antibody of the invention. Alternatively, they are substituted for the variable domains of one antigen-combining site of an antibody of the invention.
Substitution of the Fc or complementary determining regions (CDRs) of an antibody having specificity for non-hLIF antigen will create a chimeric bivalent antibody comprising one antigen-combining site having specificity for hLIF and another antigen-combining site having specificity for a different antigen. In such embodiments, the light chain is deleted and the Fv domain of the heavy chain is substituted with the desired polypeptide. These antibodies are termed bivalent or polyvalent, depending upon the number of immunoglobulin "arms" possessed by the Fc domain employed (IgMs will be polyvalent). An antibody also may be rendered multivalent by intracellular recombination of antibodies having more than one specificity. For instance, an antibody in some embodiments is capable of binding hLIF as described elsewhere herein but is also capable of binding a T-cell, osteoblast, or liver cell surface antigen. In the case of T-cells, such antigens include CD3, CD4, CD8, CD18, CD11a, CD11b or CD11c. Examples of antibodies to cell surface antigens are well known. The multispecific, multivalent antibodies are made by cotransforming a cell with DNA encoding the heavy and light chains of both the anti-hLIF antibody and the anti-cell surface antigen antibody. Those expressed antibodies having the desired multispecific, multivalent structure then are recovered by immunoaffinity chromatography or the like. Alternatively, such antibodies are made from monovalent antibodies which are recombined in vitro in conventional fashion.
Monovalent antibodies also are made by techniques that are conventional per se. Recombinant expression of light chain and a modified heavy chain is suitable. The heavy chain is truncated generally at any point in the Fc region so as to prevent heavychain crosslinking. Alternatively, the relevant cystsines are substituted with another residue or deleted so as to prevent crosslinking. In vitro methods also are used to produce monovalent antibodies. For example, Fab fragments are prepared by enzymatic cleavage of intact antibody.
For diagnostic applications, the antibodies of the invention typically will be labeled with a detectable moiety. The detectable moiety can be any one which is capable of producing, either directly or indirectly, a detectable signal. For example, the detectable moiety my be a radioisotope, such as 3 H, 14 C, 32 P, 35 S, or 125 I, a fluorescent or chemiluminescent compound, such as fluorescein isothiocyanate, rhodamine, or luciferin; radioactive isotopic labels, such as, for example, 125 I, 32 P, 14 C, technicium, or 3 H; or an enzyme, such as alkaline phosphatase, beta-galactosidase or horseradish peroxidase.
Any method known in the art for separately conjugating the antibody to the detectable moiety may be employed, including those methods described by Hunter, et al., Nature 144:945 (1962); David, et al., Biochemistry 13:1014 (1974); Pain, et al., J. Immunol. Meth. 40:219 (1981); and Nygren, J. Histochem. and Cytochem. 30:407 (1982).
The antibodies of the present invention my be employed in any known assay method, such as competitive binding assays, direct and indirect sandwich assays, and immunoprecipitation assays. Zola, Monoclonal Antibodies: A Manual of Techniques, pp.147-158 (CRC Press, Inc., 1987).
Competitive binding assays rely on the ability of a labeled standard (which may be hLIF or an immunologically reactive portion thereof) to compete with the test sample analyte (hLIF) for binding with a limited amount of antibody. The amount of hLIF in the test sample is inversely proportional to the amount of standard that becomes bound to the antibodies. To facilitate determining the amount of standard that becomes bound, the antibodies generally are insolubilized before or after the competition, so that the standard and analyte that are bound to the antibodies may conveniently be separated from the standard and analyte which remain unbound.
Sandwich assays involve the use of two antibodies, each capable of binding to a different immunogenic portion, or epitope, of the protein to be detected. In a sandwich assay, the test sample analyte is bound by a first antibody which is immobilized on a solid support, and thereafter a second antibody binds to the analyte, thus forming an insoluble three part complex. David & Greene, U.S. Pat. No. 4,376,110. The second antibody may itself be labeled with a detectable moiety (direct sandwich assays) or may be measured using an anti-immunoglobulin antibody that is labeled with a detectable moiety (indirect sandwich assay). For example, one type of sandwich assay is an ELISA assay, in which case the detectable moiety is an enzyme.
The antibodies of the invention also are useful for in vivo imaging, wherein an antibody labeled with a detectable moiety such as a radio-opaque agent or radioisotope is administered to a host, preferably into the bloodstream, and the presence and location of the labeled antibody in the host is assayed. This imaging technique is useful in the staging and treatment of neoplasms or bone disorders. The antibody may be labeled with any moiety that is detectable in a host, whether by nuclear magnetic resonance, radiology, or other detection means known in the art.
For therapeutic applications, the antibodies of the invention are administered to a mammal, preferably a human, in a pharmaceutically acceptable dosage form. They are administered intravenously as a bolus or by continuous infusion over a period of time, by intramuscular, subcutaneous, intra-articular, intrasynovial, intrathecal, oral, topical, or inhalation routes. When the antibody possesses the suitable activity it is also suitably administered by intratumoral, peritumoral, intralesional, or perilesional routes, to exert local as well as systemic therapeutic effects.
Such dosage forms encompass pharmaceutically acceptable carriers that are inherently nontoxic and nontherapeutic. Examples of such carriers include ion exchangers, alumina, aluminum stearate, lecithin, serum proteins, such as human serum albumin, buffers such as phosphate or glycine, sorbic acid, potassium sorbate, partial glyceride mixtures of saturated vegetable fatty acids, water, salts, or electrolytes such as protamine sulfate, sodium chloride, metal salts, colloidal silica, magnesium trisilicate, polyvinyl pyrrolidone, cellulosic polymers, and polyethylene glycol. Carriers for topical or gel-based forms of antibody include polysaccharides such as sodium carboxymethylcellulose or methylcellulose, polyvinylpyrrolidone, polyacrylates, polyoxyethylene-polyoxypropylene-block polymers, polyethylene glycol, and wood wax alcohols. Conventional depot forms include, for example, microcapsules, nano-capsules, liposomes, plasters, sublingual tablets, and polymer matrices such as polylactide:polyglycolide copolymers. When present in an aqueous dosage form, rather than being lyophilized, the antibody typically will be formulated at a concentration of about 0.1 mg/ml to 100 mg/ml, although wide variation outside of these ranges is permitted.
For the prevention or treatment of disease, the appropriate dosage of antibody will depend on the type of disease to be treated, as defined above, the severity and course of the disease, whether the antibodies are administered for preventive or therapeutic purposes, the course of previous therapy, the patient's clinical history and response to the antibody, and the discretion of the attending physician. The antibody is suitably administered to the patient at one time or over a series of treatments.
Depending on the type and severity of the disease, about 0.015 to 15 mg of antibody/kg of patient weight is an initial candidate dosage for administration to the patient, whether, for example, by one or more separate administrations, or by continuous infusion. For repeated administrations over several days or longer, depending on the condition, the treatment is repeated until a desired suppression of disease symptoms occurs. However, other dosage regimens may be useful and are not excluded herefrom.
According to another embodiment of the invention, the effectiveness of the antibody in preventing or treating disease may be improved by administering the antibody serially or in combination with another agent that is effective for the same clinical objective, such as another antibody directed against a different epitope than the principal antibody, or one or more conventional therapeutic agents known for the intended therapeutic indication, e.g. prevention or treatment of conditions associated with excessive bone resorption such as osteoporosis.
The antibodies of the invention also are useful as affinity purification agents. In this process, the antibodies against hLIF are immobilized on a suitable support, such a SEPHADEX resin or filter paper, using methods well known in the art. The immobilized antibody then is contacted with a sample containing the hLIF to be purified, and thereafter the support is washed with a suitable solvent that will remove substantially all the material in the sample except the hLIF, which is bound to the immobilized antibody. Finally, the support is washed with another suitable solvent, such as glycine buffer, pH 5.0, that will release the hLIF from the antibody.
The following examples are offered by way of illustration only and are not intended to limit the invention in any manner. All patent and literature references cited throughout the specification are expressly incorporated.
EXAMPLE 1
Preparation of Monoclonal Antibodies
Recombinant hLIF, Schmelzer, et al., Prot. Exp. Purificat. 1:54-62 (1990), was conjugated to keyhole limpet hemocyanin (KLH) according to the method of Nicolson, et al. Proc. Nat. Acad. Sci. 68:942 (1971). Balb/c mice were injected intraperitoneally with 10 μg of the resulting KLH-hLIF conjugate three times at two week intervals, and were boosted with the same dose of KLH-hLIF conjugate four days prior to cell fusion.
Spleen cells from the immunized mice were fused with P 3 X63Ag8U 1 myeloma cells, Yelton, et al., Curr. Top. Microbiol. Immunol. 81:1-7 (1978), using 35% polyethylene glycol (PEG) as described. Laskov, et al., Cell. Immunol. 55:251-264 (1980). Hybridomas were selected in HAT medium.
Supernatants from hybridoma cell cultures were screened for anti-hLIF antibody production by an ELISA assay using hLIF-coated microtiter plates. Antibody that was bound to hLIF in each of the wells was determined using alkaline phosphatase-conjugated goat anti-mouse IgG immunoglobulin and the chromogenic substrate p-nitrophenyl phosphate. Harlow & Lane, Antibodies: A Laboratory Manual, p.597 (Cold Spring Harbor Laboratory, 1988). Hybridomas thus determined to produce anti-hLIF monoclonal antibodies were subcloned by limiting dilution.
Initially, 65 hybridomas producing anti-hLIF monoclonal antibodies were identified by ELISA. Of those, four hybridomas, designated D3.14.1, D4.16.9, D25.1.4, and D62.3.2 were chosen for further characterization. Ascites were produced in Balb/c mice and monoclonal antibodies were purified using protein-G conjugated 4B SEPHAROSE. Hereinafter, the monoclonal antibodies produced by the D3.14.1, D4.16.9, D25.1.4, and D62.3.2 hybridomas (designated ATCC accession no. HB 11076, ATCC accession no. HB 11077, ATCC accession no. HB 11074, and ATCC accession no. HB 11075, respectively, and deposited on Jun. 23, 1992, with the American Type Culture Collection, 12301 Parklawn Drive, Rockville, Md., USA) are referred to as mAb D3.14.1, mAb D4.16.9, mAb D25.1.4, and mAb D62.3.2, respectively.
EXAMPLE 2
Characterization of Monoclonal Antibodies
A. Antigen Binding Specificity
The binding specificities of the anti-hLIF monoclonal antibodies produced by the D3.14.1, D4.16.9, D25.1.4, and D62.3.2 hybridomas were determined by ELISA. 10 μg/ml of purified monoclonal antibody was added to the wells of microtiter plates that previously had been coated with 2 μg of hLIF, human IL-1, human IL-3, human IL-6, human TNF-α, human G-CSF, human GM-CSF, or human Oncostatin M. IL-6, G-CSF, and Oncostatin M are known to share significant amino acid sequence homologies with hLIF. Rose, et al., Proc. Nat. Acad. Sci. 88:8641-8645 (1991).
Bound antibody was detected with horse radish peroxidase (HRP) conjugated goat anti-mouse IgG immunoglobulins. The HRP color reaction was developed by the addition of phosphate buffered saline (PBS) containing 0.4 mg/ml. of o-phenylenediamine diamine dihydrochloride plus 0.4 μl/ml 30% hydrogen peroxide. The reaction was stopped by the addition of 100 μl/well 2.25M sulfuric acid. The color reaction was measured at 490 nm with an ELISA plate reader.
The results of those assays showed that each of mAb D3.14.1, mAb D4.16.9, mAb D25.1.4, and mAb D62.3.2 binds to hLIF, and not appreciably to those other protein factors, except that mAb D3.14.1 showed a weak cross-reactivity with human Oncostatin M. The results of the assay of mAb D25.1.4 reactivity with various protein factors are shown in FIG. 1. The other monoclonal antibodies showed similar binding specificity for hLIF.
Additionally, the binding of mAb D3.14.1, mAb D4.16.9, mAb D25.1.4, and mAb D62.3.2 to murine LIF was determined by ELISA. As shown in FIGS. 2A-2B, mAb D4.16.9 and mAb D62.3.2 bound to murine LIF with about the same affinity as to hLIF, mAb D25.1.4 bound to murine LIF with lower affinity than to hLIF, and mAb D3.14.1 did not detectably bind to murine LIF.
B. Epitope Mapping
A competitive binding ELISA was used to determine whether the monoclonal antibodies produced by the D3.14.1, D4.16.9, D25.1.4, and D62.3.2 hybridomas bind to the same or different epitopes (sites) within hLIF. Anti-hLIF antibodies (mAb D3.14.1, mAb D4.16.9, mAb D25.1.4, and mAb D62.3.2) and an irrelevant anti-human vascular endothelial growth factor (hVEGF) antibody (mAb A3.13.1) were conjugated with horse radish peroxidase (HRP) and the competitive binding ELISA was performed as described by Kim, et al., Infect. Immun. 57:944-950 (1989).
As shown in FIG. 3, the inhibition pattern of the binding of each HRP-conjugated anti-hLIF antibody was unique, making it likely that each antibody recognizes a different epitope on hLIF. The binding of each of mAb D3.14.1 and mAb D25.1.4 was inhibited only by itself. The binding of mAb D4.16.4 was inhibited by mAb D3.14.1 and mAb D25.1.4 as well as mAb D4.16.4, while the binding of mAb D3.14.1 and mAb D25.1.4 was not blocked by mAb D4.16.9. The binding of mAb D62.3.2 was inhibited by mAb D25.1.4, but the binding of mAb D25.1.4 was not inhibited by mAb D62.3.2.
C. Isotyping
The isotypes of the anti-hLIF monoclonal antibodies produced by the D3.14.1, D4.16.9, D25.1.4, and D62.3.2 hybridomas were determined by ELISA. Hybridoma cell culture supernatants were added to the wells of microtiter plates that had previously been coated with hLIF. The captured anti-hLIF monoclonal antibodies were incubated with different isotype-specific alkaline phosphatase-conjugated goat anti-mouse immunoglobulins (Fisher Biotech, Pittsburgh, Pa. USA), and the binding of the conjugated antibodies to the anti-hLIF monoclonal antibodies was determined by the addition of p-nitrophenyl phosphate. The color reaction was measured at 405 nm with an ELISA plate reader.
By that method, the isotype of the monoclonal antibodies produced by each of the D3.14.1, D4.16.9, D25.1.4, and D62.3.2 hybridomas was determined to be IgG1.
D. Binding Affinity
The affinities of the anti-hLIF monoclonal antibodies produced by the D3.14.1, D4.16.9, D25.1.4, and D62.3.2 hybridomas were determined by a competitive binding assays. A predetermined sub-optimal concentration of monoclonal antibody was added to samples containing 20,000-40,000 cpm 125 I-hLIF (1-2 ng) and various known amounts of unlabeled hLIF (1-1000 ng) in 0.2 ml. phosphate buffered saline (PBS) containing 0.5% bovine serum albumin (BSA) and 0.05% Tween 20. After 1 hour at room temperature, 100 μl of goat anti-mouse Ig antisera (Pel-Freez, Rogers, Ark. USA) were added, and the mixtures were incubated another hour at room temperature. Complexes of antibody and bound protein (immune complexes) were precipitated by the addition of 500 μl of 6% polyethylene glycol (PEG, mol. wt. 8000) at 4° C., followed by centrifugation at 2000×G. for 20 min. at 4° C. The amount of 125 I-hLIF bound to the anti-hLIF monoclonal antibody in each sample was determined by counting the pelleted material in a gamma counter.
Affinity constants were calculated from the data by Scatchard analysis. Munson, et al., Anal. Biochem. 107:220 (1980). The affinity of each of mAb D3.14.1, mAb D4.16.9, mAb D25.1.4, and mAb D62.3.2 was determined to be in the range of about 1.4×10 9 liters/mole to 1.7×10 10 liters/mole.
F. Inhibition of hLIF Activity
The antibodies produced by the D3.14.1, D4.16.9, D25.1.4, and D62.3.2 were assayed for their ability to neutralize the ability of hLIF to inhibit growth of M1-T22 murine myeloid leukemic cells, Tomida, et al., Biochem. J. 176:655-669 (1978), and the ability of hLIF to induce release of intracellular calcium (Ca 2+ ) from Jurkat human T-cells. M1-T22 is a subclone of the murine myeloid leukemia cell line M1. Tomida, et al., Biochem. J. 176:655-669 (1978). Jurkat human T-cells were originally described by Weiss, et al., J. Immunol. 133:123-128 (1984). The Jurkat human T-cells used in the assays described herein were from a stock maintained at Genentech, Inc.
The M1-T22 cell growth inhibition assay was carried out as described by Lowe, et al., DNA 8:351-359 (1989). Generally, M1-T22 cells at 104 cells/were suspended in the wells of microtiter plates in minimal essential medium (MEM) supplemented with 10% fetal calf serum (FCS), 2 mM nonessential amino acids, 1 mM sodiumpyruvate, 1 mM glutamine, penicillin, and streptomycin, in the presence of 0.1-0.2 ng/ml recombinant hLIF, with or without added anti-hLIF monoclonal antibodies (at 5×, 25×, or 125× molar excess relative to hLIF).
As shown in FIG. 4, mAb D25.1.4 blocked up to 87% of the M1-T22 growth inhibition activity of hLIF at a 1:5 molar ratio of antigen to antibody. mAb D25.1.4 blocked up to 90% of the M1-T22 growth inhibition activity of hLIF at a 1:25 molar ratio of antigen to antibody. mAb D3.14.1 and mAb D4.16.9 only minimally blocked the M1-T22 growth inhibition activity of hLIF.
In the course of making the present invention, it was found that hLIF induces an increase in cytoplasmic calcium (Ca 2+ ) concentration in Jurkat human T-cells. To determine the ability of anti-hLIF monoclonal antibodies to inhibit that activity of hLIF, Jurkat human T-cells at 10 6 cells/ml were loaded with 5 μM indo-1 acetoxymethylester, Grynkiewicz, et al., J. Biol. Chem. 260:3440-3450 (1985), for 15 minutes at 37° C. as described. June, et al., Pathol. Immunopatho. Res. 7:409-432 (1988). The cells were then washed with RPMI medium without Ca 2+ and Mg 2+ , and resuspended in the same medium. 10 μl of anti-hLIF monoclonal antibody was incubated with 100 μl of hLIF (5 μg/ml) for one hour. hLIF alone or an antibody-hLIF mixture was then added to the indo-1 loaded Jurkat cell cultures. Immediately after, level of free cytosolic Ca 2+ in the cells was determined by fluorescence activated cell sorting, using a Coulter 753 cell sorter and 200 mW UV excitation (351.1-363.8 nm), with fluorescence emission collected as a ratio of 405 nm/525 nm as described by June, et al., Pathol. Immunopathol. Res. 1:409-432 (1988).
As shown in FIGS. 5A-5F, hLIF (not pre-incubated with antibody) induced an increase in intracellular Ca 2+ in the Jurkat cells within several minutes after its addition to the cell cultures. Preincubation of hLIF with any one of mAb D4.16.9, mAb D25.1.4, or mAb D62.3.3 reduced or eliminated the hLIF-induced increase in intracellular. Ca 2+ . Preincubation of hLIF with mAb D3.14.1 had little or no effect on hLIF-induced increase in intracellular Ca 2+ .
To determine the effect of the monoclonal antibodies on hLIF binding to its receptors, 125 I-hLIF binding to M1-T22 cells was compared in the presence and absence of anti-hLIF monoclonal antibody. 125 I-hLIF (5×10 4 cpm/2 ng) was incubated with various amounts of antibody (either 1×, 10×, or 50× the molar amount of hLIF) in a final volume of 100 μl for 30 minutes at 37° C. 10 6 M1-T22 cells were then added to the antibody-hLIF mixture and incubation continued for 30 minutes at 37° C. Unbound 125 I-hLIP was separated from bound 125 I-hLIF by loading the mixtures onto a solution of 20% sucrose, 0.1% bovine serumalbumin (BSA) in phosphate buffered saline (PBS) and centrifuging at 300×G for 10 minutes. The supernatant was removed and the radioactivity associated with the pellet was counted in a gamma counter.
As shown in FIG. 6, the anti-hLIF antibodies differed in their ability to block hLIF binding to its receptors. At a 50× molar excess of antibody to 125 I-hLIF, mAb D25.1.4, mAb D62.3.2, mAb 3.14.1, and mAb 4.16.9 reduced 125 I-hLIF binding by about 95%, 65%, 10%, and 30%, respectively. By comparison, 125 I-hLIF binding to M1-T22 cells was reduced about 80% by the addition of a 1000-fold molar excess of unlabeled hLIF.
EXAMPLE 3
Use of Anti-HLIF Monoclonal Antibodies in ELISA to Detect Human LIF
To determine levels of hLIF in clinical or other samples, and to distinguish hLIF from other protein factors, an ELISA was developed using mAb 4.16.9 as a capture antibody and horse radish peroxidase-conjugated mAb 3.14.1 as a detection antibody. As shown in FIG. 7, using that combination of antibodies in an ELISA, as little as 0.1 ng hLIF could be detected.
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The invention relates to monoclonal antibodies to human leukemia inhibitory factor. The disclosed monoclonal antibodies are believed to recognize unique epitopes on hLIF and are useful in the treatment of conditions wherein the presence of hLIF causes or contributes to undesirable pathological effects, such as cachexia, dysregulated calcium metabolism, or excessive bone cell proliferation, and in the detection of hLIF, for example, in clinical samples or specimens.
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TECHNICAL FIELD
This invention relates to a pharmaceutical composition of nalbuphine and sulindac having analgesic activity in mammals, and to a method of use of the composition to alleviate pain in mammals.
BACKGROUND OF THE INVENTION
More active analgesic combinations are in constant demand because they offer the attractive possibility of relieving pain with reduced dosages thereby diminishing the expected side effects and toxicity that would result from the otherwise required higher dosages.
U.S. Pat. No. 3,393,197, issued to Pachter and Matossian on July 16, 1968, discloses N-substituted-14-hydroxydihydronormorphines, including the N-cyclobutylmethyl derivative, commonly called nalbuphine: ##STR1## Pachter and Matossian and others, such as H. W. Elliott, et al., J. Med. (Basel), 1, 74-89 (1970); H. Blumberg, et al., Pharmacologist, 10, 189 (Fall 1968); P. Roberts, Drugs of the future, 2, 613-5 (1977), disclose the use of nalbuphine as an analgesic for the control of moderate to severe pain.
U.S. Pat. No. 4,237,140, issued to J. R. Dudzinski on Dec. 2, 1980, describes an analgesic mixture of nalbuphine and acetaminophen. U.S. Pat. No. 4,282,215, issued to J. R. Dudzinski and W. K. Schmidt on Aug. 4, 1981, describes an analgesic mixture of nalbuphine and aspirin.
U.S. Pat. Nos. 3,654,349 and 3,647,858 issued to Shen et al. and Hinckley et al., respectively, disclose the synthesis and analgesic utility of (Z)-5-fluoro-2-methyl-1-{[4-(methylsulfinyl)phenyl]methylene}-1H-indene-3-acetic acid, commonly called sulindac: ##STR2## Van Arman et al., Fed. Proc., 31, 577 (1972) disclose the pharmacological properties and metabolism of sulindac. U.S. Pat. No. 4,207,340 issued to J. F. Gardocki describes an analgesic mixture of sunlindac and acetaminophen.
SUMMARY OF THE INVENTION
It has now been found that combinations of nalbuphine and sulindac provide unexpectedly enhanced analgesic activity. Specifically, a pharmaceutical composition comprising a combination of synergistically effective analgesic amounts of nalbuphine, or a pharmaceutically suitable salt thereof, and sulindac, or a pharmaceutically suitable salt thereof, has been found to provide enhanced pain relief in mammals. Another aspect of the invention comprises the method of alleviating pain in a mammal by administering an effective analgesic amount of the composition described above to the mammal.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE is an isobologram plot characterizing effective pain relieving doses which produce analgetic responses in one half the mice subjected to the phenyl-p-benzoquinone induced writhing test at various dose ratios of nalbuphine and sulindac.
DETAILED DESCRIPTION OF THE INVENTION
Nalbuphine, which has the chemical name (-)-17-(cyclobutylmethyl)-4,5α-epoxymorphinan-3,6α,14-triol, and its preparation are described in U.S. Pat. No. 3,393,197, the disclosure of which is hereby incorporated by reference. Sulindac, which has the chemical name (Z)-5-fluoro-2-methyl-1-{[4-(methylsulfinyl)phenyl]methylene}-1H-indene-3-acetic acid, and its preparation are described in U.S. Pat. Nos. 3,654,349 and 3,647,858, the disclosures of which are hereby incorporated by reference. When the terms nalbuphine or sulindac are used herein, it is to be understood that any of the pharmaceutically suitable salts thereof which have analgesic properties in man and other mammals are included by the term. For nalbuphine, such salts include the hydrochloride, hydrobromide, hydroiodide, sulfate, bisulfate, nitrate, citrate, tartrate, bitartrate, phosphate, malate, maleate, fumarate, succinate, acetate and pamoate, while for sulindac, pharmaceutically suitable salts would include those of calcium, potassium, and sodium.
In the composition of the invention, nalbuphine and sulindac are combined and have been utilized at dose ratios based on weight of nalbuphine to sulindac of from 1:0.175 to 1:4.37 in mice subjected to the phenyl-p-benzoquinone induced writhing test to establish analgetic effectiveness. The phenyl-p-benzoquinone induced writhing test in mice [H. Blumberg et al., Proc. Soc. Exp. Biol. Med., 118, 763-766 (1965)] is a standard procedure for detecting and comparing the analgetic activity of different classes of analgesic drugs with a good correlation with human analgetic activity. Data for the mouse, as presented in the isobologram, can be translated to other species where the orally effective analgesic dose of the individual compounds is known or can be estimated. The method simply consists of reading the % ED50 DOSE for each dose ratio on the best fit regression analysis curve from the mouse isobologram, multiplying each component by its effective species dose, and then forming the ratio of the amount of nalbuphine to sulindac. This basic correlation for analgesic properties enables estimation of the range of human effectiveness. [E. W. Pelikan, The Pharmacologist, 1, 73 (1959).]
Application of an equieffective dose substitution model and a curvilinear regression analysis utilizing all the data for the individual compounds and various dose ratios establishes the existence of unexpectedly enhanced analgetic activity of combinations of nalbuphine and sulindac, i.e., the resulting activity is greater than the activity expected from the sum of the activities of the individual components.
The composition of the invention presents the opportunity of obtaining relief from pain with reduced dosages of nalbuphine and sulindac, thereby diminishing the side effects and toxicity which would result from the otherwise required amounts of the individual drug components.
DOSAGE FORMS
The combination of analgetic agents of the invention can be administered to treat pain by any means that produces contact of the active agent with the agent's site of action in the body of a mammal. The composition of the invention can be administered by any conventional means available for use in conjunction with pharmaceuticals. It can be administered alone, but is generally administered with a pharmaceutical carrier selected on the basis of the chosen route of administration and standard pharmaceutical practice.
The dosage administered will, of course, vary depending upon known factors such as the pharmacodynamic characteristics of the particular agent, and its mode and route of administration; age, health, and weight of the recipient; nature and extent of symptoms, kind of concurrent treatment, frequency of treatment, and the effect desired. Usually a daily dosage can be such that the active ingredient is administered at a daily dosage of from about 0.25 to 7.50 milligrams per kilogram (mg/kg) of body weight of nalbuphine and from about 1.0 to 13 mg/kg of sulindac. Ordinarily, administration of the composition of the invention in divided doses 2-5 times a day or in a sustained release form is effective to obtain desired results.
Dosage forms (compositions) suitable for internal administration contain from about 15 milligrams to about 600 milligrams of active ingredients per unit. In these pharmaceutical compositions the active ingredients will ordinarily be present in an amount of about 0.5-95% by weight based on the total weight of the composition.
The active ingredients can be administered orally in solid dosage forms, such as capsules, tablets, and powders, or in liquid dosage forms, such as elixirs, syrups, and suspensions.
Gelatin capsules contain the active ingredients and powdered carriers, such as lactose, sucrose, mannitol, starch, cellulose derivatives, magnesium stearate, stearic acid, and the like. Similar diluents can be used to make compressed tablets. Both tablets and capsules can be manufactured as sustained release products to provide for continuous release of medication over a period of hours. Compressed tablets can be sugar coated or film coated to mask any unpleasant taste and protect the tablet from the atmosphere, or enteric coated for selective disintegration in the gastrointestinal tract.
Liquid dosage forms for oral administration can contain coloring and flavoring to increase patient acceptance.
Suitable pharmaceutical carriers are described in Remington's Pharmaceutical Sciences, A. Osol, a standard reference text in this field.
Useful pharmaceutical dosage-forms for administration of the composition of the invention can be illustrated by the following examples.
EXAMPLE 1
______________________________________Nalbuphine/Sulindac Tablets (30/30 mg)Formula mg/Tablet______________________________________Nalbuphine HCl 30.0Sulindac 30.0Microcrystalline Cellulose 170.0Starch, modified 16.0Stearic Acid 4.0 250.0______________________________________
EXAMPLE 2
______________________________________Nalbuphine/Sulindac Tablets (30/150 mg)Formula mg/Tablet______________________________________Nalbuphine HCl 30.0Sulindac 150.0Microcrystalline Cellulose 150.0Starch, modified 14.0Stearic Acid 6.0 350.0______________________________________
EXAMPLE 3
______________________________________Nalbuphine/Sulindac Tablets (7.5/300 mg)Formula mg/Tablet______________________________________Nalbuphine HCl 7.5Sulindac 300.0Microcrystalline Cellulose 212.5Starch, modified 22.0Stearic Acid 8.0 550.0______________________________________
EXAMPLE 4
______________________________________Nalbuphine/Sulindac Capsules (30/30 mg)Formula mg/Capsule______________________________________Nalbuphine HCl 30.0Sulindac 30.0Microcrystalline Cellulose 170.0Starch, modified 112.0Starch 8.0 350.0______________________________________
EXAMPLE 5
______________________________________Nalbuphine/Sulindac Capsules (30/150 mg)Formula mg/Capsule______________________________________Nalbuphine HCl 30.0Sulindac 150.0Microcrystalline Cellulose 150.0Starch, modified 12.0Starch 8.0 350.0______________________________________
EXAMPLE 6
______________________________________Nalbuphine/Sulindac Capsules (7.5/300 mg)Formula mg/Capsule______________________________________Nalbuphine HCl 7.5Sulindac 300.0Microcrystalline Cellulose 110.0Starch, modified 9.5Starch 8.0 435.0______________________________________
TEST METHODS
The unexpectedly enhanced analgetic activity obtained in the method of the invention is evidenced by tests conducted on mice. Male CF 1 mice obtained from Charles River Breeding Laboratories, fasted for 16-22 hours and weighing 18-22 g at the time of testing are used throughout. All mice are dosed sequentially by the oral route with suspensions of sulindac and/or of nalbuphine hydrochloride solutions. A dosing volume of 10 ml/kg is used for each sequential solution or suspension. It will be appreciated by those skilled in the art that the enhanced activity will be obtained whether the sulindac and nalbuphine are administered simultaneously as a mixture or sequentially as the two individual components. All doses are coded and the test is performed under a code not known to the observer.
A stock suspension of sulindac is prepared by mixing 800 mg sulindac with 50 ml of an aqueous vehicle containing 2% by volume of Tween 80®, a pharmacological dispersant manufactured by Fisher Scientific Company and containing 100% polysorbate 80, and 1% by weight of Methocel® MC powder, a suspending agent manufactured by DOW Chemical Company and containing 100% methylcellulose, in distilled water. The mixture is sonicated at 150 watts for 1-2 minutes with an ultrasound system, then shaken for two hours at 280 oscillations/minute with 15-20 gm of glass beads. The resultant suspension contains 16 mg/ml of sulindac; all dosing suspensions are prepared by dilution of the stock suspension with the Methocel®/Tween 80® vehicle; the vehicle control is Methocel®/Tween 80®. All suspensions are prepared fresh daily.
Stock solutions of nalbuphine HCl are prepared by dissolving dry nalbuphine hydrochloride powder with distilled water. All dosing solutions are prepared by dilution of the stock solution with distilled water; the vehicle control is distilled water.
As indicated above, the standard procedure based upon the prevention of phenyl-p-benzoquinone induced writhing in mice is utilized to detect and quantify the analgetic activity of compositions containing nalbuphine and sulindac.
Mice, intubated with various doses of nalbuphine hydrochloride, sulindac, combined doses of nalbuphine hydrochloride and sulindac, or vehicle, are injected intraperitoneally with a challenge dose of phenyl-p-benzoquinone 5 minutes prior to the designated observation period. The phenyl-p-benzoquinone is prepared as an 0.1 mg/ml solution in 5% by volume of ethanol in water; the writhing dose is 1.25 mg/kg injected in a volume of 0.25 ml/20 g. For scoring purposes a "writhe" is indicated by whole body stretching or contraction of the abdomen; mice are observed 10 minutes for the presence or absence of writhing beginning 5 minutes after receiving the phenyl-p-benzoquinone dose. Each mouse is used only once, then discarded. The alleviation of pain is quantified by determining the dosage at which 50% of the mice in a test group exhibit an analgesic response for the composition being tested. This dosage as described herein is referred to as the ED50. All ED50 values and their 95% confidence limits are determined numerically by the computer-assisted methods of Finney. [D. J. Finney, "Probit Analysis", Third Edition, Cambridge University Press, Cambridge, England, 1971].
In order to study the interaction between nalbuphine and sulindac, 5 precise dosage ratios of nalbuphine hydrochloride and sulindac are selected. Four or five coded doses of each selected combination are studied for analgesic effectiveness at 40 minutes using an experimental design which permits coding and complete randomization of the separate dosage forms tested. Altogether 35 separate dosage forms are used and each form is represented in each experimental session. The experiments are continued by running experimental sessions with an equal number of mice per group being tested until the total number, N, of mice tested per group is 30.
The nature of the analgetic interaction (addition, synergism, or antagonism) is determined by graphing the results in a Loewe isobologram [S. Loewe, Pharm. Rev. 9:237-242 (1957)]. The isobologram is a quantitative method for measuring interactions between drugs where dose-effect relationships are depicted in a multi-dimensional array with lines connecting dose pairs that are equieffective in relationship to a common pharmacological endpoint. In this instance, the antiphenylquinone writhing test is used to estimate a common level of analgesic activity (ED50 dose) for the two component drugs separately and for each fixed dose-ratio combination. In the isobolographic figure, areas of dose addition, synergism, and/or antagonism are clearly defined by reference to the theoretical "ED50 Addition Line." According to Loewe's isobolographic theory, ED50's falling under the curve (between the ED50 Addition Line and the origin) would represent unexpectedly enhanced analgetic activity and combination ED50's located above the line would represent unexpectedly diminished analgetic activity.
Most importantly, the isobolographic technique permits a full range of doses and dose combinations to be examined where the proportion of the first drug to the second actually varies from 0 to infinity, and to determine, by virtue of the graphical display, whether any one or more of the paired drug combinations displays unique pharmacological properties in comparison to the entire body of data generated. The isobologram is also valuable for organizing the data in a form which is easily amenable to statistical assessment of observed differences.
The synergistic interaction of nalbuphine hydrochloride and sulindac on phenyl-p-benzoquinone induced writhing in mice is demonstrated by the data in Table I and in the FIGURE, the Loewe isobologram. In the isobolographic figure, the analgetic effect of nalbuphine alone is presented in the ordinate, and that of sulindac alone is on the abscissa. The dotted lines radiating from the origin represent the exact fixed dosage ratios based on weight of nalbuphine HCl:sulindac in the ranges of 1:0.175 to 1:4.37. ED50 values are marked on the ordinate and abscissa, representing nalbuphine and sulindac alone, and on the dotted radial lines, representing the compositions of nalbuphine and sulindac at the fixed dosage ratios. The arrows extending above and below each ED50 point represent the 95% confidence limits of the ED50's.
As drawn in the FIGURE, the solid diagonal line joining the ED50 values of the two drugs given separately represents the "ED50 Addition Line," the theoretical line for simple additivity of drug effects which would be observed in the absence of a synergistic response. The drawing clearly shows that in the method of the invention, all of the tested fixed ratio compositions give unexpectedly enhanced analgetic activity since the ED50 values for each of these ratios fall below the line of simple additivity.
By utilizing an equieffective dose substitution model and a statistical regression analysis of all of the data, one can obtain a more reliable assessment of the existence of a synergistic property, in this case unexpectedly enhanced analgetic activity. The effects of two compounds are additive if the response to a dose of the two in combination does not change when a portion of one is removed from the mixture and replaced by an equipotent portion of the other. If such substitution increases the response, the mixing together of the compounds is said to potentiate their effects and synergism exists.
Consider ED50 doses of mixtures of X units of compound B with Y units of compound A, whose ED50 doses are β and α, respectively. Given the hypothesis of additivity, all doses of mixtures satisfying the straight line relation,
Y=α-(α/β)X, (1)
will be ED50 doses. To test the hypothesis of additivity, ED50 doses of mixtures are estimated through probit analysis of data from experiments run at various ratios of A to B. Linear and curvilinear regression models are fitted to the data to estimate the amounts of A in respective ED50 doses, given the amount of B, (or, conversely, the amount of B, given A). If a curvilinear regression fit the data significantly better than a straight line regression, the hypothesis of additivity is refuted and synergism exists for the two compounds for the property of interest.
Values of Y calculated from the straight line of Equation 1, and values of Y calculated from the curvilinear regression are plotted against X on an ED50 isobologram to describe the synergism.
It is convenient to standardize the units of dose such that 100 units of either compound alone is its respective estimated ED50 dose. The additivity hypothesis, then, will be represented by a straight line from 100 on the Y-axis to 100 on the X-axis on the isobologram, and Equation (1) becomes:
Y=100-X.
The isobologram in the FIGURE shows the straight line additivity hypothesis for nalbuphine HCl and sulindac 40 minutes post oral dosing in the mouse antiphenylquinone writhing test. Data were standardized to the ED50 doses of nalbuphine HCl (30.8 mg/kg) and sulindac (21.2 mg/kg). Synergism is demonstrated by the regression fitted to ED50 dose levels estimated by probit analysis. Its curvilinearity is statistically significant.
The regression is fitted to the data by the method of least squares. Residual squared deviations about the line of best fit are minimized in directions along lines from the origin through respective data points on the isobologram, these lines making angles with X-axis, tan -1 (Y/X). This is accomplished by a transformation prior to the regression analysis. Its inverse is applied to transform the coordinates of the regression curve back to the X,Y coordinates of the isobologram.
Let D r be an ED50 dose of a mixture of A and B, where r is the fraction of compound B in the mixture; i.e.
r=X/(X+Y).
It follows from Equation 1 that ##EQU1## From the additivity hypothesis, the logarithms of the ED50 doses at various mixture ratios are a straight line function of (Log D r ). To test the hypothesis, polynomial regressions, as follows, are fitted to ED50 estimates from experimental data obtained at various mixture ratios: ##EQU2## The additivity hypothesis is refuted if a polynomial of degree higher than one fit the data significantly better than a straight line, ##EQU3##
Since X and Y are uniquely determined by F r and r, the coordinates of the regression are transformed readily to the coordinates of the isobologram.
If data are scaled to ED50 dose levels of 100 standard dose units, Equation (2) becomes
F.sub.s =log 100=2.
The additivity hypothesis implies that F s is independent of r s , and may be tested by analysis of the regression model ##EQU4## the subscripts, s, indicating that the data are scaled. A statistically significant regression will refute the hypothesis.
The method of least squares utilizes jointly the information contained in all of the separate data points. Statistical significance of the curvilinearity of the regression model establishes the existence of synergism (or antagonism) of the compounds in the biological system studied. The parameters in the model describe its intensity over the range of mixture ratios, from 0 to 1, the nature of which is seen readily when the regression is plotted on the isobologram. This method was used to determine the best-fitting ED50 regression line through the seven (7) ED50 data points representing equivalent levels of analgetic activity for each of the five (5) dose-ratios and for nalbuphine and sulindac alone given in Table I. As shown in the isobologram plot of the FIGURE, the calculated quartic polynomial "ED50 Regression Line" fits the data significantly better than the straight "ED50 Addition Line" as established by Fisher's F test, statistically significant at p≦0.005, to compare the goodness of fit between the straight line and curvilinear regressions. Thus, consistent with Loewe's isobolographic model, the hypothesis of anagetic additivity is refuted and analgetic synergism is established for all combinations of nalbuphine and sulindac.
By substitution of the expected analgetic activity of nalbuphine alone and sulindac alone from test results in other warm blooded mammals, it is possible to use the isobologram in conjunction with the correlation method discussed above to predict the equivalent range of maximum potentiating dosages for man. Thus utilizing the data of the present invention and the equivalent ratios in man, it is predicted that nalbuphine and sulindac would demonstrate analgetic potentiation over a range of doses exceeding 1:0.1 to 1:400.
As described above, all tests of statistical significance establishing the best fit regression equation for the experimental data and its difference from the ED50 Addition Line were carried out using stringent 95% confidence limits. The use of less stringent limits merely reinforces the conclusions.
It will be apparent that the instant specification and examples are set forth by way of illustration and not limitation, and that various modifications and changes may be made without departing from the spirit and scope of the present invention.
TABLE I__________________________________________________________________________ORAL NALBUPHINE/SULINDAC COMBINATIONS IN THEMOUSE ANTIPHENYLQUINONE WRITHING TEST40 MIN (N-30 Mice/Dose) ED50 AT 40 MINDRUG COMBINATIONS DRUG DOSE (mg/kg) (95% Confidence Limits)Nalbuphine HCl: Nalbuphine % MICE NalbuphineSulindac HCl Sulindac BLOCKED HCl Sulindac__________________________________________________________________________Control (0:0) 0 0 10.0% -- --Nalbuphine 5.45 0 16.7%Only (1:0) 10.9 0 40.0% 30.8 0.0 21.8 0 36.7% (18.0-45.0) 43.6 0 63.3% 87.2 0 90.0%1:0.175 4.54 0.792 10.0% 9.08 1.58 46.7% 11.5 2.01 18.2 3.17 76.7% (8.42-14.4) (1.47-2.51) 36.3 6.33 96.7% 72.7 12.7 100.0%1:0.435 3.63 1.58 13.3% 7.27 3.17 30.0% 10.1 4.39 14.5 6.33 83.3% (7.52-12.4) (3.27-5.38) 29.1 12.7 96.7% 58.1 25.3 100.0%1:0.872 2.73 2.38 6.7% 5.45 4.75 36.7% 7.32 6.39 10.9 9.5 80.0% (5.49-8.99) (4.79-7.85) 21.8 19.0 96.7% 43.6 38.0 100.0%1:1.74 1.82 3.17 30.0% 3.63 6.33 20.0% 6.13 10.7 7.27 12.7 83.3% (0.00-364) (0.00-633) 14.5 25.3 100.0% 29.1 50.7 100.0%1:4.37 0.908 3.96 10.0% 1.82 7.92 43.3% 2.26 9.87 3.63 15.8 80.0% (1.70-2.75) (7.41-12.0) 7.27 31.7 100.0% 14.5 63.3 100.0%Sulindac 0 4.75 20.0%Only (0:1) 0 9.5 20.0% 0.0 21.2 0 19.0 46.7% (16.6-25.2) 0 38.0 96.7%__________________________________________________________________________
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Pharmaceutical compositions of nalbuphine and sulindac have been found to exhibit unexpectedly enhanced analgesic activity by applying an analysis model which considers data characterizing the analgesic effect of both the pure components as well as the fixed dose ratio combinations. This synergism enables the use of lower doses of either or both drugs with a concomitant reduction in risk of possible side effects.
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BACKGROUND OF THE INVENTION
The present application claims priority under 35 U.S.C. § 119 to Japanese Patent Application No. 2003-059868, filed on Mar. 6, 2003, the disclosure of which is incorporated herein by reference in its entirety.
1. Field of the Invention
The present invention relates to reagent injection devices. More particularly, this invention relates to an injection device that injects a specified reagent (which need not but may contain cells, chemicals, etc.) into lesions and other areas of body tissue.
2. Description of the Related Art
In various medical procedures, catheters and other medical apparatuses have traditionally been inserted into components of the cardiovascular system, the gastrointestinal tract, the urinal tract, and other tubular organs of the human body. Recently, as illustrated in Japanese Patent Application Laid-open Nos. 2001-104487 and 2001-299927, reagent injection catheters have been used to inject specific reagents into lesions of body tissues.
Reagent injection catheters of the prior art typically consist of a tubular catheter body, a needle tube, and a needle. The needle usually projects out of the catheter body and pierces various areas of body tissue. However, conventional reagent injection devices are generally equipped with a long, flexible needle tube, which can become bent or retracted upon contact with the relatively hard lesions of body tissue. Consequently, it can be difficult to insert the needle to a desired depth or to a specific position in lesions of body tissues.
SUMMARY OF THE INVENTION
Preferred embodiments of the present invention comprise reagent injection devices that reliably allow a needle of a needle tube to pierce through tissues and lesions of tissues to a desired depth with a desired position.
Particularly preferred embodiments of the reagent injection device of the present invention comprise a main tube comprising a tubular body which is insertable into the human body. The main tube further comprises a projection hole on its exterior and a needle tube which preferably comprises a flexible tube with a needle at its tip. The needle tube is preferably inserted into the main tube and is movable in the axial direction, which causes the needle to project out of the projection hole of the main tube.
Embodiments of the device further comprise a reagent supplier configured to supply a specified reagent into the needle tube. The main tube can be inserted into the body, and the needle of the needle tube is preferably projected out of the projection hole of the main tube and caused to pierce a specified tissue in the body. A reagent is then delivered from the reagent supplier through the needle tube and is injected into the body tissue.
In preferred embodiments, the reagent injection device further comprises a first guide wire that is inserted into the main tube. The first guide wire is preferably axially movable and extends through a tip aperture provided at the front of the main tube, as viewed in the direction of its insertion into the body. Preferred embodiments also comprise a second guide wire that is inserted into the main tube. The second guide wire is preferably axially movable and extends through a side hole that opens in the direction orthogonal to both the opening direction of the projection hole and the opening direction of the aforementioned tip aperture.
In preferred embodiments, the extension-direction vectors of the first and second guide wires cross each other. Preferred embodiments of the present invention. ensure that the tip of the needle of the needle tube can be projected out of the projection hole of the tubular wall of the main tube, in a direction virtually orthogonal to the plane that includes the extension-direction vectors of the first guide wire and second guide wire, along with the axial-direction movement of the needle tube inside the main tube. This projection of the needle is achievable when the actual extension directions of the first and second guide wires do not cross each other but are displaced from each other.
In preferred embodiments of the reagent injection device, the plane formed by the first and second guide wires will virtually approximate the surface of the lesion of body tissue. This approximation can preferably occur when the first and second guide wires are positioned to extend out along the surface of the lesion of body tissue, by means, for example, of inserting the guide wires into a blood vessel running over the body tissue, as the needle of the needle tube is pierced into the lesion of body tissue. In this case, the needle will preferably project out of the projection hole in the main tube in a direction perpendicular to the surface of the lesion. This preferably enables the needle to pierce at specified position of the body tissue lesion.
Furthermore, when the needle is pierced into the body tissue, a majority of the reactive force generated as the needle progresses into the body tissue will act in a direction perpendicular to the surface of the body tissue. For example, the force will act in a direction perpendicular to the plane that includes the respective extension directions of the first and second guide wires, which is also the direction opposite to the progressing direction of the needle. Therefore, the reactive force will be divided and each component force can preferably be sufficiently and reliably supported by the first and second guide wires. This configuration preferably allows the needle to progress into the body tissue in a very smooth and reliable manner.
For the above reasons, a reagent injection device based on the present invention allows the needle of the needle tube to reliably pierce through to a desired depth at a specified position in the desired lesion of body tissue, even when the lesion is relatively hard. As a result, the effectiveness of the treatment or procedure of injecting a specified reagent into the lesion can be further increased.
One preferred embodiment of the reagent injection device comprises, within the aforementioned main tube, a first lumen that opens toward the outside through the tip aperture in the main tube. The device further comprises a second lumen that opens to the outside through the side hole, and a third lumen that opens to the outside through the projection hole. The first guide wire is preferably inserted into the first lumen and is preferably movable in the axial direction. The second guide wire is preferably inserted into the second lumen and is preferably movable in the axial direction. The needle tube is preferably inserted into the third lumen so that it is moveable in the axial direction. This configuration allows the first and second guide wires and needle tube to move smoothly in the axial direction within the main tube, thereby enabling the applicable medical technique to be performed more smoothly.
Another preferred embodiment of a reagent injection device based on the present invention allows the first lumen to open sideways through an insertion hole provided in the tubular wall at the rear end of the main tube, as viewed in the direction of its insertion into the body. Furthermore, this embodiment allows the first guide wire to be inserted into the first lumen through the insertion hole, while simultaneously allowing the second lumen to open to the rear through a rear-end aperture at the rear of the main tube. This embodiment preferably allows the second guide wire to be inserted into the second lumen through the rear-end aperture. By using this configuration, the first and second guide wires can each bend at a single location. The first guide wire can bend at the insertion position of the first lumen, and the second guide wire can bend at the extension position out of the second lumen. This configuration minimizes the bending of each guide wire. Instead of the first and second guide wires bending at the two locations of the insertion and extension positions into and out of the first and second lumens, each guide wire can preferably receive a favorably smaller slide resistance as it moves inside of each lumen. This results in an enhanced usability and operability of the reagent injection device.
An additional preferred embodiment of the present. reagent injection device comprises a first lumen and second lumen provided inside of the main tube. The plane that includes the center axes of the respective lumens preferably lies orthogonal to the opening direction of the projection hole. In such reagent injection devices, the needle at the tip of the needle tube can preferably be more reliably projected out of the projection hole in a direction orthogonal to the plane that includes the extension directions of the first and second guide wires. This preferably causes a majority of the reactive force, generated as the needle progresses into the body tissue, to be sufficiently and reliably supported by the first and second guide wires. Consequently, the needle will progress into the body tissue in a smoother and more reliable manner.
Yet another preferred embodiment comprises a third lumen positioned inside of the main tube so that the center of the projection hole is preferably positioned in the plane that includes the center axes of the third lumen and the main tube. This configuration allows the needle tube to be preferably positioned inside of the main tube in a more balanced manner, thus allowing smoother performance of the applicable medical technique.
In an embodiment of the reagent injection device based on the present invention, it is advantageous to position the aforementioned third lumen inside of the main tube in so that its center axis corresponds to the center axis of the main tube. Moreover, the first and second lumens are positioned inside of the main tube, on both sides of the third lumen, in such a way that their center axes are positioned in the same plane that includes the center axis of the third lumen. This configuration preferably causes the distance between the first and second lumens to be maximized, thereby increasing the distance between the first and second guide wires extending out of the first and second lumens. Consequently, a majority of the reactive force generated as the needle progresses into the body tissue can be sufficiently and reliably supported by the first and second guide wires.
Another preferred embodiment of the present invention comprises an expandable and/or shrinkable balloon attached to the exterior of the main tube. The embodiment preferably comprises a fourth lumen, that supplies a liquid for expanding the balloon, positioned within the main tube so that the center of the aforementioned projection hole is positioned in the same plane that includes the center axes of the fourth lumen and main tube. In a reagent injection device comprising this configuration, the main tube can preferably be fixed in a specified position in the blood vessel into which the main tube is inserted. This is preferably achieved by expanding the balloon inside of the blood vessel. This allows the needle to project out of the main tube and pierce a desired location of body tissue in a more reliable manner. The fourth lumen that supplies the liquid for expanding the balloon can preferably be positioned inside of the main tube in a more balanced manner. As a result, the applicable medical technique using the reagent injection device can be performed more smoothly.
In preferred embodiments, a guide surface is provided in the main tube that guides the needle into the projection hole by means of the frictional contact created by the needle and the axial movement of the needle tube. The guide surface is preferably formed with a convex pattern that curves in the opening direction of the projection hole toward the front of the main tube, as viewed in the direction of its insertion into the body. This configuration allows for a smoother projection of the needle out of the main tube, thus enabling smoother performance of the applicable medical technique.
In further embodiments, the needle at the tip of the needle tube preferably comprises a curved shape corresponding to the convex guide surface as formed inside the main tube. Consequently, the needle tube can preferably be caused to deform in a manner creating a deeper curve by combining the convex curved pattern of the guide surface and the curved shape at the tip of the aforementioned needle tube. The convex curved pattern of the guide surface and the curved shape at the tip of the needle tube are combined when the needle of the needle tube projects out of the projection hole in the main tube in a direction orthogonal to the plane that includes the extension directions of the first and second guide wires. This configuration preferably causes the needle tube to curve further and enables projection near the projection hole, which facilitates identification of the position of the tip of the needle tube through the projection hole. The needle tube preferably projects out of the projection hole at an angle closer to the right angle with respect to the axial direction of the main tube, which results in an increase in the component force that acts in a direction perpendicular to the axial direction of the main tube when the needle tube progresses into a desired location in the lesion of body tissue. Consequently, the needle tube can be inserted more smoothly into a desired location in the lesion of body tissue.
Another particularly preferred embodiment of the present invention comprises a flexible reagent injection device that comprises a main tube inserted into the body, a first axially moveable guide wire that is inserted into the main tube, a second guide wire that is inserted into the main tube and that can be extended out of the main tube and moved back and forth in a direction crossing with the first guide wire, an axially moveable needle tube that is inserted into the main tube, and a reagent supplier configured to supply reagent through the aforementioned needle tube. The needle tube is preferably formed to project out of the main tube in a direction virtually orthogonal to the plane that includes the respective extension-direction vectors of the first and second guide wires. The needle tube preferably projects out of the main tube in a direction virtually orthogonal to the plane that includes the respective extension-direction vectors of the first and second guide wires, so that the tip of the needle tube can reliably and smoothly be pierced and progressed into a specified position in the lesion of a body tissue. Additionally, a majority of the reactive force that is generated in the direction opposite to the needle-progressing direction in the lesion, when the tip of the needle tube progresses into the lesion of body tissue, will be sufficiently and reliably supported by the first and second guide wires. This allows the tip of the needle tube to progress into the lesion of body tissue in a smooth and reliable manner. Therefore, in this preferred embodiment the needle of the needle tube can be pierced in a reliable manner through to a desired depth at a specified position in the targeted lesion of body tissue, even when the lesion is hard. As a result, the effectiveness of the treatment or procedure of injecting a specified reagent into the targeted lesion of tissue can be significantly increased.
For purposes of summarizing the invention and the advantages achieved over the related art, certain objects and advantages of the invention have been described above. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.
Further aspects, features and advantages of this invention will become apparent from the detailed description of the preferred embodiments which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of this invention will now be described with reference to the drawings of preferred embodiments which are intended to illustrate and not to limit the invention.
FIG. 1 shows a schematic front view of a preferred reagent injection catheter of the present invention.
FIG. 2 shows an enlarged cross-sectional view of line II-II of FIG. 1 .
FIG. 3 shows a close up view of the positions of the center axes of the needle tube and first/second guide wires inserted into the catheter body of the reagent injection catheter shown of FIG. 1 .
FIG. 4 shows an enlarged view, with the exterior wall partially removed to show the internal structure, of a portion of the reagent injection catheter of FIG. 1 .
FIG. 4A shows a close-up view of the marker tube of FIG. 4 .
FIG. 5 shows injection of a specified reagent into a lesion in the myocardium using the reagent injection catheter shown in FIG. 1 , further illustrating the condition of the first guide wire and second guide wire inserted into the main blood vessel and branch blood vessel, respectively, at the surface of the myocardium.
FIG. 6 shows another example of injecting a specified reagent into a lesion in the myocardium using the reagent injection catheter shown in FIG. 1 , illustrating the condition of the needle pierced into the myocardium.
FIG. 7 shows a cross-sectional view of another example of a reagent injection catheter.
FIG. 8 shows a cross-sectional view of another example of a reagent injection catheter.
FIG. 9 shows a cross-sectional view of another example of a reagent injection catheter.
FIG. 10 shows a cross-sectional view of another example of a reagent injection catheter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The structures of reagent injection devices embodied by the present invention are explained below in detail by referring to the drawings, in order to further elaborate on the present invention.
FIGS. 1 and 2 show a front and cross sectional view, respectively, of a preferred embodiment of a reagent injection device of the present invention. FIGS. 1 and 2 , show a catheter body ( 10 ), or main tube, comprising a long tubular body. There is provided a needle tube ( 12 ) comprising a needle ( 11 ) at its tip, a first guide wire ( 14 ) and a second guide wire ( 16 ), each of which are inserted into the catheter body and movable in their respective axial directions.
The catheter body ( 10 ) preferably has a thickness (approximately 2.0 mm in diameter) and length that allows the catheter to be preferably inserted into the blood vessels extending from the thighs or wrists to the heart in the human body at any point over their entire lengths. The catheter body ( 10 ) preferably comprises flexible, tubular inner and outer layers comprising a specific resin, which in some preferred embodiments comprises sandwiching stainless wires. This construction ensures both appropriate stiffness and flexibility to enable smooth insertion into a winding blood vessel. Other preferred embodiments comprise various materials with desired elasticity known to those skilled in the art that could be used to construct such a catheter body ( 10 ), such as polyamide and other composite resin materials, Ni—Ti alloy and other ultra-elastic alloy materials, and stainless steel and other metals.
The catheter body ( 10 ) preferably further contains four independent lumens, from first through fourth ( 18 a through 18 d ), which preferably have different diameters and extend continuously in the longitudinal direction.
Of the four lumens ( 18 a through 18 d ), the first and second lumens ( 18 a , 18 b ) preferably have the same diameter, which is smaller than the third lumen ( 18 c ) but larger than the fourth lumen ( 18 d ). The third lumen ( 18 c ) preferably has the largest diameter, and the fourth lumen ( 18 d ) has the smallest diameter. The first and second lumens ( 18 a , 18 b ) are preferably arranged in such a way that the center axis (P 0 ) of the catheter body ( 10 ) is positioned in the plane (α) (indicated by the two-dot chain line in FIG. 2 ) that includes the center axes (P 1 , P 2 ) of the first and second lumens ( 18 a , 18 b ). In accordance with preferred embodiments, the third lumen ( 18 c ) is arranged in such a way that its center axis (P 3 ) corresponds to the center axis (P 0 ) of the catheter body ( 10 ) and is positioned at the center between the first lumen ( 18 a ) and second lumen ( 18 b ). Furthermore, the fourth lumen ( 18 d ) is preferably arranged in such a way that the plane (β) (indicated by the two-dot chain line in FIG. 2 ) that includes its center axis (P 4 ) and the center axis (P 3 ) of the third lumen ( 18 c ) lies orthogonal to the plane (α) that includes the center axes (P 1 , P 2 ) of the first and second lumens ( 18 a , 18 b ).
The catheter body ( 10 ) containing these four lumens ( 18 a through 18 d ) preferably comprises a tip aperture ( 20 ) that opens in the axial direction at the tip of the front end (right side in FIG. 1 ) as viewed in the insertion direction into the blood vessel. In addition, a projection hole ( 22 ) that opens to the side through the tubular wall is preferably formed in the catheter body ( 10 ) at a position slightly to the rear of the tip of its front end. Furthermore, a side hole ( 24 ) that penetrates through the tubular wall is preferably provided at a position further to the rear of the projection hole ( 22 ), at the front end of the catheter body ( 10 ).
As shown in FIGS. 2 and 3 , of the above three holes ( 20 , 22 , 24 ) provided at the front end of the catheter body ( 10 ), the tip aperture ( 20 ) and side hole ( 24 ) are preferably arranged in such a way that their centers (O 1 , O 2 ) are positioned in the plane (α) that includes the center axes (P 1 , P 2 ) of the first lumen ( 18 a ) and second lumen ( 18 b ). In accordance with preferred embodiments, the projection hole ( 22 ) is arranged in such a way that its center (O 3 ) is positioned in the aforementioned plane (β) that includes the center axis (P 0 ) of the catheter body ( 10 ) and that lies orthogonal to the plane (α). This preferably allows the side hole ( 24 ) to open perpendicularly to the opening direction of the tip aperture ( 20 ) and to that of the projection hole ( 22 ).
In one preferred embodiment, the tip aperture ( 20 ) provided at the front end of the catheter body ( 10 ) connects to the first lumen ( 18 a ), the side hole ( 24 ) connects to the second lumen ( 18 b ), and the projection hole ( 22 ) connects to the third lumen ( 18 c ). This preferred configuration allows the first lumen ( 18 a ) to open in the forward axial direction (right direction in FIG. 1 ) through the tip aperture ( 20 ) at the front end of the catheter body ( 10 ). The second lumen ( 18 b ) preferably opens sideways through the side hole ( 24 ) perpendicularly to the opening direction of the first lumen ( 18 a ), while the third lumen ( 18 c ) opens through the projection hole ( 22 ) perpendicularly to both the opening directions of the first lumen ( 18 a ) and the second lumen ( 18 b ) (downward direction in FIG. 1 ).
In accordance with preferred embodiments of the present invention, three connectors ( 28 , 30 , 32 ) are attached to the catheter body ( 10 ) at its rear end as viewed in the insertion direction into the blood vessel (left side in FIG. 1 ). The connectors ( 28 , 30 , 32 ) are preferably attached via a branching socket ( 26 ), which branches the catheter body ( 10 ) into three parts. In addition, an insertion hole ( 34 ) that penetrates through the tubular wall of the catheter body ( 10 ) is preferably provided at a specified distance from the front of the installation position of the branching socket ( 26 ) at the rear end of the catheter body ( 10 ). The insertion hole preferably opens in the direction opposite to the opening direction of the aforementioned side hole ( 24 ), along the direction of the diameter of the catheter body ( 10 ).
The three connectors ( 28 , 30 , 32 ) each preferably connect to the second through fourth lumens ( 18 b - 18 d ) provided inside of the catheter. body ( 10 ). The insertion hole ( 34 ) also preferably connects to the first lumen ( 18 a ). This configuration preferably allows the first lumen ( 18 a ) to open outward through the insertion hole ( 34 ) at the rear end of the catheter body ( 10 ) as viewed in the insertion direction into the blood vessel, while allowing the second, third and fourth lumen ( 18 b through 18 d ) to open outward through the three connectors ( 28 , 30 , 32 ).
In accordance with preferred embodiments, the needle tube ( 12 ) and first and second guide wires ( 14 , 16 ) are inserted into the catheter body ( 10 ) to allow movement in their respective axial directions. The first guide wire ( 14 ) is preferably inserted into the first lumen ( 18 a ) provided in the catheter body ( 10 ) through the insertion hole ( 34 ) provided in the tubular wall at the rear end of the catheter body ( 10 ). The second guide wire ( 16 ) is preferably inserted into the second lumen ( 18 b ) provided in the catheter body ( 10 ) through the rear-end aperture opening in the connector ( 28 ) attached at the rear end of the catheter body ( 10 ). Further, the needle tube ( 12 ) is preferably inserted into the third lumen ( 18 c ) provided in the catheter body ( 10 ) through the opening in the connector ( 30 ) attached at the rear end of the catheter body ( 10 ).
As illustrated in FIGS. 1 and 3 , which show the center axis positions of the needle tube ( 12 ) and guide wires ( 14 , 16 ), the first guide wire ( 14 ) preferably moves in the forward axial direction inside of the first lumen ( 18 a ) and extends out of the first lumen ( 18 a ) in the forward axial direction within the aforementioned plane (α) and through the tip aperture ( 20 ) at the front end of the catheter body ( 10 ). The second guide wire ( 16 ) preferably moves in the forward axial direction inside of the second lumen ( 18 b ), and extends out of the second lumen ( 18 b ) sideways within the aforementioned plane (α) and through the side hole ( 24 ) at the front end of the catheter body ( 10 ). In accordance with preferred embodiments, the needle tube ( 12 ) moves in the forward axial direction inside of the third lumen ( 18 c ) and the tip of the needle ( 11 ) extends out of the third lumen ( 18 c ) perpendicular to both the extension direction of the first ( 14 ) and second guide wires ( 16 ), inside of the plane (β) orthogonal to the aforementioned plane (α) and through the projection hole ( 22 ) at the front end of the catheter body ( 10 ).
The needle tube ( 12 ) which is inserted into the third lumen ( 18 c ) preferably comprises a flexible tube. A part of the needle tube ( 12 ), excluding the needle ( 11 ) at its tip, comprises a reagent flow channel ( 36 ) comprising a thin tube which is preferably longer than the catheter body ( 10 ) and which preferably comprises a diameter of approx 0.4 mm. In preferred embodiments, the needle tube ( 12 ) is continuous with the needle ( 11 ) and reagent flow channel ( 36 ).
The reagent flow channel ( 36 ) of the needle tube ( 12 ) preferably comprises a flexible composite resin material such as polytetrafluoroethylene or polyimide. The needle ( 11 ) preferably comprises an elastic alloy material such as Ni—Ti alloy, stainless steel, or other material known to those skilled in the art. The reagent flow channel ( 36 ), of the needle tube ( 12 ) is preferably connected to a syringe ( 38 ), which is attached to the connector ( 30 ) at the rear end of the catheter body ( 10 ) and which provides a reagent supplier for supplying a specified reagent.
Preferred structures of the needle tube ( 12 ) allows smooth insertion axial movement inside of the third lumen ( 18 c ) of the catheter body ( 10 ), which preferably has sufficient flexibility and/or elasticity for insertion into the winding blood vessel. The forward axial movement inside of the third lumeri ( 18 c ) causes the needle ( 11 ) to project out of the projection hole ( 22 ) of the catheter body ( 10 ) and pierce the myocardium. In particularly preferred embodiments, a reagent containing osteoblasts and/or growth factor for regenerating nearly or substantially dead cells of the myocardium, such as bFGF (basic Fibroblast Growth Factor), VEGF (Vascular Endothelial-cell Growth Factor) or HGF (Hepatic Growth Factor), can be introduced into the reagent flow channel ( 36 ) and discharged through the opening in the needle ( 11 ) by means of the syringe ( 38 ).
As illustrated in FIG. 4 , the interior surface of the front end of the third lumen ( 18 c ), which includes the peripheral edge of the opening of the projection hole ( 22 ), preferably provides a guide surface ( 40 ) consisting of a convex curved surface curving in the forward axial direction toward the opening direction of the projection hole ( 22 ). In addition, the needle ( 11 ) of the needle tube ( 12 ) comprises a curved shape corresponding to the curved structure of the guide surface ( 40 ). This allows the needle ( 11 ) to be guided smoothly toward the projection hole ( 22 ) by the guide surface ( 40 ), through sliding contact with the guide surface ( 40 ), as the needle tube ( 12 ) moves in the forward axial direction.
Appropriate curved shapes of the guide surface ( 40 ) and needle ( 11 ) can preferably be determined by considering the stiffness of the needle ( 11 ). While the radius of curvature and other properties of the curved sections of the guide surface ( 40 ) and needle ( 11 ) are not specified herein, it is desirable that the projection angle (θ), which is formed at the contact point of the two sections when the curved pattern of the guide surface ( 40 ) is combined with the curved shape of the needle ( 11 ) when the needle ( 11 ) is projected out of the projection hole ( 22 ), is about forty-five degrees. In other preferred embodiments, the projection angle (θ) is more than forty-five degrees.
As shown in FIG. 4 , the curved shapes of the guide surface ( 40 ) and needle ( 11 ) preferably allow the tip of the needle ( 11 ) to be positioned close to the projection hole ( 22 ) when the needle ( 11 ) is projected sufficiently out of the projection hole ( 22 ), thereby allowing the projecting position of the needle ( 11 ) to be easily identified. In addition, the tangential line (m) of the needle ( 11 ) can be caused to cross orthogonally, at a position closer to the projection hole ( 22 ), the center axis (P 0 ) of the catheter body ( 10 ) and the center axis (P 3 ) of the third lumen ( 18 c ) into which the needle tube ( 12 ) is inserted. As a result, the component force in the progressing direction of the needle tube ( 12 ) into the myocardium (of the two vectors Vv and Vh shown in FIG. 3 , this component force corresponds to Vv, which is the vector perpendicular to the center axis (P 3 ) of the third lumen ( 18 c )) will increase, thereby enabling the needle tube ( 12 ) to be inserted more smoothly into the myocardium.
Furthermore, the tip surface of the needle ( 11 ), namely the opening end face ( 41 ) of the opening in the needle ( 11 ), preferably provides an inclined surface facing the opening of the projection hole ( 22 ) when the needle ( 11 ) is projecting from the catheter body ( 10 ) (namely, the downward inclined surface shown in FIG. 4 ).
In preferred embodiments, a balloon ( 42 ) is provided between where the projection hole ( 22 ) and side hole ( 24 ) are formed at the front end of the catheter body ( 10 ). This balloon ( 42 ) preferably comprises a soft composite resin material and has a known structure that allows it to expand in the opening direction of the projection hole ( 22 ) when saline solution or other liquid is injected inside of the balloon. The balloon preferably shrinks from an extended state when such liquid is discharged. The fourth lumen ( 18 d ) preferably opens toward the inside of the balloon ( 42 ). As shown in FIG. 1 , when being connected to the fourth lumen ( 18 d ), the connector ( 32 ) attached at the rear end of the catheter body ( 10 ) preferably has a syringe ( 44 ) connected thereto. The syringe ( 44 ) provides a means for supplying fluid to expand the balloon ( 42 ).
In the preferred embodiments of FIGS. 1 , 4 and 4 A, a marker tube ( 46 ) can be made of a radio-opaque material such as gold, platinum or platinum-rhodium alloy. Preferred embodiments of the marker tube ( 46 ) have an inclined opening end face on one side of the axial direction, with the longest and shortest sections ( 46 b , 46 a ) in the axial direction formed along the cylinder wall. This marker tube ( 46 ) is preferably inserted over the front end of the catheter body ( 10 ) and is preferably fixed at a position where either the longest or shortest sections ( 46 b , 46 a ) of the cylinder wall corresponds to the position of the projection hole ( 22 ) at the front end of the catheter body ( 10 ). The tip of the marker tube ( 46 ) preferably corresponds to the tangential line (m) of the needle tube ( 12 ) (needle ( 11 )) when the needle tube ( 12 ) is projected. This allows the position of the projection hole ( 22 ) and that of the tip of the needle tube ( 12 ), in a condition where the catheter body ( 10 ) is inserted into the blood vessel, to be identified easily through an X-ray fluoroscopy of the tip, the longest section ( 46 b ), and the shortest section ( 46 a ) of the cylinder wall of the marker tube ( 46 ). In the preferred embodiment shown in FIG. 4 , the shortest section ( 46 a ) of the cylinder wall of the marker tube ( 46 ) is preferably positioned on the side which comprises the projection hole ( 22 ).
Embodiments of the present invention further comprise methods of injecting a specified reagent into tissue, such as a nearly or substantially necrosis tissue or other lesion in the myocardium, using a reagent injection catheter of the present invention.
When implementing a reagent injection therapy using such a reagent injection catheter, the first guide wire ( 14 ) is preferably inserted into the main blood vessel ( 50 ) at the surface of the myocardium ( 48 ), as shown in FIG. 5 . The second guide wire ( 16 ) is preferably inserted into the branch blood vessel ( 52 ) at the surface of the myocardium ( 48 ), which is branching from the main blood vessel ( 50 ) in which the first guide wire ( 14 ) is inserted. In some preferred embodiments, the insertion operations of the first and second guide wires ( 14 , 16 ) into the main blood vessel ( 50 ) and branch blood vessel ( 52 ) can be performed manually.
The catheter body ( 10 ) is then preferably inserted into the main blood vessel ( 50 ) at the surface of the myocardium ( 48 ), along the first guide wire ( 14 ). This insertion operation of the catheter body ( 10 ) into the main blood vessel ( 50 ) is preferably performed while checking, using X-ray fluoroscopy and a monitor or other means known to those skilled in the art, the position of the marker tube ( 46 ) inserted over the front end of the catheter body ( 10 ) as viewed in the insertion direction. When the marker tube ( 46 ) reaches a specified position in the main blood vessel ( 50 ), as the catheter body ( 10 ) progresses into the main blood vessel ( 50 ), the insertion operation of the catheter body ( 10 ) can be temporarily stopped. The positions of the shortest section ( 46 a ) and longest section ( 46 b ) of the marker tube ( 46 ) are then preferably checked, and the catheter body ( 10 ) rotated around its axis so that the projection hole ( 22 ) opens toward the specified position in the lesion in the myocardium ( 48 ) into which the reagent will be injected. The axial-direction position of the catheter body in the blood vessel ( 50 ) can be simultaneously adjusted.
When the catheter body ( 10 ) reaches the aforementioned specified position in the main blood vessel ( 50 ), as shown in FIG. 6 , saline solution or other liquid can be introduced from the syringe ( 44 ) into the fourth lumen ( 18 d ) inside the catheter body ( 10 ) to expand the balloon ( 42 ) toward the opening direction of the projection hole ( 22 ). This preferably fixes the catheter body ( 10 ) inside the main blood vessel ( 50 ) over the lesion in the myocardium ( 48 ) into which the reagent will be injected.
Next, the needle tube ( 12 ) is preferably inserted into the third lumen ( 18 c ) in the catheter body ( 10 ) through the connector ( 30 ), and is moved forward in the insertion direction of the catheter body ( 10 ) into the main blood vessel ( 50 ). Once the needle ( 11 ) at the tip of the needle tube ( 12 ) reaches the front end of the third lumen ( 18 c ), the needle ( 11 ) can progress forward smoothly toward the projection hole ( 22 ) by means of sliding contact with the guide surface ( 40 ) provided on the interior surface of the third lumen ( 18 c ) at the front end, as shown by the two-dot chain line in FIG. 6 . By this further forward movement of the needle tube ( 12 ), the needle ( 11 ) is preferably caused to project out of the projection hole ( 22 ), as shown by the solid line in FIG. 6 . This projection operation of the needle ( 11 ), by means of the movement of the needle tube ( 12 ), can preferably be performed manually or by using a known screw mechanism known by those skilled in the art.
Preferred embodiments of the reagent injection catheter allow the needle ( 11 ) of the needle tube ( 12 ) to be projected out of the projection hole ( 22 ) in a direction virtually perpendicular to the extension direction of the first guide wire ( 14 ), which extends out of the tip aperture ( 20 ) in the catheter body ( 10 ). Preferred embodiments of the reagent injection catheter also allow the needle ( 11 ) of the needle tube ( 12 ) to be projected out of the projection hole ( 22 ) in a direction virtually perpendicular to the extension direction of the second guide wire ( 16 ), which extends out of the side hole ( 24 ) in the catheter body ( 10 ). The first guide wire ( 14 ) is inserted into the main blood vessel running at the surface of the myocardium ( 48 ), and the second guide wire ( 16 ) is inserted into the branch blood vessel ( 52 ) which also runs at the surface of the myocardium ( 48 ). Thus, the surface formed by the first and second guide wires ( 14 , 16 ) virtually approximates the surface of the myocardium ( 48 ).
The needle ( 11 ) of the needle tube ( 12 ) projecting out of the projection hole ( 22 ) in the catheter body ( 10 ) via the aforementioned operation will preferably project in the direction virtually perpendicular to the surface of the myocardium ( 48 ). Furthermore, the curved shape of the needle ( 11 ), which is curved in the projection direction out of the projection hole ( 22 ) in the moving direction of the needle tube ( 12 ), preferably allows the tangential line (m) at the tip to cross orthogonally the center axis (P 0 ) of the catheter body ( 10 ) when the needle is projecting out of the projection hole ( 22 ). The term “virtually perpendicular” is used here because, since the myocardium ( 48 ) actually has a complex shape, in the strict sense the needle ( 11 ) may not always project perpendicularly to the surface of the myocardium ( 48 ).
In preferred embodiments, the needle ( 11 ) of the needle tube ( 12 ) projecting out of the projection hole ( 22 ) in the catheter body ( 10 ) will pierce through the vascular wall ( 54 ) of the main blood vessel ( 50 ) to reach the specified position in the lesion in the myocardium ( 48 ). As the needle tube ( 12 ) moves forward in the catheter body ( 10 ), the needle ( 11 ) will progress in a direction virtually perpendicular to the surface of the myocardium ( 48 ) to reach the specified depth in the lesion.
When the needle ( 11 ) progresses into the lesion, a majority of the reactive force generated in response to the progress of the needle ( 11 ) into the myocardium ( 48 ) will act on the catheter body ( 10 ) in the direction opposite to the progressing direction of the needle ( 11 ), or, the direction perpendicular to the surface of the myocardium ( 48 ). However, the first guide wire ( 14 ) and second guide wire ( 16 ) can be inserted into the main blood vessel ( 50 ) and branch blood vessel ( 52 ), respectively, at the surface of the myocardium ( 48 ). Therefore, such reactive force can be divided and each component force can be sufficiently and reliably supported by the first and second guide wires. This operation preferably allows the needle to progress to a specified depth in the lesion in the myocardium ( 48 ) in a smooth and reliable manner.
In accordance with preferred embodiments, when the needle ( 11 ) reaches the desired depth in the lesion in the myocardium ( 48 ), the movement of the needle tube ( 12 ) will be terminated. Thereafter, a reagent containing osteoblast and/or growth factor, or other reagent known to those skilled in the art, to regenerate the myocardium ( 48 ) can be introduced into the internal hole of the needle tube ( 12 ) via the syringe ( 44 ) connected to the connector ( 32 ) at the basal position of the needle tube ( 12 ). Such a reagent is preferably discharged from the tip aperture of the needle ( 11 ) and injected into the lesion in the myocardium ( 48 ).
Thereafter, when the reagent is injected into one location of lesion in the myocardium ( 48 ), the needle tube ( 12 ) can be preferably retracted within the catheter body ( 10 ), and the needle ( 11 ) pulled into the catheter body ( 10 ). This reagent injection operation at a lesion in the myocardium ( 48 ) can preferably be repeated multiple times, thereby allowing the reagent to be injected into multiple lesions in the myocardium ( 48 ).
The needle ( 11 ) projecting out of the projection hole ( 22 ) in the catheter body ( 10 ) preferably pierces a specified position in the lesion in the myocardium ( 48 ) in a reliable manner. In addition, a majority of the reactive force generated by such piercing of the myocardium ( 48 ) by the needle ( 11 ) can be sufficiently and reliably supported by the first guide wire ( 14 ) and second guide wire ( 16 ) inserted into the main blood vessel ( 50 ) and branch blood vessel ( 52 ), respectively, at the surface of the myocardium ( 48 ). This allows the needle ( 11 ) to preferably progress into a specified depth at the lesion in the myocardium ( 48 ) in a very smooth and reliable manner.
Thus, by using such a reagent injection catheter of this example, the needle ( 11 ) will preferably pierce through to a desired depth at a specified position in the lesion in the myocardium ( 48 ), even when the lesion has been hardened. This further and sufficiently increases the effect of the treatment or procedure to inject into the lesion in the myocardium ( 48 ) a reagent for regenerating the myocardium ( 48 ).
In preferred embodiments, the first through fourth lumens ( 18 a through 18 d ) are provided independently inside the catheter body ( 10 ) in a manner extending continuously in the longitudinal direction of the catheter body ( 10 ). The first, second and third lumens ( 18 a through 18 c ) preferably contain the first and second guide wires ( 14 , 16 ) and needle tube ( 12 ), respectively, in a manner which allows movement in the axial direction. This configuration allows the first and second guide wires ( 14 , 16 ) and needle tube ( 12 ) to smoothly move in the axial direction inside the catheter body ( 10 ). Consequently, a smoother implementation of the applicable medical technique becomes possible.
Furthermore, in embodiments of the present invention, the first guide wire ( 14 ) is inserted into the first lumen ( 18 a ) through an insertion hole ( 34 ) that opens to the side at the rear end of the catheter body ( 10 ), and extends straight in the forward axial direction via the tip aperture ( 20 ) in the catheter body ( 10 ). Additionally, the second guide wire ( 16 ) is inserted straight into the second lumen ( 18 b ) through the opening in the connector ( 26 ) attached at the rear end of the catheter body ( 10 ), and extends sideways via the side hole ( 24 ) that opens to the side at the front end of the catheter body ( 10 ).
In preferred reagent injection catheters both the first guide wire ( 14 ) and second guide wire ( 16 ) preferably pass through the catheter body ( 10 ) in a condition that is bent or curved at only one location. Therefore, when the catheter body ( 10 ) is inserted into the main blood vessel ( 50 ) at the surface of the myocardium ( 48 ) along the first and second guide wires ( 14 , 16 ), the guide wires ( 14 , 16 ) will experience relatively small slide resistance, thus allowing for a smoother insertion of the catheter body ( 10 ) into the main blood vessel ( 50 ).
The third lumen ( 18 c ), into which the needle tube ( 12 ) is inserted, can be preferably arranged so that its center axis (P 3 ) corresponds to the center axis (P 0 ) of the catheter body ( 10 ). This ensures a good overall balance of the reagent injection catheter and enables the applicable medical technique for injecting a reagent into a lesion in the myocardium ( 48 ) to be performed in a more stable manner.
In preferred embodiments of the reagent injection catheter the projection hole ( 22 ) is arranged so that the center (O 3 ) of the projection hole ( 22 ), through which the needle ( 11 ) of the needle tube ( 12 ) projects, is positioned in the plane (β) lying orthogonal to the plane (α) that includes the center axis (P 3 ) of the third lumen ( 18 c ) into which the needle tube ( 12 ) is inserted, the corresponding center axis (P 0 ) of the catheter body ( 10 ), and the center axes (P 1 , P 2 ) of the first and second lumens ( 18 a , 18 b ) into which the first and second guide wires ( 14 , 16 ) are inserted. This allows a preferable layout balance of the needle tube ( 12 ) inside of the catheter body ( 10 ), and a good balance when the needle ( 11 ) is projected out of the projection hole ( 22 ). As a result, the applicable medical technique to inject a reagent into a lesion in the myocardium ( 48 ) can be performed in a more stable and smoother manner.
In preferred embodiments the center axes (P 1 , P 2 ) of the first and second lumens ( 18 a , 18 b ), into which the first and second guide wires ( 14 , 16 ) are inserted, are positioned in the aforementioned single plane (α) together with the center axis (P 0 ) of the catheter body ( 10 ) and the center axis (P 3 ) of the third lumen ( 18 c ) into which the needle tube ( 12 ) is inserted. Moreover, the first and second lumens ( 18 a , 18 b ) can be preferably located on both sides of the third lumen ( 18 c ). This configuration preferably maximizes the distance between the first lumen ( 18 a ) and second lumen ( 18 b ), thereby increasing the distance between the first guide wire ( 14 ) and second guide wire ( 16 ) extending out form these two lumens ( 18 a , 18 b ) through the tip aperture ( 20 ) and side hole ( 24 ) in the catheter body ( 10 ), respectively. As a result, a majority of the reactive force generated as the needle ( 11 ) progresses into the lesion in the myocardium ( 48 ) can be supported by the first guide wire ( 14 ) and second guide wire ( 16 ).
In accordance with preferred embodiments, the fourth lumen ( 18 d ) that supplies the liquid for expanding the balloon ( 42 ) is positioned in such a way that its center axis (P 4 ) is positioned in the aforementioned plane (β) that includes the center axis (P 3 ) of the third lumen ( 18 c ) into which the needle tube ( 12 ) is inserted, the center axis (P 0 ) of the catheter body, and the center (O 3 ) of the projection hole ( 22 ). This configuration preferably ensures a good overall balance of the reagent injection catheter, thus allowing the applicable medical technique for injecting a reagent into a lesion in the myocardium ( 48 ) to be performed in a more stable manner.
The interior surface at the front end of the third lumen ( 18 c ), into which the needle tube ( 12 ) is inserted, preferably provides a guide surface ( 40 ) consisting of a convex curved surface curving in the opening direction of the projection hole ( 22 ) in the forward axial direction. Additionally, the needle ( 11 ) of the needle tube ( 12 ) is also preferably formed with a curved shape corresponding to the guide surface ( 40 ). Therefore, as the needle tube ( 12 ) moves forward inside the catheter body ( 10 ), the needle ( 11 ) will preferably project out of the projection hole ( 22 ) in a direction perpendicular to the surface of the myocardium ( 48 ). This structure also allows the applicable medical technique for injecting a reagent into a lesion in the myocardium ( 48 ) to be performed in a more stable and reliable manner.
Preferred embodiments provide various possible configurations of the positions of the first through fourth lumens ( 18 a through 18 d ) provided within the catheter body ( 10 ). For example, as shown in FIG. 7 the third lumen ( 18 c ) can be preferably arranged so that its center axis (P 3 ) deviates from the center axis (P 0 ) of the catheter body ( 10 ) toward the projection hole ( 22 ) along the diameter direction of the catheter body ( 10 ), while the first and second lumens ( 18 a , 18 b ) can be arranged in such a way that the plane (α) including their respective center axes (P 1 , P 2 ) deviates from the center axis (P 0 ) of the catheter body ( 10 ) toward the opposite direction of the projection hole ( 22 ) along the diameter direction of the catheter body ( 10 ).
Moreover, as shown in FIG. 8 , the third lumen ( 18 c ) can preferably be arranged in such a way that its center axis (P 3 ) deviates from the center axis (P 0 ) of the catheter body ( 10 ) toward the opposite direction of the projection hole ( 22 ) along the diameter direction of the catheter body ( 10 ). The first and second lumens ( 18 a , 18 b ) can simultaneously be arranged in such a way that the plane (α), including their respective center axes (P 1 , P 2 ), deviates from the center axis (P 0 ) of the catheter body ( 10 ) toward the projection hole ( 22 ) along the diameter direction of the catheter body ( 10 ).
In the two embodiments shown in FIGS. 7 and 8 , the needle ( 11 ) of the needle tube ( 12 ) is projected in a direction perpendicular to the extension directions of the first and second guide wires ( 14 , 16 ). Therefore, these second and third examples can function similarly to the previously described embodiments.
As shown in FIG. 9 , the third lumen (l 8 c ) can preferably be arranged coaxially to the catheter body ( 10 ), while the first lumen ( 18 a ) can be arranged in such a way that its center axis (P 1 ) is positioned on the opposite side of the center (O 3 ) of the projection hole ( 22 ) across the center axis (P 3 ) of the third lumen ( 18 c ) inside the plane (β) that includes the center axis (P 3 ) of the third lumen ( 18 c ), the center axis (P 0 ) of the catheter body ( 10 ) and the center (O 3 ) of the projection hole ( 22 ). The second lumen ( 18 b ) can then preferably be arranged in such a way that its center axis (P 2 ) is positioned in the plane (α) that lies orthogonally to the above plane (β), and includes the center axis (P 3 ) of the third lumen ( 18 c ), and the center axis (P 0 ) of the catheter body ( 10 ).
Furthermore, as shown in FIG. 10 , the first, second and third lumens ( 18 a through 18 c ) can be arranged in such a way that their center axes (P 1 through P 3 ) are positioned in the aforementioned plane (β) that includes the center axis (P 0 ) of the catheter body ( 10 ) and the center (O 3 ) of the projection hole ( 22 ). The fourth lumen ( 18 d ) can also be arranged in a position different from those in the first through third examples explained above.
In the embodiments shown in FIGS. 9 and 10 , the first lumen ( 18 a ) and second lumen ( 18 b ) are displaced and parallel with each other, and the positions of their respective center axes (P 1 , P 2 ) have a deviation (d) in the diameter direction of the catheter body ( 10 ). However, such deviation (d) is minute, and is preferably smaller than the diameter of the catheter body ( 10 ). Therefore, the extension-direction vectors of the first and second guide wires ( 14 , 16 ), which are inserted into these first and second lumens ( 18 a , 18 b ), still preferably cross each other, and thus the needle tube ( 12 ) can virtually project onto the plane that includes these vectors. Thus, in preferred embodiments little impact is caused by the minute deviation (d).
In accordance with preferred embodiments of FIGS. 9 and 10 , the needle ( 11 ) of the needle tube ( 12 ) preferably projects in a direction virtually perpendicular to the extension directions of the first and second guide wires ( 14 , 16 ).
Further preferred embodiments of the reagent injection catheter of the present invention provide numerous structural variations. For example, the balloon ( 42 ) provided externally to the catheter body ( 10 ), and the fourth lumen ( 18 d ) provided in the catheter body ( 10 ) to supply the liquid for expanding such a balloon ( 42 ), can be omitted from some embodiments. Of course, in the event that the balloon ( 42 ) and fourth lumen ( 18 d ) are to be provided, their positions and quantities should not be limited to those in the aforementioned examples. Other preferred embodiments comprise a guide surface ( 40 ) comprising a convex curved surface on the interior surface at the front end of the third lumen ( 18 c ), and comprise a needle ( 11 ) having a straight shape.
Furthermore, while in the aforementioned examples the opening end face ( 41 ) of the needle ( 11 ) provides an inclined surface (downward inclined surface in FIG. 1 ) that slopes in the projection direction of the needle ( 11 ), toward the moving direction of the needle tube ( 12 ) when the needle ( 11 ) projects out of the projection hole ( 22 ), preferred embodiments can alternatively comprise an opening end face ( 41 ) that can be provided as an inclined surface (upward inclined surface in FIG. 1 ) that slopes in the projection direction of the needle ( 11 ) toward the opposite direction to the moving direction of the needle tube ( 12 ) when the needle ( 11 ) projects out of the projection hole ( 22 ). In certain embodiments, an opening end face ( 41 ) which comprises a downward inclined surface (see FIG. 1 ) can preferably prevent the interior surface of the third lumen ( 18 c ) from being scratched or damaged due to contact with the needle ( 11 ), which might otherwise occur as the needle ( 11 ) moves inside the third lumen ( 18 c ).
Preferred embodiments of the present invention, including but not limited to the aforementioned embodiments, can also be used for injecting a reagent into tissues other than the myocardium. Moreover, preferred embodiments of the present invention can also apply to non-catheter reagent injection devices for injecting a reagent into myocardium lesions or other tissues known to those skilled in the art.
The present invention can be embodied with various changes, modifications or improvements added based on the knowledge of those skilled in the art, although specific examples of such changes, modifications and improvements are not listed here. Of course, such embodiments are included in the scope of the present invention unless they deviate from the purpose of the present invention.
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Embodiments of the present invention relate to an injection devices that inject a specified reagent with cells into lesions and other areas of body tissue. Particular embodiments comprise a main tube with a projection hole on its exterior, an axially-moveable needle tube with a needle at its tip, a reagent supplier configured to supply a specified reagent into the needle tube, and axially-moveable guide wires.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application claims priority under 35 U.S.C. §119 to Japanese Application No. 2008-331270, filed on Dec. 25, 2008, entitled “IMAGE PICKUP APPARATUS AND METHOD FOR PICKING UP IMAGES”. The content of which is incorporated by reference herein in its entirety.
FIELD
Embodiments of the present invention relate generally to image pickup devices, and more particularly relate to an image pickup device comprising solid-state image pickup devices.
BACKGROUND
Some mobile information devices can capture images. Such mobile information devices may comprise image pickup devices, such as Complementary Metal Oxide Semiconductor (CMOS) sensors, Charge Coupled Devices (CCD), and the like as an image pickup device. In the image pickup device, when three primary colors such as red (R), green (G), and blue (B) are obtained, light is transmitted through color separation filters having optical bands corresponding to R, G, and B. The color separation filters comprise a dye or a pigment, and a target color is transmitted through a corresponding color separation filter. However, the color separation filters transmit light in an infrared region and at a constant rate while transmitting the target color.
Human visual sensory systems have a sensitivity characteristic to colors of about 380 nm to about 780 nm, which is called a visible region. A near-infrared region has a wavelength of about 780 nm to about 2500 nm, and an infrared region has a wavelength of about 2500 nm or more. Although rays of light may not be directly seen by a naked eye, the rays of light can be seen by a monitor of a digital camera or a video camera comprising an image pickup device. In order to match a sensitivity characteristic of the image pickup device with that of human eyes, sometimes an image pickup device comprises an Infrared Ray Cut Filter (IRCF). The IRCF generally cuts the rays in the infrared and near-infrared regions.
The IRCF may reduce color distortion by blocking absorption of the infrared light from the image pickup device. Blocking absorption of the infrared light from the image pickup device allows the image pickup device to optimize reception for visible light. However, during low light conditions lack of energy from the infrared light may reduce total light energy received by the image pickup device below a useful threshold for image reception. Therefore, there is a need for improving color reproducibility of an image pickup device during high light level and low light level conditions.
SUMMARY
An image pickup device comprising visible color optimization under received near-infrared and infrared light conditions is disclosed. Color signals corresponding to light received through each of a plurality of color filters are processed to determine a near-infrared and infrared light energy contribution. The color signals are processed to optimize color of received images.
A first embodiment comprises an image pickup apparatus. The image pickup apparatus comprises a group of color filters comprising a plurality of colors. The group of color filters comprising a first color filter comprising a first color having a first spectral characteristic. The image pickup apparatus further comprises an image pickup device operable to output a plurality of color signals corresponding to light transmitted through each of the color filters respectively. The color signals comprise a first color signal corresponding to the first color filter. The image pickup apparatus also comprises a color processing unit. The color processing unit is operable to combine the color signals excluding the first color signal to obtain a second color signal having a second spectral characteristic substantially equal to the first spectral characteristic in a visible region. The color processing unit is also operable to compare the first color signal to the second color signal to obtain incident light quantities in near-infrared and infrared regions.
A second embodiment comprises a method for correcting infrared light. The method comprises generating a first color signal corresponding to light received through a first color filter. The first color signal has a first spectral characteristic. The method further comprises computing a second color signal by combining color signals of light transmitted through at least two color filters which are different from the first color filter. The method also comprises performing correction to the second color signal to obtain a corrected second color signal having a second spectral characteristic substantially equal to the first spectral characteristic in a visible region. The method also comprises estimating an incident light quantity in an infrared region by comparing the first color signal and the corrected second color signal.
A third embodiment comprises an imaging method. The imaging method comprises receiving a plurality of light rays transmitted through a group of color filters comprising a first color filter of a first color having a first spectral characteristic. The imaging method further comprises generating a plurality of color signals corresponding to the light rays transmitted respectively. The color signals comprising a first color signal corresponding to a first light ray transmitted through the first color filter. The imaging method also comprises computing a second color signal by combining at least two color signals corresponding to light rays transmitted through at least two color filters that are different from the first color filter. The imaging method also comprises performing correction to the second color signal to obtain a corrected second color having a second spectral characteristic substantially equal to the first spectral characteristic in a visible region. The imaging method also comprises estimating incident light quantities in near-infrared and infrared regions by comparing the first color signal and the corrected second color signal.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention are hereinafter described in conjunction with the following figures, wherein like numerals denote like elements. The figures are provided for illustration and depict exemplary embodiments of the invention. The figures are provided to facilitate understanding of the embodiments without limiting the breadth, scope, scale, or applicability of the invention. The drawings are not necessarily made to scale.
FIG. 1 is an illustration of a block diagram of an exemplary configuration of an image pickup apparatus according to an embodiment of the present invention.
FIG. 2 is an illustration of a unit pixel.
FIG. 3 is an illustration of an exemplary arrangement of a unit filter comprising color filters of four colors according to an embodiment of the present invention.
FIG. 4 is an illustration of an exemplary arrangement of a unit filter comprising color filters of four colors according to an embodiment of the present invention.
FIG. 5 is an illustration of an exemplary graph showing spectral sensitivity characteristic of an image pickup device on which the unit filter of complementary colors (cyan, magenta, yellow, and green) of FIG. 3 is mounted.
FIG. 6 is an illustration of an exemplary graph showing spectral sensitivity characteristic of an image pickup device on which the unit filter of the primary colors (red, blue, and two green filters) of FIG. 4 is mounted.
FIG. 7 is an illustration of an exemplary graph showing spectral transmittance characteristic in which the infrared ray cut filter IRCF is added to the image pickup device on which the primary color filter is mounted.
FIG. 8 is an illustration of an exemplary graph showing sensitivity distributions of a first light source, a second light source, and a third light source.
FIG. 9 is an illustration of an exemplary graph showing spectral reflection factors of colors of a natural leaf and an artificial plant (leaf).
FIG. 10 is an illustration of an exemplary graph showing spectral characteristic when the natural leaf and the artificial leaf are taken with the image pickup device comprising the infrared ray cut filter IRCF.
FIG. 11 is an illustration of an exemplary graph showing spectral characteristic when the natural leaf and the artificial leaf are taken with the image pickup device that does not comprise the infrared ray cut filter IRCF.
FIGS. 12A to 12C are illustrations of exemplary graphs showing spectral characteristics when the light emitted each light source having the characteristic of FIG. 8 is transmitted while the infrared ray cut filter IRCF is mounted.
FIGS. 13A to 13C are illustrations of exemplary graphs showing spectral characteristics when the light emitted from each light source having the characteristic of FIG. 8 is transmitted while the infrared ray cut filter IRCF is not mounted.
FIG. 14 is an illustration of an exemplary graph showing a spectral characteristic of green that is of the second color obtained from the complementary color, and green that is of the first color transmitted through the green filter when the gain is not adjusted.
FIG. 15 is an illustration of an exemplary graph showing a spectral characteristic of green that is of the second color obtained from the complementary color, and green that is of the first color transmitted through the green filter when the gain is adjusted according to an embodiment of the present invention.
FIG. 16 is an illustration a flow diagram showing an exemplary process for a correction after light reaches an image pickup device through a group of color filters according to an embodiment of the invention.
DETAILED DESCRIPTION
The following detailed description is exemplary in nature and is not intended to limit the invention or the application and uses of the embodiments of the present invention. Descriptions of specific devices, techniques, and applications are provided only as examples. Modifications to the examples described herein will be readily apparent to those of ordinary skill in the art, and the general principles defined herein may be applied to other examples and applications without departing from the spirit and scope of the invention. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. The present invention should be accorded scope consistent with the claims, and not limited to the examples described and shown herein.
The following description is presented to enable a person of ordinary skill in the art to make and use the embodiments of the present invention. The following detailed description is exemplary in nature and is not intended to limit the invention or the application and uses of the embodiments of the present invention. Descriptions of specific devices, techniques, and applications are provided only as examples. Modifications to the examples described herein will be readily apparent to those of ordinary skill in the art, and the general principles defined herein may be applied to other examples and applications without departing from the spirit and scope of the invention. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. The present invention should be accorded scope consistent with the claims, and not limited to the examples described and shown herein.
Embodiments of the present invention are described herein in the context of one practical non-limiting application, namely, a mobile terminal with a digital camera. Embodiments of the present invention, however, are not limited to such mobile terminal applications such as cell phones, PDA (personal digital assistance) and the like, and the techniques described herein may also be utilized in other applications of optical systems. For example, embodiments may be applicable to digital cameras, personal computers, and the like.
As would be apparent to one of ordinary skill in the art after reading this description, these are merely examples and the embodiments of the present invention are not limited to operating in accordance with these examples. Other embodiments may be utilized and structural changes may be made without departing from the scope of the exemplary embodiments of the present invention.
FIG. 1 is an illustration of a block diagram of an exemplary configuration of an image pickup apparatus according to an embodiment of the present invention. The image pickup apparatus 10 comprises a lens system (i.e., an optical system) 11 , an image pickup device 12 , a group of color filters 13 and a color processing unit 14 .
The lens system 11 forms an image of an object OBJ onto an imaging surface of the image pickup device 12 through the group of color filters 13 .
The image pickup device 12 may, for example and without limitation, be a semiconductor sensor such as a CCD sensor, a CMOS sensor, and the like. In an embodiment, the image pickup device 12 may comprise a plurality of pixels arranged in a matrix. The image pickup device 12 produces an analog color signal corresponding to light transmitted through each color filter of the group of color filters 13 . The produced analog color signal may be converted into a digital color signal which may be sent to the color processing unit 14 .
The group of color filters 13 comprises color filters of various colors. The group of color filters 13 may have four or more color filters corresponding to visible light. In one embodiment, the group of color filters 13 may comprise color filters of four colors. The group of color filters 13 is located on a light incident side of the imaging surface of the image pickup device 12 .
FIG. 2 is an illustration of a unit pixel UPXL. As illustrated in FIG. 2 , the image pickup device 12 may comprise four pixels PXL in which unit pixels UPXL are arrayed into a 2-by-2 matrix shape forming a pixel array of the image pickup device 12 .
FIG. 3 is an illustration of an exemplary arrangement of a unit filter UFLT 1 comprising color filters of four colors according to an embodiment of the present invention. The unit filter UFLT 1 comprises a 2-by-2 matrix comprising the color filters of four colors arrayed corresponding to the unit pixel UPXL of FIG. 2 . The unit filter UFLT 1 comprises a Cyan (Cy) filter CFLT, a Yellow (Ye) filter YFLT, and a Yellow (Ye) filter YFLT, a Magenta (Mg) filter MFLT, transmitting the complementary colors (transmitted complementary colors) Cy, Ye, and Mg shown in pixels 302 , 304 , and 306 respectively. The unit filter UFLT 1 also comprises a primary color filter PCFLT comprising one of primary colors, Red (R), Green (G), or Blue (B) shown in pixel 308 . Each of the primary colors may be an obtained (computed primary color) using at least two colors from the transmitted complementary colors Cy, Ye, and Mg.
The color processing unit 14 can combine various transmitted complementary color signals transmitted through color filters CFLT, YFLT and MFLT. The color processing unit 14 may obtain a color signal of a computed primary color that has a spectral characteristic equal to that of the transmitted primary color in the visible region. Then the color processing unit 14 compares the color signal of the primary color transmitted through the primary color filter PCFLT with the color signal of the computed primary color to obtain light quantities in near-infrared and infrared regions.
FIG. 4 is an illustration of an exemplary arrangement of a unit filter UFLT 2 comprising color filters of four colors according to an embodiment of the present invention. The unit filter UFLT 2 comprises the color filters of four colors arrayed into the 2-by-2 matrix corresponding to the unit pixel UPXL of FIG. 2 . The unit filter UFLT 2 comprises a Red (R) filter RFLT, a Green (G) filter GFLT, and a Blue (B) filter BFLT, transmitting the primary colors Red (R), Green (G), and Blue (B) (transmitted primary colors) shown in pixels 402 , 404 , and 406 respectively.
The unit filter UFLT 2 also comprises a complementary color filter CCFLT comprising one of the complementary colors such as Cyan (Cy), Magenta (Mg), and Yellow (Ye) shown in pixel 408 . Each of the complementary colors may be obtained (computed complementary color) using at least two colors from the transmitted primary colors Red (R), Green (G), or Blue (B).
The color processing unit 14 can combine various transmitted primary color signals transmitted through color filters RFTL, GFLT and BFLT. The color processing unit 14 may obtain a color signal of the computed complimentary color that has a spectral characteristic equal to that of the transmitted complimentary color in the visible region. Then the color processing unit 14 compares the color signal of a transmitted complimentary color transmitted through the complementary color filter CCFLT with the color signal of the computed complimentary color to obtain light quantities in near-infrared and infrared regions.
For example, the color processing unit 14 obtains the light quantities (or infrared light quantities) in the near-infrared and infrared spectrums by a difference (i.e., CC 1 −CC 2 or CC 2 −CC 1 ) or a ratio (i.e., CC 1 /CC 2 or CC 2 /CC 1 ) between a component CC 1 of the transmitted primary color or transmitted complimentary color and a component CC 2 of the computed primary color or computed complimentary color, respectively.
The color processing unit 14 can adjust a gain such that the color signal of the transmitted primary color and the computed primary color are substantially matched with each other in a luminosity region or the visible region, and that the color signal of the transmitted complimentary color and the computed complimentary color are substantially matched with each other in a luminosity region or the visible region.
In the image pickup apparatus 10 , because the signal whose gain is adjusted as mentioned above comprises a signal out of the luminosity region or the visible region, an output value of a color signal of the transmitted primary color and the transmitted complimentary color differs from an output value of a color signal of the computed primary color or the computed complimentary color respectively.
The transmitted primary color means a filter color of the primary color, such as Green (G) when the filter UFLT 1 of FIG. 3 is used. The transmitted complementary color means a filter color of the complementary color, such as Magenta (Mg) when the filter UFLT 2 of FIG. 4 is used. In this document, the transmitted primary color or the transmitted complementary color may be referred to as a first color.
The computed primary color is generated by combining at least two transmitted color signals transmitted through the cyan filter CFLT, the magenta filter MFLT, and the yellow filter YFLT when the unit filter UFLT 1 of FIG. 3 is used. The computed complimentary color is generated by combining at least two transmitted color signals transmitted through the red filter RFLT, the green filter GFLT, and the blue filter BFLT when the unit filter UFLT 2 of FIG. 4 is used. In this document, the computed primary color or the computed complementary color may be referred to as a second color.
The color processing unit 14 comprises a memory 141 , an infrared light quantity (IR) estimating unit 142 in near-infrared and infrared regions, and an image processing unit 143 .
The memory 141 retains the digital color signal of the image pickup device 12 , and the memory 141 supplies data of the digital color signal to the infrared light quantity estimating unit 142 and the image processing unit 143 .
A color correction coefficient corresponding to an infrared light quantity computed from the color signal is stored in the memory 141 . The memory 141 supplies the color correction coefficient to the image processing unit 143 .
The infrared light quantity estimating unit 142 compares the color signal of a light transmitted through the color filter of the transmitted primary color, or transmitted through the color filter of the transmitted complimentary color with the color signal of the computed primary color or the computed complimentary color, respectively to estimate the incident light quantities in the near-infrared and infrared spectrums. For example, as mentioned above the incident light quantities in the near-infrared and infrared spectrums can be estimated by the difference or ratio between the transmitted primary color component and the computed primary color component, or between the transmitted complimentary color component and the computed complimentary color component. In this document, the color signal transmitted through the color filter of the transmitted primary color, or the color signal transmitted through the color filter of transmitted complimentary color may be referred to as a first color signal. Similarly, the color signal of the computed primary color, or the color signal of the computed complimentary color may be referred to as a second color signal.
The infrared light quantity estimating unit 142 computes the infrared light quantity correction amount to realize proper color reproduction through the estimation processing, and the infrared light quantity estimating unit 142 sends the result to the image processing unit 143 .
The image processing unit 143 receives the correction amount from the infrared light quantity estimating unit 142 , the image processing unit 143 reads the color correction coefficient corresponding to the correction amount from the memory 141 , and the image processing unit 143 performs color correction processing to the original image using the read color correction coefficient.
The image pickup apparatus 10 comprises the color filters of, for example and without limitation, four colors, and compares a color signal of the second color that is computed from at least two colors by the color processing unit 14 and the color signal of the first color that is transmitted through the color filter having a wavelength region substantially equal to that of the computed signal (the second signal).
The color processing unit 14 determines that the amount of infrared signal is large when the difference between a signal of the first color and a signal of the second color is large in the near-infrared and infrared regions. The color processing unit 14 also recognizes that the amount of infrared signal is not large when the difference between the first signal and the second signal is small in the near-infrared and infrared regions.
The infrared light quantity estimating unit 142 feeds the estimation result of the infrared light quantity back to a color correction processing system of the image of the image processing unit 143 . For example, when the group of color filters of FIG. 3 is used, the image pickup apparatus 10 compares the computed primary color such as a green component (second color) that is computed from the color signals transmitted through the Cyan (Cy), Magenta (Mg), and Yellow (Ye) color filters in the complementary color filters, with the transmitted primary color such as a green component (first color) transmitted through the green filter GFLT, thereby estimating the infrared light quantity of the incident light.
The color reproducibility can be improved by performing the feedback to the color correction based on the estimated infrared light quantity. The color reproduction processing as well as a filter characteristic and a principle of the infrared light quantity estimation in the image pickup apparatus 10 of an embodiment will be described more specifically with reference to FIGS. 5 to 16 .
FIG. 5 is an illustration of an exemplary graph showing spectral sensitivity characteristic of an image pickup device on which the unit filter of complementary colors (cyan, magenta, yellow, and green) of FIG. 3 is mounted. Cy (Cyan) designated by the letter A in the graph has a peak near 500 nm because Cy is a mixed color of blue and green, and Cy has a high quantum conversion efficiency in a range of 400 nm to 500 nm compared with G (Green) designated by the letter B in the graph. Ye (Yellow) designated by the letter C in the graph has a peak near 600 nm because Ye is a mixed color of red and green. Because Mg (Magenta) designated by the letter D in the graph is a mixed color of red and blue, the color mixing is performed by wavelengths different from each other, and Mg has two peaks.
FIG. 6 is an illustration of an exemplary graph showing a spectral characteristic of an image pickup device on which the unit filter of the primary colors (i.e., red, blue, and two green filters) of FIG. 4 is mounted. The complementary color filter of FIG. 3 is the color mixing filter of the three primary colors. On the other hand, because the primary color filter is formed by the three primary colors, advantageously a steep peak is obtained in each filter, and the primary color filter has good color reproducibility. The reason why the primary color filter has the two green filters is that the peak of sensitivity (i.e., luminosity factor) of a human eye exists in green.
The infrared ray is generally cut according to the human luminosity characteristic when the image pickup device is actually used in a digital still camera. An infrared ray cut filter IRCF is used to cut the infrared ray.
In FIGS. 5 and 6 , a horizontal axis indicates a wavelength, and a vertical axis indicates quantum efficiency. In FIG. 5 , a curve A shows a spectral characteristic of the cyan filter CFLT, a curve B shows a spectral characteristic of the green filter GFLT, a curve C shows a spectral characteristic of the yellow filter YFLT, and a curve D shows a spectral characteristic of the magenta filter MFLT. In FIG. 6 , a curve A shows a spectral characteristic of the red filter RFLT, a curve B shows a spectral characteristic of the green filter GFLT, and a curve C shows a spectral characteristic of the blue filter BFLT.
As illustrated in FIGS. 5 and 6 , the use of the complementary color filter shows better quantum efficiency than the use of the primary color filter. This is because the image pickup device has a sensitivity characteristic as the human has the luminosity characteristic. In the image pickup device (monochrome) on which no color filter is mounted, quantum conversion efficiency of red is higher than blue. As can be seen from FIG. 6 , the quantum conversion efficiency of the curve A (red) is higher than the curve C (blue). Therefore, in the complementary color filter, magenta is formed by mixing red in blue having the low quantum conversion efficiency, and cyan is formed by mixing green in blue, thereby enhancing the sensitivity.
FIG. 7 is an illustration of an exemplary graph showing a spectral transmittance characteristic in which the infrared ray cut filter IRCF is added to the image pickup device on which the primary color filter is mounted. In FIG. 7 , a horizontal axis indicates a wavelength, and a vertical axis indicates quantum efficiency. A curve A shows a spectral transmittance characteristic of the red filter RFLT, a curve B shows a spectral transmittance characteristic of the green filter GFLT, a curve C shows a spectral transmittance characteristic of the blue filter BFLT, and a curve D shows a spectral transmittance characteristic of the infrared ray cut filter IRCF.
The infrared ray cut filter IRCF sufficiently exerts a blocking effect in a wavelength region of about 700 nm or above. The infrared ray cut filter IRCF is mounted for adapting the image pickup apparatus 10 to the human luminosity characteristic. Unless the infrared ray cut filter IRCF is mounted, because the image pickup device 12 senses the light in the infrared region (about 800 nm) that is invisible to the human eye, the image of the object OBJ is different from the image that is visible to the human eye. The spectral transmittance characteristic of FIG. 7 differs from the spectral transmittance characteristic of FIG. 6 in the wavelength region of 700 nm or above. For an ultraviolet region, because the luminosity factor is substantially equal to the spectral characteristic of the image pickup device, the ultraviolet cut filter is not particularly provided.
FIG. 8 is an illustration of an exemplary graph showing sensitivity distributions of a first light source, a second light source, and a third light source. A horizontal axis indicates a wavelength, and a vertical axis indicates sensitivity. A curve X is a spectral distribution characteristic of a first light source or an A light source in ISO-CIE standard, a curve Y is a spectral distribution characteristic of a second light source of a D65 light source in ISO-CIE standard, and a curve Z is a spectral distribution characteristic of a third light source or a C light source in ISO-CIE standard.
The first light source has a color temperature of about 2850 degrees K that is substantially equal to that of a household electric bulb. The second light source has a color temperature of about 6500 degrees K. The color temperature of the third light source is close to daylight and that of the second light source is closer to daylight compared with the C light source.
FIG. 9 is an illustration of an exemplary graph showing spectral reflection factors of colors of a natural leaf and an artificial plant (i.e., leaf) as an example for explaining that an object visible to the human is different from an object visible to the image pickup device. In practice, the example of FIG. 9 is not limited to the leaf. For example, although black of a nylon cloth, black paper, and cotton dyed in black are visible to the human eye as the same black, the black of a nylon cloth, black paper, and cotton dyed in black are not visible to the image pickup device as the same black.
In FIG. 9 , a horizontal axis indicates a wavelength, and a vertical axis indicates quantum efficiency. In FIG. 9 , a curve A is a reflectivity characteristic of a natural leaf, and a curve B is a reflectivity characteristic of an artificial plant. As can be seen from FIG. 9 , the infrared light reflected by the natural leaf is larger than the infrared light reflected by the artificial plant.
Human visual sensory systems may not distinguish the reflectivity characteristic results of the natural leaf and the artificial plant from each other. The natural leaf and the artificial plant are visible to the human eye as the same object because the human cannot identify the wavelength region of about 650 nm or above. On the other hand, the image pickup device can identify the wavelength region of 650 nm or above, and the natural leaf receives more light than the artificial plant does. Therefore, the natural leaf is brighter than the artificial plant in the image pickup device.
FIG. 10 is an illustration of an exemplary graph showing a spectral characteristic when the natural leaf and the artificial leaf are taken with the image pickup device having the infrared ray cut filter IRCF according to an embodiment of the present invention. A horizontal axis indicates a wavelength, and a vertical axis indicates quantum efficiency. A curve A is a reflectivity characteristic of a natural leaf, and a curve B is a reflectivity characteristic of an artificial plant.
As illustrated in FIG. 10 , because the infrared component is cut by the infrared ray cut filter IRCF, the natural leaf and the artificial plant are taken as the same green. The infrared ray cut filter IRCF is mounted such that the object is taken as the image identical to that of the human eye when the digital still camera is used. As illustrated in FIG. 10 , because the infrared component is cut by the infrared ray cut filter IRCF, the natural leaf and the artificial plant are taken as the same green. This is because the colors are expressed within the human visual sensory system luminosity region (human luminosity region).
FIG. 11 is an illustration of an exemplary graph showing a spectral characteristic when the natural leaf and the artificial leaf are taken with the image pickup device that does not comprise the infrared ray cut filter IRCF. FIG. 11 illustrates the result in which the quantum efficiency showed in FIG. 9 and the quantum efficiency showed in FIG. 6 are multiplied together in each wavelength. In FIG. 11 , a horizontal axis indicates a wavelength, and a vertical axis indicates quantum efficiency. A curve A is a reflectivity characteristic of a natural leaf, and a curve B is a reflectivity characteristic of an artificial plant. FIG. 11 illustrates that the image pickup device receives the reflected light up to the infrared light out of the human luminosity region because of the absence of the infrared ray cut filter IRCF.
Therefore, when the infrared ray cut filter IRCF is removed, different colors are outputted between the artificial leaf (i.e., plant) and the natural leaf. In this manner, the artificial leaf and the natural leaf are visible to the human eye as the same color because the human does not have the sensitivity in the infrared region.
FIG. 12A are illustrations of exemplary graphs showing spectral characteristics of the natural leaf and the artificial plant when the light emitted from the first light source is transmitted while the infrared ray cut filter IRCF is mounted according to an embodiment of the present invention. FIG. 12B illustrates spectral characteristics of the natural leaf and the artificial plant when the light emitted from the second light source is transmitted while the infrared ray cut filter IRCF is mounted. FIG. 12C illustrates spectral characteristics of the natural leaf and the artificial plant when the light emitted from the third light source is transmitted while the infrared ray cut filter IRCF is mounted.
The spectral characteristic results of FIGS. 12A to 12C are obtained by multiplying the leaf characteristic of FIG. 9 , the light source characteristic of FIG. 8 , and D (IRCF characteristic) of FIG. 7 . The first light source emits light including a large amount of a component in the infrared region, and the second light source emits light whose component in the infrared region is smaller than that of the first light source.
In FIGS. 12A to 12C , a horizontal axis indicates a wavelength, and a vertical axis indicates quantum efficiency. As illustrated in FIGS. 12A to 12C , although the amount of the infrared ray vary depending on the light source, the same object as seen by the human eye can be seen by the image pickup device including the infrared ray cut filter IRCF because the infrared light is cut by the infrared ray cut filter IRCF.
FIG. 13A is an illustration of an exemplary graph showing spectral characteristics of the natural leaf and the artificial plant when the light emitted from the first light source is transmitted while the infrared ray cut filter IRCF is not mounted. FIG. 13B is an illustration of an exemplary graph showing spectral characteristics of the natural leaf and the artificial plant when the light emitted from the second light source is transmitted while the infrared ray cut filter IRCF is not mounted. FIG. 13C is an illustration of an exemplary graph showing spectral characteristics of the natural leaf and the artificial plant when the light emitted from the third light source is transmitted while the infrared ray cut filter IRCF is not mounted.
In FIGS. 13A to 13C , a horizontal axis indicates a wavelength, and a vertical axis indicates quantum efficiency. As illustrated in FIGS. 13A to 13C , because the amount of the infrared ray varies depending on the light source, the artificial leaf differs from the natural leaf according to the light source.
As illustrated in FIGS. 13A to 13C , the infrared light quantity tends to be increased when the color temperature is low like the first light source. The color remains approximately the same to human eyes in an environment such as the high color temperatures of the second light source of FIG. 13B or the third light source of FIG. 13C , while the color is changed in an environment such as the low color temperatures of FIG. 13A .
FIG. 14 is an illustration of an exemplary graph showing spectral characteristics of a primary color of green (first color) transmitted through the green filter and a computed primary color of green (second color) computed from the complementary colors when the gain is not adjusted. A correction similar to that for green can be performed for red and blue. In FIG. 14 , a horizontal axis indicates a wavelength, and a vertical axis indicates quantum efficiency. In FIG. 14 , a curve C shows the spectral characteristic of the first color, and a curve D shows the spectral characteristic of the second color.
For example, the second color can be obtained as follows: the second color can be obtained by equation (1) shown below when the first color is green; the second color can be obtained by equation (2) shown below when the first color is red, and the second color can be obtained by equation (3) shown below when the first color is blue. In the equations 1-3, G represents green, R represents red, B represents blue, Cy represents cyan, Mg represents magenta, and Ye represents yellow.
G=(Cy+Ye−Mg)/2 (1)
R=(Ye+Mg−Cy)/2 (2)
B=(Mg+Cy−Ye)/2 (3)
FIG. 15 illustrates a spectral characteristic of green that is of the second color obtained from the complementary color (computed primary color), and green that is of the first color (transmitted primary color) transmitted through the green filter PCFLT ( FIG. 3 ) when the gain is adjusted according to an embodiment of the present invention. That is, the gain of the curve D in FIG. 14 is adjusted such that an area of the curve D in the visible region of FIG. 14 is made equal to an area of the curve C in the visible region of FIG. 14 and the result is shown in FIG. 15 . Alternatively, the gain may be adjusted such that substantially maximum peak heights are equal.
In FIG. 15 , a horizontal axis indicates a wavelength, and a vertical axis indicates quantum efficiency. In FIG. 15 , a curve C shows the spectral characteristic of green that is of the first color, and a curve D shows the spectral characteristic of green that is of the second color.
As can be seen from FIG. 15 , when the spectral characteristic falls within the human luminosity region according to the light source and the reflectivity characteristic of an object, it is necessary that green computed from the complementary color (second color) and the green transmitted through the green color filter PCFLT (first color) have substantially identical signals.
When the spectral characteristic comprises infrared light rays, there is a difference between the computed primary color (second color) such as the computed green and the transmitted primary color such as the transmitted green (first color) in a wavelength region E shown in FIG. 15 . Therefore, the computed green differs from the transmitted green in an output value.
The amount of the infrared light rays present in the spectral characteristic is increased with an increasing difference between the computed green and the transmitted green. The amount of the infrared ray present in the spectral characteristic is estimated by the signal difference to perform the color correction.
The reason the color correction is performed is that the image pickup device receives the light out of the luminosity region to change the color unless the infrared ray cut filter IRCF is mounted on the image pickup device.
A color reproduction operation of the image pickup apparatus 10 is described below.
FIG. 16 is an illustration of a flow diagram showing an exemplary process 1600 for a correction after the light reaches the image pickup device 12 through the group of color filters 13 according an embodiment of the present invention. The various tasks performed in connection with process 1600 may be performed by software, hardware, firmware, a computer-readable medium having computer executable instructions for performing the process method, or any combination thereof. The process 1600 may be recorded in a computer-readable medium such as a semiconductor memory, a magnetic disk, an optical disk, and the like, and can be accessed and executed, for example, by a computer CPU in which the computer-readable medium is stored. It should be appreciated that process 1600 may include any number of additional or alternative tasks, the tasks shown in FIG. 16 need not be performed in the illustrated order, and process 1600 may be incorporated into a more comprehensive procedure or process having additional functionality not described in detail herein. For illustrative purposes, the following description of process 1600 may refer to elements mentioned above in connection with FIGS. 1-15 . In practical embodiments, portions of process 1600 may be performed by different elements of the image pickup apparatus 10 , for correcting colors, e.g., the image pickup device 12 , the group of color filters 13 , the color processing unit 14 , etc. Process 1600 shows an exemplary operation in the case of the image pickup device 12 having the configuration of FIG. 3 with the complementary color filter having the characteristic of FIG. 5 .
Process 1600 may begin by light reaching the image pickup device 12 (Task ST 0 ). The light is then transmitted through color filters to obtain color signal of each pixel (task ST 1 ). For example, when the group of color filters of FIG. 3 is used, the light is transmitted through the cyan filter CFLT, the magenta filter MFLT, the yellow filter YFLT, and the green filter GFLT (complementary color filter CCFLT), and the color signal of each pixel is supplied as a digital signal to the color processing unit 14 .
The infrared light quantity estimating unit 142 of the color processing unit 14 computes RGB components from the color signals obtained by transmitting the light through the cyan filter CFLT, the magenta filter MFLT, and the yellow filter YFLT, which are of the complementary color filters (Task ST 2 ). For example, a signal of a computed primary color (second color) such as a green signal is computed using the complementary colors.
The infrared light quantity estimating unit 142 obtains a green component transmitted through the green filter GFLT as the first color (transmitted primary color) (Task ST 3 ).
The infrared light quantity estimating unit 142 then compares the computed primary color computed from the cyan (Cy), magenta (Mg), and yellow (Ye) color signals in the complementary color filters with the transmitted primary color (first color) transmitted through the green filter GFLT, thereby estimating the infrared light quantity of the incident light (Task ST 4 ).
The image processing unit 143 performs the RGB color correction based on the estimated infrared light quantity (Task ST 5 ), and the image processing unit 143 outputs the corrected image to a subsequent signal processing system (Task ST 6 ).
As mentioned above, the image pickup apparatus 10 comprises the color filters of at least four colors. The color signal of the second color computed from at least two colors, and the color signal of the first color transmitted through the color filter having the wavelength region equal to that of the computed signal are obtained and compared to each other (compared signals) in the color processing unit 14 .
The infrared light quantity estimating unit 142 of the color processing unit 14 determines that the infrared light quantity is large in the incident light, if the difference between the compared signals is increased, and determines that the influential incident light quantity is not present in the incident light, if the difference between the compared signals is decreased.
The infrared light quantity estimating unit 142 feeds the infrared light quantity estimation result back to the color correction of the image processing unit 143 .
As mentioned above, color filters having various color pixels are used in which at least one color can be obtained (second color) by combining other colors. In this manner, a color signal of the first color transmitted through a single pixel is compared with a color signal of the second color computed from the various color pixels to determine the infrared light quantity, thereby enabling the high-sensitivity color reproduction without providing the infrared ray cut filter.
Therefore, high-sensitivity photography can be performed during the darkness hours such as nighttime without providing a mechanism that inserts and extracts the infrared ray cut filter in and from the optical path, the correction amount can be estimated more precisely so as to be matched with the human luminosity characteristic, and therefore the color reproducibility can be improved during the bright hours such as daytime.
In this way, an image pickup device that is matched with the human luminosity characteristic can be implemented without providing a drive unit that moves the infrared ray cut filter from an optical path.
While at least one exemplary embodiment has been presented in the foregoing detailed description, the present invention is not limited to the above-described embodiment or embodiments. Variations may be apparent to those skilled in the art. In carrying out the present invention, various modifications, combinations, sub-combinations and alterations may occur in regard to the elements of the above-described embodiment insofar as they are within the technical scope of the present invention or the equivalents thereof. The exemplary embodiment or exemplary embodiments are examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a template for implementing the exemplary embodiment or exemplary embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope of the invention as set forth in the appended claims and the legal equivalents thereof. Furthermore, although embodiments of the present invention have been described with reference to the accompanying drawings, it is to be noted that changes and modifications may be apparent to those skilled in the art. Such changes and modifications are to be understood as being included within the scope of the present invention as defined by the claims.
Terms and phrases used in this document, and variations hereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as mean “including, without limitation” or the like; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; and adjectives such as “conventional,” “traditional,” “normal,” “standard,” “known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Likewise, a group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should also be read as “and/or” unless expressly stated otherwise. Furthermore, although items, elements or components of the invention may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated. The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. The term “about” when referring to a numerical value or range is intended to encompass values resulting from experimental error that can occur when taking measurements.
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An image pickup device comprising visible color optimization under received near-infrared and infrared light conditions is disclosed. Color signals corresponding to light received through each of a plurality of color filters are processed to determine a near-infrared and infrared light energy contribution. The color signals are processed to optimize color of received images.
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[0001] The present invention relates to a method for controlling the titre of the air-fuel mixture in an internal combustion engine, in particular an internal combustion engine for driving vehicles.
BACKGROUND OF THE INVENTION
[0002] The regulations relating to road vehicles are requiring an increasingly thorough reduction of the pollutant emissions emitted by internal combustion engines. These pollutant emissions can be reduced substantially in two ways: by optimising the combustion process in the cylinders of the engine or by treating the exhaust gases before they are emitted into the atmosphere (typically using exhausts of a catalytic type). In order to optimise the combustion process in the cylinders it is necessary to maintain the titre of the air-fuel mixture as close as possible to the stoichiometric value in each cylinder.
[0003] The internal combustion engines that are currently in use are provided with a plurality of cylinders (generally four), each of which has a respective exhaust duct communicating with a common exhaust manifold disposed upstream of an exhaust provided with a device for reducing pollutant agents. In order to contain costs, only the overall stoichiometric ratio of all the cylinders is measured by means of a linear oxygen sensor disposed in the common exhaust manifold.
[0004] By means of appropriate reconstruction methods and starting from the measurements of the overall stoichiometric ratio, the stoichiometric ratios of the individual cylinders are estimated and these stoichiometric ratios are used to control the intake of fuel into the individual cylinders, in order to cause each individual cylinder to work as close as possible to the stoichiometric value.
[0005] These known reconstruction methods for estimating the stoichiometric ratios of the individual cylinders from the measurements of the overall stoichiometric ratio are, however, relatively imprecise and very complex.
SUMMARY OF THE INVENTION
[0006] The object of the present invention is to provide a method for controlling the titre of the air-fuel mixture in an internal combustion engine, which is free from the above-described drawbacks and which is, moreover, simple and economic to implement.
[0007] In accordance with the present invention, a method for controlling the titre of the air-fuel mixture in an internal combustion engine according to claim 1 is provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention will now be described with reference to the accompanying drawings, which show a non-limiting embodiment thereof, in which:
[0009] [0009]FIG. 1 is a diagrammatic view of an internal combustion engine using the control method of the present invention; and
[0010] [0010]FIG. 2 is a diagrammatic view of a control unit of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0011] In FIG. 1, a device for controlling the titre of the air-fuel mixture in an internal combustion engine 2 provided with four cylinders 3 (shown diagrammatically) disposed in line is shown overall by 1 . Each cylinder 3 receives the fuel from a respective injector 4 of known type and is provided with a respective exhaust duct 5 which communicates with an exhaust manifold 6 common to all the cylinders 3 .
[0012] The exhaust manifold 6 communicates with an exhaust device 7 of known type and comprises a linear oxygen probe 8 (commonly known to persons skilled in the art by the name “UEGO probe”), which is adapted to measure the percentage of oxygen present in the manifold 6 ; as is known, the percentage of oxygen in the exhaust gases of the cylinders 3 is in a bi-univocal relationship with the overall air-fuel ratio of the cylinders 3 and a measurement of this oxygen percentage therefore corresponds substantially to a measurement of the overall air-fuel ratio of the cylinders 3 .
[0013] The control device 1 comprises a control unit 9 , which is connected to the probe 8 in order to receive the measurements of the overall air-fuel ratio of the cylinders 3 , and is connected to the injectors 4 in order to provide each injector 4 with a correction value of the quantity of fuel injected into the respective cylinder 3 . Each injector 4 is in particular controlled in a known manner by an injection control unit (not shown) in order to inject a predetermined quantity of fuel into the respective cylinder 3 (or into an intake duct of this cylinder 3 ); each injector 4 also receives a signal for the correction of the quantity of fuel to be injected from the control unit 9 in order to try to cause the respective cylinder 3 to work as close as possible to the stoichiometric value.
[0014] The control device 1 further comprises a sensor 10 of known type (typically an angular encoder) which is connected to the control unit 9 and is adapted to read the angular position of a drive shaft 11 (shown diagrammatically).
[0015] As shown in FIG. 2, the control unit 9 comprises a device 12 for filtering the measurement signal from the linear oxygen probe 8 .
[0016] The filtering device 12 comprises a filter having a transfer function of a “high pass” type in order to filter the measurement signal of the overall air-fuel ratio of the cylinders 3 from the linear oxygen probe 8 . The filter of the filtering device 12 has a transfer function in the Laplace domain comprising a zero and two poles which are disposed at frequencies higher than zero. The filtering device 12 further comprises a limitation of the filtered signal within a predetermined acceptability range in order to eliminate any noise pulse components.
[0017] The measurement signal from the liner oxygen probe 8 needs to be filtered to recover some dynamics weakened as a result of the response characteristics of the linear oxygen probe 8 , particularly as a result of the capacitance effect due to a protective hood (known and not shown) of this probe 8 . In order to obviate this critical factor, the filtering device amplifies the frequencies characteristic of the combustion phenomenon and at the same time reduces the high frequencies in order not to amplify noise.
[0018] The signal filtered by the filtering device 12 is strongly under-sampled by a sampling device 13 , which stores four measurement values AFR COMPL of the overall air-fuel ratio of the cylinders 3 for each complete revolution of the engine shaft 11 . The measurement values AFR COMPL are in particular stored at the exhaust phase of each cylinder 3 such that each measurement value AFR COMPL is as indicative as possible of the state of combustion of a respective cylinder 3 . According to a preferred embodiment, the measurement values AFR COMPL are stored at each top dead centre of each cylinder 3 .
[0019] As output from the sampling device 13 , each measurement AFR COMPL is transmitted to a reconstruction device 14 which is adapted to estimate the values AFR CIL of the air-fuel ratio of each cylinder 3 by processing the measured values AFR COMPL of the overall air-fuel ratio.
[0020] After many experimental tests, it has been decided to use a model with two coefficients to represent the relationship existing between the measured values AFR COMPL of the overall air-fuel ratio and the estimated values AFR CIL of the air-fuel ratio of each cylinder 3 . This model is summarised by the following equation:
AFR comp ( k )= B RICOSTR *AFR CIL ( k )+ A RICOSTR *AFR COMP ( k− 1)
[0021] where AFR COMP (k) represents the k th measured value of the overall air-fuel ratio (i.e. the value measured at the moment k), AFR COMP (k-1) represents the (k−1) th measured value of the overall air-fuel ratio (i.e. the value measured at the moment k−1), and AFR CIL (k) represents the k th estimated value of the air-fuel ratio of the last cylinder 3 combusted (i.e. the estimated value of the air-fuel ratio of the cylinder 3 combusted at the moment k). A RICOSTR and B RICOSTR are two identified coefficients which are characteristic of the engine 3 and are obtained experimentally.
[0022] Resolving the above equation with respect to AFR CIL (k) provides:
AFR CIL ( k )=1 /B RICOSTR *( AFR COMP ( k )− A RICOSTR *AFR COMP ( k −1)
[0023] which can be rewritten as:
AFR CIL ( k )= C 1 *AFR COMP ( k )− C 2 *AFR COMP ( k −1)
C 1=1 /B RICOSTR
C 2 =A RICOSTR /B RICOSTR
[0024] It has been observed that the coefficients C1 and C2 are not constant but depend on the operating point of the engine 3 , and in particular on the number of revolutions and the torque transmitted (or the quantity of air introduced) by the engine 3 . It is preferable, therefore, to implement a table which supplies the values of C1 and C2 corrected for the current operating point of the engine 3 in a known manner within the reconstruction device 14 .
[0025] It has further been observed that the coefficients A RICOSTR and B RICOSTR , and therefore the coefficients C1 and C2, are not independent from one another, but are connected by the equation:
A RICOSTR =1− B RICOSTR
[0026] and therefore:
C 2 =C 1−1
[0027] It is therefore possible to reduce the mathematical model to a single coefficient.
[0028] It will be appreciated from the above description that it is possible to estimate the value AFR CIL (k) of the air-fuel ratio of the final cylinder 3 combusted by means of a linear composition of the last measured value AFR COMP (k) and the penultimate measured value AFR COMP (k−1) of the overall air-fuel ratio.
[0029] On each complete revolution of the engine shaft 11 , the sampling device 14 carries out an estimate of the values AFR CIL of the last four cylinders combusted applying the formulae:
AFR CIL ( k )= C 1 *AFR COMP ( k )− C 2 *AFR COMP ( k −1)
[0030] Once the values AFR CIL of the last four cylinders combusted have been estimated, the reconstruction device 14 supplies the four values AFR CIL to a synchroniser device 15 which associates each value AFR CIL with a respective cylinder 3 by means of a predetermined criterion of association stored in a memory of this synchroniser device 15 .
[0031] According to a preferred embodiment, the above-mentioned association criterion is formed by a bi-univocal law of association, which associates each AFR CIL with a respective cylinder; for instance AFR CIL (k) is associated with the cylinder 3 -I and will subsequently be indicated by the symbol λ CIL1 , AFR CIL (k−1) is associated with the cylinder 3 -III and will subsequently be indicated by the symbol λ CIL3 , AFR CIL (k−2) is associated with the cylinder 3 -II and will subsequently be indicated by the symbol λ CIL2 and AFR CIL (k−3) is associated with the cylinder 3 -IV and will subsequently be indicated by the symbol λ CIL4 .
[0032] The association law is initially determined in a theoretical manner by associating each estimated value AFR CIL of the air-fuel ratio with the cylinder 3 which, on the basis of the angular position of the engine shaft 11 , is combusted at the moment closest to the moment of measurement of the value AFR COMP of the overall air-fuel ratio used in the estimate. This association criterion is not always valid, as it does not take account of the output velocity of the exhaust gases from the cylinders 3 , which velocity is substantially different depending on the speed of rotation of the engine 2 .
[0033] The above-mentioned association law is not constant but may be modified during the operation of the engine 2 in order to adapt to the changed operating conditions of this engine 2 . The synchroniser device 15 in particular implements an algorithm which verifies the overall stability of the system in order to verify the accuracy of the current association law. It is also the case that if the association law is not correct the system becomes unstable, i.e. the difference between the estimated values λ CIL of the air-fuel ratios of the cylinders 3 and a reference value λ TARGET of the air-fuel ratio over time tends to increase and not to decrease (i.e. tends to diverge and not to converge towards zero).
[0034] If the synchroniser device 15 discovers an instability in the system, this synchroniser device 15 modifies the association law, typically by modifying the bi-univocal association functions by one step; for instance:
Initial Association Law
[0035] AFR CIL (k)→Cylinder 3 -I (λ CIL1 )
[0036] AFR CIL
[0037] (k−1)→Cylinder 3 -III (λ CIL3 )
[0038] AFR CIL (k−2)→Cylinder 3 -II (λ CIL2 )
[0039] AFR CIL (k−3)→Cylinder 3 -IV (λ CIL4 )
Modified Association Law
[0040] AFR CIL (k)→Cylinder 3 -III (λ CIL3 )
[0041] AFR CIL (k−1)→Cylinder 3 -II (λ CIL2 )
[0042] AFR CIL (k−2)→Cylinder 3 -IV (λ CIL4 )
[0043] AFR CIL (k−3)→Cylinder 3 -I (λ CIL1 )
[0044] In order to verify the stability of the system, the synchroniser device 15 calculates a value D of divergence of the estimated values λ CIL of the air-fuel ratio. This divergence value D is calculated using either the value of the derivative over time of the estimated values λ CIL of the air-fuel ratio of each cylinder 3 or by using the absolute value of the differences between the reference value λ TARGET and the estimated values λ CIL of the air-fuel ratio of each cylinder 3 .
[0045] In particular, if the value of the derivative of an estimated value λ CIL is positive and the estimated value λ CIL itself is greater than the reference value λ TARGET , there is a potential situation of instability.
[0046] If the divergence value D is higher than a predetermined threshold, the synchroniser device 15 then modifies the association law.
[0047] Once the association has been carried out, the synchroniser device 15 communicates the four values λ CIL (λ CIL1 , λ CIL2 , λ CIL3 , λ CIL4 ), each of which indicates for a respective cylinder 3 an estimate of the air-fuel ratio with which this cylinder 3 is working, to a calculation device 16 .
[0048] Once the four values λ CIL have been received, the calculation device 16 calculates a mean value λ mean of the air-fuel ratio of the four cylinders 3 , and calculates for each cylinder 3 a respective dispersion value Δ CIL indicating the difference between the corresponding value λ CIL of the cylinder 3 and the value λ mean.
λ mean =(λ CIL1 +λ CIL2 +λ CIL3 +λ CIL4 )/4
Δ CIL1 =λ CIL1 +λ mean
Δ CIL2 =λ CIL2 +λ mean
Δ CIL3 =λ CIL3 +λ mean
Δ CIL4 =λ Cil4 +λ mean
[0049] The calculation device 16 communicates the value λ mean and the values Δ CIL to a regulator 17 which is adapted to supply, to each injector 4 , the above-mentioned correction signal for the quantity of fuel to be injected into the respective cylinder 3 .
[0050] The regulator 17 receives the reference value λ TARGET of the air-fuel ratio from a memory 18 and attempts to cause each cylinder 3 to work with an air-fuel ratio which is as close as possible to the reference value λ TARGET . The regulator 17 comprises two control loops 19 and 20 , which are closed (i.e. work in feedback), are separate from one another and are disposed one within the other.
[0051] The control loop 19 corrects the dispersion values Δ CIL by attempting to bring them to a zero value; in particular, the inner loop 19 has the task of recovering the imbalances of the air-fuel ratio of the various cylinders 3 by making corrections bearing a zero mean value.
[0052] The outer loop 20 carries out an overall control (i.e. without distinction between the various cylinders 3 ), attempting to adapt the mean value λ mean of the air-fuel ratio of the four cylinders 3 to the reference value λ TARGET .
[0053] The outer loop 20 has a comparator 21 , which compares, in negative feedback, the reference value λ TARGET with the mean value λ mean of the air-fuel ratio of the four cylinders 3 ; the error resulting from this comparison is supplied to a control device 22 , which is typically a control device of PID type and is able to generate, as a function of the error signal received as input, a control signal for the injectors 4 .
[0054] The inner loop 19 comprises four control devices 23 , each of which receives as input a respective dispersion value Δ CIL from the calculation device 16 , is typically a control device of PID type and is able to generate, as a function of the signal received as input, a control signal for a respective injector 4 . The inner loop 19 is for all purposes a closed feedback loop, wherein each dispersion value Δ CIL is already an error signal to be cancelled out.
[0055] According to a preferred embodiment showed in FIG. 2, a filter 24 , which has a transfer function of a “low pass” type and is adapted to cleanse the values Δ CIL of high frequency noise, is disposed between the calculation device 16 and the control device 23 .
[0056] The signal from each control device 23 is combined with a signal from the control device 22 by means of a respective adding device 25 and is supplied to a respective injector 4 to correct the quantity of fuel injected into the respective cylinder 3 . In this way, the value of the air-fuel ratio of each cylinder 3 is corrected by combining a first correction signal, which is determined on the basis of a mean value ο mean of the air-fuel ratio of all the cylinders 3 , with a second correction signal, which is determined on the basis of the estimated value λ CIL of the air-fuel ratio of the cylinder 3 .
[0057] According to a preferred embodiment, the outer control loop 20 has lower time constants than the inner control loop 19 ; in other words, the outer control loop 20 is slower to respond than the inner control loop 19 . This ensures a greater overall stability of the process of correction of the quantity of fuel injected by the injectors 4 .
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A method for controlling the titer of the air-fuel mixture in an internal combustion engine provided with at least two cylinders, in which the exhaust gas present in a common exhaust manifold is analyzed in order to measure at least two successive values of the overall air-fuel ratio of the cylinders; a value of the air-fuel ratio of a final combusted cylinder being estimated by carrying out a linear composition of the two successive values of the overall air-fuel ratio of the cylinders and the value of the air-fuel ratio of the final combusted cylinder being attributed to a first of the cylinders and being used to correct a titer of the air-fuel mixture introduced into the first cylinder.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to Japanese Patent Application No. 2014-059415 filed Mar. 24, 2014, the content of which is hereby incorporated herein by reference.
BACKGROUND
The present disclosure relates to an apparatus and a non-transitory computer-readable medium that stores computer-readable instructions.
A known embroidery sewing machine stores sewing data and stitch data that indicates a reference position that is necessary for positioning a pattern such that aligning of a pattern to an already sewn pattern is to be performed efficiently and accurately in a case where a plurality of patterns are combined and sewn. In the embroidery sewing machine, the pattern that is sewn first and a stitch that indicates the reference position for that pattern are sewn on a cloth based on the sewing data and the stitch data. A user is therefore able to recognize the reference position.
SUMMARY
For example, a case may occur in which the user desires to sew a plurality of decorative patterns of comparatively small size on individual characters of a character pattern that is made up of a plurality of characters, in order to make the pattern more decorative. Hereinafter, the resulting pattern is called a decorated character pattern. Specifically, the decorated character pattern is an embroidery pattern that is made by combining a character pattern and a decorative pattern. In a case where a decorated character pattern is sewn by the embroidery sewing machine that is described above, the user need to manually align the sewing positions of the character pattern and the decorative pattern. That task means time and effort for the user.
Embodiments of the broad principles derived herein provide an apparatus that can easily generate sewing data for combining and sewing a plurality of patterns, and also provide a non-transitory computer-readable medium that stores computer-readable instructions.
Embodiments provide an apparatus including a processor and a memory. The memory is configured to store computer-readable instructions. The computer-readable instructions, when executed by the processor, cause the apparatus to perform processes of acquiring first pattern data and second pattern data, the first pattern data being data for sewing a first embroidery pattern, and the second pattern data being data for sewing each of at least one second embroidery pattern, identifying, based on the first pattern data, at least one characteristic point of a pattern shape describing the first embroidery pattern, setting positioning data for positioning and sewing the at least one second embroidery pattern at the respective identified at least one characteristic point, and generating sewing data, based on the first pattern data, the second pattern data, and the positioning data. The sewing data is data for sewing the first embroidery pattern and the at least one second embroidery pattern in a sewing order in which the at least one of second embroidery pattern is sewn after the first embroidery pattern is sewn.
Embodiments also provide a non-transitory computer-readable medium storing computer-readable instructions that, when executed by a processor of an apparatus, cause the apparatus to perform processes that include acquiring first pattern data and second pattern data, the first pattern data being data for sewing a first embroidery pattern, and the second pattern data being data for sewing each of at least one second embroidery pattern, identifying, based on the first pattern data, at least one characteristic point of a pattern shape describing the first embroidery pattern, setting positioning data for positioning and sewing the at least one second embroidery pattern at the respective identified at least one characteristic point, and generating sewing data, based on the first pattern data, the second pattern data, and the positioning data. The sewing data is data for sewing the first embroidery pattern and the at least one second embroidery pattern in a sewing order in which the at least one of second embroidery pattern is sewn after the first embroidery pattern is sewn.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments will be described below in detail with reference to the accompanying drawings in which:
FIG. 1 is a block diagram that shows an electrical configuration of sewing data generation device;
FIG. 2 is a conceptual diagram that shows various types of storage areas in a hard disk device;
FIG. 3 is an oblique view of a sewing machine;
FIG. 4 is a flowchart of decorated character pattern creation processing;
FIG. 5 is a figure that shows a character pattern;
FIG. 6 is a figure that shows a decorative pattern;
FIG. 7 is a conceptual diagram of a portion of block data that configure the character pattern;
FIG. 8 is a conceptual diagram of block data with a thread density of 5 ;
FIG. 9 is a flowchart of characteristic point identification processing;
FIG. 10 is a flowchart of the characteristic point identification processing, continuing from FIG. 9 ;
FIG. 11 is a figure that shows an example in which a point q 1 is on a side p 2 -p 4 in the block data;
FIG. 12 is a figure that shows a line segment of the block data in the character pattern;
FIG. 13 is a figure that shows an example in which the point q 1 is on a side p 3 -p 4 in the block data;
FIG. 14 is a figure that shows a character pattern that is configured from single-stitch data only;
FIG. 15 is a figure that shows a character pattern that is configured by intermingling the block data and the single-stitch data;
FIG. 16 is an explanatory figure of a method for determining an ending point of a character line in the character pattern;
FIG. 17 is an explanatory figure of a method for determining a vertex point of a character line in the character pattern;
FIG. 18 is a figure that shows candidate points for positioning decorative patterns in the character pattern;
FIG. 19 is a figure that shows candidate points for positioning decorative patterns in parts of the character pattern that are configured from the single-stitch data;
FIG. 20 is a flowchart of pattern positioning processing;
FIG. 21 is a figure that shows a form in which decorative patterns are positioned at a starting point and an ending point of a first character line (m=0);
FIG. 22 is a figure that shows a decorated character pattern after the pattern positioning processing;
FIG. 23 is a flowchart of thinning-out processing;
FIG. 24 is a figure that shows a surface area in which rectangular areas that are indicated by mask data for two decorative patterns partially overlap; and
FIG. 25 is a figure that shows the decorated character pattern after the thinning-out processing.
DETAILED DESCRIPTION
An embodiment will be explained with reference to the drawings. The configuration of a sewing data generation device 1 will be explained with reference to FIG. 1 . The sewing data generation device 1 is a device that is able to generate embroidery data for the forming, by a sewing machine 3 (refer to FIG. 3 ), of stitches of an embroidery pattern in a sewing workpiece (for example, a work cloth) that is held by an embroidery frame 41 .
The sewing data generation device 1 may be a device that is dedicated to generating the embroidery data. The sewing data generation device 1 may be a general-purpose device such as a personal computer or the like. In the present embodiment, the general-purpose sewing data generation device 1 is used as an example. The sewing data generation device 1 includes a CPU 11 , which is a controller that performs control of the sewing data generation device 1 . A RAM 12 , a ROM 13 , and an input/output (I/O) interface 14 are connected to the CPU 11 . The RAM 12 temporarily stores various types of data, such as computation results and the like that are produced by computational processing by the CPU 11 . The ROM 13 stores a bios and the like.
The I/O interface 14 performs mediation of data transfers. A hard disk device (HDD) 15 , an input circuit 16 , an output circuit 17 , an external communication interface 18 , and a connector 19 are connected to the I/O interface 14 .
An input portion 20 , such as a keyboard or the like, is connected to the input circuit 16 . A display 21 , which is a display device, is connected to the output circuit 17 . The external communication interface 18 is an interface that can connect to a network 25 . The sewing data generation device 1 can connect to an external device through the network 25 . A storage medium 55 , such as a memory card or the like, can be connected to the connector 19 . Through the connector 19 , the sewing data generation device 1 is able to read data from the storage medium 55 and write data to the storage medium 55 .
Various types of storage areas in the HDD 15 will be explained with reference to FIG. 2 . The HDD 15 includes various types of storage areas, including a program storage area 151 , a character pattern data storage area 152 , a decorative pattern data storage area 153 , and a sewing data storage area 154 . The program storage area 151 stores various types of programs, including a program for performing decorated character pattern creation processing (refer to FIG. 4 ).
The character pattern data storage area 152 stores character pattern data. The character pattern data include shape data for a character pattern, thread color data that indicate the color of a thread, mask data for the character pattern, and the like. The character pattern is an embroidery pattern that indicates the shape of a character, as do alphabetic character patterns 51 to 53 shown in FIG. 5 , for example. The shape data are data for creating the shape of a character. The shape data include block data, single-stitch data, and the like, for example. The block data and the single-stitch data will be explained below. The mask data for a character pattern are data that indicate the smallest rectangle that can encompass the character pattern. The center point of the character pattern is defined by the coordinates of the intersection point of the diagonals of the rectangle that is indicated by the mask data. Coordinate data are data that indicate the coordinates in an XY coordinate system (refer to FIG. 3 ) that will be described below.
The decorative pattern data storage area 153 stores decorative pattern data. The decorative pattern data include coordinate data for needle drop points of a sewing needle 44 (refer to FIG. 3 ) in a decorative pattern, stitch data that indicate types of and setting values for stitches in the decorative pattern, thread color data that indicate the color of a thread, mask data for the decorative pattern, and the like. The decorative patterns are embroidery patterns that are used when a decorated character pattern (refer to FIG. 25 ) is created by combining the decorative patterns, such as a floral decorative pattern 85 shown in FIG. 6 , with the character pattern. The stitches of the decorative pattern may be satin stitches, fill stitches, and the like, for example. The needle drop point is a point where the sewing needle 44 , which is disposed directly above a needle hole (not shown in the drawings), pierces the sewing workpiece when a needle bar 35 is moved downward from above the sewing workpiece. The setting values are setting values for stitch angles, thread density, and the like, for example. The mask data for a decorative pattern are data that indicate the smallest rectangle that can encompass the decorative pattern. The center point of the decorative pattern is defined by the coordinates of the intersection point of the diagonals of the rectangle that is indicated by the mask data. Coordinate data are data that indicate the coordinates in an XY coordinate system that will be described below. A user can use a pattern editing function of the sewing data generation device 1 to edit the character pattern and the decorative pattern, and can also generate sets of pattern data for forming the character pattern and the decorative pattern, respectively.
The sewing data storage area 154 stores various types of sewing data. The various types of sewing data include sewing data for sewing a decorated character pattern that is generated by the decorated character pattern creation processing (refer to FIG. 4 ), which will be described below. The various types of sewing data also include sewing data and the like for sewing an ordinary embroidery pattern. The sewing data are data that, in the same manner as the stitch data, indicate the coordinates of the needle drop points and the stitch order for forming the stitches of the embroidery pattern. The sewing data for the decorated character pattern will be described below.
The sewing machine 3 will be explained briefly with reference to FIG. 3 . The sewing machine 3 is capable of sewing an embroidery pattern based on the sewing data. The sewing machine 3 includes a bed 30 , a pillar 36 , an arm 38 , and a head 39 . The bed 30 is the base of the sewing machine 3 and is long in the left-right direction. The pillar 36 extends upward from the right end portion of the bed 30 . The arm 38 extends to the left from the upper end of the pillar 36 such that the arm 38 is positioned opposite the bed 30 . The head 39 is a portion that is joined to the left end of the arm 38 .
When performing embroidery sewing, the user of the sewing machine 3 may mount an embroidery frame 41 that holds a sewing workpiece onto a carriage 42 that is disposed on the bed 30 . The embroidery frame 41 is moved to the coordinates of a needle drop point by a Y axis moving mechanism (not shown in the drawings) and an X axis moving mechanism (not shown in the drawings). The Y axis moving mechanism is contained in the carriage 42 . The X axis moving mechanism is contained in a body case 43 . The coordinates of the needle drop point are indicated by an XY coordinate system that is specific to the sewing machine 3 . In the present embodiment, the X direction is the left-right direction of the sewing machine 3 . The positive X direction is the direction from left to right. The negative X direction is the direction from right to left. The Y direction is front-rear direction of the sewing machine 3 . The positive Y direction is the direction from the rear to the front. The negative Y direction is the direction from the front to the rear. In conjunction with the moving of the embroidery frame 41 , a shuttle mechanism (not shown in the drawings) and the needle bar 35 on which the sewing needle 44 is attached are driven. The embroidery pattern is thus formed on the sewing workpiece. The Y axis moving mechanism, the X axis moving mechanism, the needle bar 35 , and the like are controlled based on the sewing data by a CPU (not shown in the drawings) that is built into the sewing machine 3 .
A connector 37 is provided on a side face of the pillar 36 of the sewing machine 3 . The storage medium 55 may be mounted in and removed from the connector 37 . For example, the sewing data generated by the sewing data generation device 1 are stored in the storage medium 55 through the connector 19 , as shown in FIG. 1 . Then the storage medium 55 may be mounted in the connector 37 of the sewing machine 3 . The stored sewing data may be read and stored in the sewing machine 3 . Based on the stored sewing data, the CPU of the sewing machine 3 may control the operation of sewing the embroidery pattern. The sewing machine 3 is thus able to sew the embroidery pattern based on the sewing data generated by the sewing data generation device 1 .
The decorated character pattern creation processing that the CPU 11 performs will be explained with reference to FIGS. 4 to 25 . The sewing data generation device 1 is capable of performing both the decorated character pattern creation processing and ordinary processing. The decorated character pattern creation processing is processing that generates the sewing data for the decorated character pattern. The ordinary processing is processing that generates the sewing data for an ordinary embroidery pattern. Using the input portion 20 , the user can perform operations to select and start various types of processing. When the CPU 11 detects the operations to select and start the decorated character pattern creation processing, the CPU 11 reads into the RAM 12 the program for performing the decorated character pattern creation processing stored in the program storage area 151 of the HDD 15 , then performs the processing below by executing the instructions contained in the program.
As shown in FIG. 4 , first, the CPU 11 performs character selection processing (Step S 1 ). The character selection processing is processing that allows the user to select a character pattern. The CPU 11 displays a character pattern selection screen, for example, on the display 21 , then waits until the CPU 11 detects that a character pattern is selected by the user. A single character may be selected, and a plurality of characters may be selected. For each of the character patterns, there are a plurality of variations, in which the shape, the style, the color, and the like of the character are different. In the present embodiment, it is assumed that the user selects the three character patterns 51 to 53 shown in FIG. 5 . The character pattern 51 is the alphabetic character “K”, the character pattern 52 is the alphabetic character “S”, and the character pattern 53 is the alphabetic character “L”.
When the CPU 11 detects that the character patterns 51 to 53 is selected, the CPU 11 acquires from the character pattern data storage area 152 of the HDD 15 the character pattern data sets that correspond to the selected character patterns 51 to 53 (Step S 2 ) and stores the character pattern data sets in the RAM 12 . Each one of the character patterns 51 to 53 is configured from block data that will be described below.
The block data will be explained with reference to FIGS. 7 and 8 . The block data are coordinate data for the individual vertices of a four-sided block that is defined by four points. FIG. 7 shows two blocks that configure a portion of a character pattern 54 . One of the blocks is configured from points p 1 , p 2 , p 3 , and p 4 , and another of the blocks is configured from points p 3 , p 4 , p 5 , and p 6 . The points p 1 and p 4 are positioned at opposite ends of a diagonal of the first block. The points p 2 and p 3 are positioned at opposite ends of another diagonal of the first block. The points p 3 and p 6 are positioned at opposite ends of a diagonal of the second block. The points p 4 and p 5 are positioned at opposite ends of another diagonal of the second block. A rectangle that is indicated by mask data 57 for the character pattern 54 encompasses the two blocks. The point p 1 is the vertex that is the closest to a start point 56 of the mask data 57 . The start point 56 is a point that indicates the position where the sewing by the sewing machine 3 is to be started. For the block data for each of the four-sided blocks, the CPU 11 computes needle drop points on two opposing sides of the four-sided block such that a predetermined thread density can be achieved. The thread density is information about the number of stitches that is to be disposed within one block, and the thread density is included in the character pattern data.
FIG. 8 shows an example of block data for which the thread density is 5 . Needle drop points q 1 and q 3 are set on a side p 2 -p 4 , which is one side of one four-sided block. Needle drop points q 2 and q 4 are set on a side p 1 -p 3 , which is another side of the one four-sided block. Five stitches s 1 to s 5 are disposed within the block. The stitch s 1 data indicate a stitch that links the starting point p 1 and the ending point q 1 . The stitch s 2 data indicate a stitch that links the starting point q 1 and the ending point q 2 . The stitch s 3 data indicate a stitch that links the starting point q 2 and the ending point q 3 . The stitch s 4 data indicate a stitch that links the starting point q 3 and the ending point q 4 . The stitch s 5 data indicate a stitch that links the starting point q 4 and the ending point p 4 .
Next, as shown in FIG. 4 , the CPU 11 performs decorative pattern selection processing (Step S 3 ). The decorative pattern selection processing is processing that allows the user to select a decorative pattern that is to be disposed in combination with the character pattern. In the same manner as in the character selection processing, the CPU 11 displays a decorative pattern selection screen, for example, on the display 21 . The CPU 11 then waits until the CPU 11 detects that a decorative pattern is selected by the user. In the present embodiment, it is assumed that the user selects the floral decorative pattern 85 shown in FIG. 6 . When the CPU 11 detects that the floral decorative pattern 85 is selected, the CPU 11 acquires the decorative pattern data for the selected floral decorative pattern 85 from the decorative pattern data storage area 153 of the HDD 15 (Step S 4 ) and stores the decorative pattern data in the RAM 12 . The decorative pattern data for the decorative pattern 85 include mask data 85 A (refer to FIG. 6 ) and the like. A center point O of the decorative pattern 85 is set at the intersection point of diagonals of the mask data 85 A.
Next, as shown in FIG. 4 , the CPU 11 performs characteristic point identification processing (Step S 5 ). The characteristic point identification processing is processing that identifies characteristic points of the character pattern. The characteristic points of the character pattern are points that characterize the shape of the character pattern. The characteristic points of the character pattern include endpoints and a vertex of the character pattern, for example. The endpoints are the starting point and the ending point of at least one line segment that corresponds to one stroke of the character (and is equivalent to a character line that will be described below). The vertex may be, for example, an intersection point of two line segments that form a corner of the character. This sort of characteristic point is a candidate point for positioning the decorative pattern.
The characteristic point identification processing will be explained with reference to FIGS. 9 and 10 . First, the CPU 11 initializes to zero the values of a block counter i, a stitch counter r, a line segment counter k, and a character line counter m (Step S 10 ). The block counter i counts the number of blocks that are indicated by the block data. The stitch counter r counts the number of stitches in the single-stitch data. The line segment counter k counts the total of the number of line segments that correspond to center lines of the blocks that are indicated by the block data and the number of line segments that correspond to the stitches in the single-stitch data. The character line counter m counts the number of the character lines. The character line is the at least one line segment that corresponds to one stroke of the character, and the character line will be described in detail below. The counter values for each one of the counters i, r, k, and m are stored in the RAM 12 .
Next, the CPU 11 defines, as target data, the first set of the shape data for creating the character pattern 51 , which is the first of the character patterns 51 to 53 selected in the character selection processing at Step S 1 . The CPU 11 determines whether the target data are block data (Step S 11 ). The CPU 11 may start the processing from one of the character patterns 52 and 53 .
In a case where the target data are block data (YES at Step S 11 ), the CPU 11 sets the value of a total number of blocks imax to the number of blocks that are continuous from the block that the target data (the block data) indicate (Step S 12 ). For example, in a case where the number of continuous blocks is 3, including the block that the target data (the block data) indicate, the total number of blocks imax is set to 3. The CPU 11 initializes the block counter i to zero (Step S 13 ). From the target i-th block data, the CPU 11 acquires the coordinates of the vertices p 1 to p 4 (refer to FIG. 12 ) of the block that the block data indicate (Step S 14 ). In a case where the value of the block counter i is zero, the i-th block data are the first block data.
Next, in order to determine a direction of the block data, the CPU 11 acquires the coordinates for the point q 1 , which is the ending point of the first stitch s 1 in the block data (Step S 15 ). The direction of the block data means the direction in which the character is written. The first stitch s 1 is a stitch for which the point p 1 , which is the start point, is defined as the starting point. The CPU 11 determines whether the point q 1 is on the side p 2 -p 4 (Step S 16 ). In a case where the point q 1 is on the side p 2 -p 4 (YES at Step S 16 ), as shown in FIG. 11 , the direction of the block data is from the side p 1 -p 2 toward the side p 3 -p 4 . Accordingly, the CPU 11 defines the center point of the side p 1 -p 2 as the starting point of a k-th line segment (hereinafter called the line segment [k]) in the block data and defines the center point of the side p 3 -p 4 as the ending point of the line segment [k] (Step S 18 ). The line segment [k] is equivalent to a center line of the block data. In a case where the value of k is zero, the k-th line segment (the line segment [ 0 ]) is the first line segment. For example, in a first block 61 (i=0) of the character pattern 51 , the positions of the starting point and the ending point of a line segment 61 A (k=0) are defined, as shown in FIG. 12 .
In contrast, in a case where the point q 1 is not on the side p 2 -p 4 (NO at Step S 16 ), the CPU 11 determines whether the point q 1 is on the side p 3 -p 4 (Step S 17 ). In a case where the point q 1 is on the side p 3 -p 4 (YES at Step S 17 ), as shown in FIG. 13 , the direction of the block data is from the side p 1 -p 3 toward the side p 2 -p 4 . Accordingly, the CPU 11 defines the center point of the side p 1 -p 3 as the starting point of the line segment [k] and defines the center point of the side p 2 -p 4 as the ending point of the line segment [k] (Step S 19 ). The CPU 11 can thus determine the coordinates of the starting point and the ending point of the line segment [k] based on the block data and the coordinate data for the point q 1 , which is the ending point of the first stitch. For each line segment [k], the CPU 11 stores the coordinate data for the starting point and the ending point of the line segment [k] in the RAM 12 . In a case where the point q 1 is not on the side p 3 -p 4 (NO at Step S 17 ), the CPU 11 cannot define the starting point and the ending point of the line segment [k], so the CPU 11 forces the termination of the processing without doing anything.
In this manner, the positions of the starting point and the ending point of the line segment [k] are defined for the block data for one block. Therefore, the CPU 11 adds 1 to the block counter i and adds 1 to the line segment counter k (Step S 20 ). Next, the CPU 11 determines whether the value of the block counter i has reached the value of the total number of blocks imax (Step S 21 ). In a case where the value of the block counter i is less than the value of the total number of blocks imax (NO at Step S 21 ), the CPU 11 returns to Step S 14 and repeats the processing described above for the block data for the next block (Steps S 14 to S 20 ).
In a case where the value of the block counter i has reached the value of the total number of blocks imax (YES at Step S 21 ), the calculation of the starting points and the ending points of the line segments [k] for the blocks that are continuous from the block that the target data (the block data) indicate has been completed. Accordingly, the CPU 11 determines whether all of the calculations of the starting points and the ending points of the line segments [k] have been completed for all of the shape data for creating the character pattern 51 (Step S 27 ). In a case where the value of the line segment counter k matches the number of sets of the shape data for the character pattern, all of the calculations of the starting points and the ending points of the line segments [k] have been completed for the character pattern. The character pattern 51 is defined by the block data only. Therefore, in a case where the value of the block counter i has reached the value of the total number of blocks imax, the calculations of the starting points and the ending points of the line segments [k] have all been completed (YES at Step S 27 ). In this case, as shown in FIG. 10 , the CPU 11 advances the processing to Step S 29 , which will be described below.
The character pattern 51 shown in FIG. 12 is defined by the block data only. Depending on the style of the character pattern, the character pattern may be defined by the single-stitch data only or by a combination of the block data and the single-stitch data. The single-stitch data are coordinate data for the endpoints (the starting points and the ending points) of the stitches that form the shape of the character or the like. FIG. 14 shows character patterns 71 to 73 , which are examples of a character style that is defined by the single-stitch data only. The character pattern 71 is the alphabetic character “K”, the character pattern 72 is the alphabetic character “S”, and the character pattern 73 is the alphabetic character “L”. Where the character pattern is defined by the single-stitch data only, it is often the case that the shape of the character pattern is formed by the stitches themselves.
In contrast, FIG. 15 shows character patterns 81 to 83 , which are examples of a character style that is defined by a combination of the block data and the single-stitch data. The character pattern 81 is the alphabetic character “K”, the character pattern 82 is the alphabetic character “S”, and the character pattern 83 is the alphabetic character “L”. A character style that is defined by a combination of the block data and the single-stitch data has a different visual quality from a character style that is defined by the block data only or the single-stitch data only, making a more creative impression. In a case where the character pattern is defined by the block data only, as described above, the CPU 11 calculates the starting point and the ending point of the line segment [k], which is the center line of the block. In a case where the shape data for the character pattern include the single-stitch data, then for the part of the character pattern that is defined by the single-stitch data, the CPU 11 may calculate starting points and ending points of line segments that correspond to stitches.
Returning to Step S 9 , in a case where the target data are single-stitch data, not block data (NO at Step S 11 ), the CPU 11 sets the value of a total number of stitches rmax to the number of stitches that are continuous from the stitch that the target data (the single-stitch data) indicate (Step S 22 ). For example, in a case where the number of continuous stitches is 3, including the stitch that the target data (the single-stitch data) indicate, the total number of stitches rmax is set to 3. The CPU 11 initializes the stitch counter r to zero (Step S 23 ). Then the CPU 11 defines the starting point of the line segment [k] as the starting point of the target stitch [r] and defines the ending point of the line segment [k] as the ending point of the stitch [r] (Step S 24 ). The CPU 11 stores the coordinate data for the starting point and the ending point of the line segment [k] in the RAM 12 .
In this manner, the positions of the starting point and the ending point of the line segment [k] are defined for one stitch that the single-stitch data indicate. The CPU 11 adds 1 to the stitch counter r and the line segment counter k (Step S 25 ). The CPU 11 determines whether the value of the stitch counter r has reached the value of the total number of stitches rmax (Step S 26 ). In a case where the value of the stitch counter r is less than the value of the total number of stitches rmax (NO at Step S 26 ), the CPU 11 returns to Step S 24 and repeats the processing described above for the next set of the single-stitch data (Steps S 24 , S 25 ).
In a case where the value of the stitch counter r has reached the value of the total number of stitches rmax (YES at Step S 26 ), the calculation of the starting points and the ending points of the line segments [k] for the single-stitch data that indicate the stitches that are continuous from the stitch that the target data (the single-stitch data) indicate has been completed. Accordingly, the CPU 11 determines whether all of the calculations of the starting points and the ending points of the line segments [k] have been completed for all sets of the shape data for creating the character pattern (Step S 27 ). For example in a case where the block data follow the single-stitch data for which the calculations have been completed, the calculations of the starting points and the ending points of the line segments [k] have not all been completed for the character pattern (NO at Step S 27 ). Accordingly, the CPU 11 returns to Step S 11 and, for the block data that indicate the next continuous block (YES at Step S 11 ), repeats the processing that is described above (Steps S 12 to S 21 ). In a case where all of the calculations of the starting points and the ending points of the line segments [k] have been completed for the character pattern (YES at Step S 27 ), the CPU 11 advances the processing to Step S 29 , as shown in FIG. 10 .
As shown in FIG. 10 , the CPU 11 defines the starting point of the first character line (m=0) as the starting point of the first block (or the first stitch) (Step S 29 ). The character line is the at least one line segment that corresponds to one stroke of the character, and the character line is configured from the line segments [k]. The CPU 11 sets the value of a total number of line segments kmax to the current value of the line segment counter k (Step S 30 ). The total number of line segments kmax is the total number of the line segments [k] in the character pattern 51 . The CPU 11 once again initializes the line segment counter k to zero (Step S 31 ).
Next, the CPU 11 determines whether the coordinates of the ending point of the line segment [k] are different from the coordinates of the starting point of the next line segment [k+1] (Step S 32 ). In a case where the coordinates of the ending point of the line segment [k] are different from the coordinates of the starting point of the next line segment [k+1] (YES at Step S 32 ), the ending point of the line segment [k] and the starting point of the next line segment [k+1] are in different positions. Accordingly, the CPU 11 defines the endpoint of the line segment [k] as the endpoint of the m-th character line (hereinafter called the character line [m]) (Step S 34 ) and defines the starting point of the next line segment [k+1] as the starting point of the next character line [m+1] (Step S 35 ). The CPU 11 stores the coordinates of the ending point of the character line [m] and the coordinates of the starting point of the character line [m+1] in the RAM 12 . The CPU 11 adds 1 to the character line counter m (Step S 36 ). In a case where the value of the character line counter m is zero, the m-th character line (the character line [ 0 ]) is the first character line.
Conversely, in a case where the coordinates of the ending point of the line segment [k] and the starting point of the next line segment [k+1] are the same (NO at Step S 32 ), the positions of the ending point of the line segment [k] and the starting point of the next line segment [k+1] overlap. For example, as shown in FIG. 16 , in blocks 91 to 95 at the beginning of the top of the “S” character pattern 52 , the ending point of a line segment 91 A of the block 91 and the starting point of a line segment 92 A of the block 92 overlap at a point T 1 . The ending point of a line segment 93 A of the block 93 and the starting point of a line segment 94 A of the block 94 overlap at a point T 2 . The ending point of the line segment 94 A of the block 94 and the starting point of a line segment 95 A of the block 95 overlap at a point T 3 . In other words, two line segments are connected at each one of the point T 1 , the point T 2 , and the point T 3 . Therefore, the point T 1 , the point T 2 , and the point T 3 are not endpoints of the character pattern.
In this sort of case, the CPU 11 determines whether the overlapping point is a vertex of the character pattern. The CPU 11 determines whether an angle that is formed by the line segment [k] and the next line segment [k+1] is less than or equal to a threshold value Ta (Step S 33 ). The threshold value Ta may be 150 degrees, for example, but the threshold value Ta may be modified. In a case where the angle is greater than the threshold value Ta (NO at Step S 33 ), the angle that is formed by the line segment [k] and the next line segment [k+1] is not small enough that the overlapping point can be regarded as a characteristic point. In this case, the overlapping point is not regarded as a vertex. Accordingly, the CPU 11 adds 1 to the line segment counter k (Step S 37 ). In the example shown in FIG. 16 , the angle at each one of the point T 1 , the point T 2 , and the point T 3 is greater than the threshold value Ta. Therefore, none of the point T 1 , the point T 2 , and the point T 3 is a vertex.
On the other hand, in a case where the angle is less than or equal to the threshold value Ta (YES at Step S 33 ), the angle that is formed by the line segment [k] and the next line segment [k+1] is small enough that the overlapping point can be regarded as a characteristic point. The overlapping point is therefore regarded as a vertex. Accordingly, the CPU 11 defines the ending point of the line segment [k] as the ending point of the character line [m] (Step S 34 ) and defines the starting point of the next line segment [k+1] as the starting point of the next character line [m+1] (Step S 35 ). The CPU 11 stores the coordinates of the ending point of the character line [m] and the coordinates of the starting point of the character line [m+1] in the RAM 12 . The CPU 11 adds 1 to the character line counter m (Step S 36 ).
For example, as shown in FIG. 17 , in blocks 97 to 99 at the end of the “L” character pattern 53 , the ending point of a line segment 97 A of the block 97 and the starting point of a line segment 98 A of the block 98 overlap at a point T 4 . The ending point of the line segment 98 A of the block 98 and the starting point of a line segment 99 A of the block 99 overlap at a point T 5 . Therefore, the point T 4 and the point T 5 are not endpoints. At the point T 4 , the angle that is formed by the line segment 97 A and the line segment 98 A is greater than the threshold value Ta. Therefore, the point T 4 is not a vertex. In contrast, at the point T 5 , the angle that is formed by the line segment 98 A and the line segment 99 A is not greater than the threshold value Ta. Therefore, the point T 5 is a vertex.
Next, returning to FIG. 10 , the CPU 11 determines whether the value of the line segment counter k has reached a value that is 1 less than the value of the total number of line segments kmax (Step S 38 ). When the final line segment [k] is reached, there is no next line segment. Accordingly, there is no need to consider whether the ending point of the final line segment [k] is an endpoint. Therefore, at Step S 38 , the CPU 11 determines whether the value of the line segment counter k has reached the value that is 1 less than the value of the total number of line segments kmax. In a case where the value of the line segment counter k has not reached the value that is 1 less than the value of the total number of line segments kmax (NO at Step S 38 ), the CPU 11 returns to Step S 32 . The CPU 11 proceeds to repeat the processing (Steps S 32 to S 37 ) for determining the endpoint of the next character line. In a case where the value of the line segment counter k has reached the value that is 1 less than the value of the total number of line segments kmax (YES at Step S 38 ), the CPU 11 defines the ending point of the character line [m] as the ending point of the final block (or the final stitch, in the case of the single-stitch data) (Step S 39 ). The CPU 11 stores the coordinates of the ending point of the character line [m] in the RAM 12 . The CPU 11 sets the current value of the character line counter m to a total number of character lines mmax (Step S 40 ). The total number of character lines mmax is the total number of the character lines in the character pattern 51 . The CPU 11 processes the character patterns 52 and 53 in the same manner as the character pattern 51 . The CPU 11 terminates the characteristic point identification processing and returns to the decorated character pattern creation processing shown in FIG. 4 .
At the point when the characteristic point identification processing is terminated, the coordinate data for the starting point and the ending point of every character line [m] in each of the character patterns 51 to 53 are stored in the RAM 12 . The starting point and the ending point of each character line [m] are the candidate points for positioning the decorative pattern 85 . For example, the candidate points in the character patterns 51 to 53 , which are defined by the block data only, are the center positions of the circles shown in FIG. 18 . On the other hand, the candidate points in the character patterns 81 to 83 , which are defined by a combination of the block data and the single-stitch data, are the center positions of the circles shown in FIG. 19 . In FIG. 19 , the candidate points for the character patterns 82 and 83 is omitted from the drawing. Next, the CPU 11 performs pattern positioning processing, which is shown in FIG. 20 (Step S 6 ).
The pattern positioning processing will be explained with reference to FIG. 20 . The pattern positioning processing is processing that positions the decorative pattern at the candidate points identified by the characteristic point identification processing. First, the CPU 11 initializes the character line counter m and a positioned pattern counter n to zero (Step S 41 ). The positioned pattern counter n counts the number of decorative patterns positioned on one character pattern. As shown in FIG. 21 , the endpoints of each of the character lines [m] (refer to the broken lines in FIG. 21 ) in the character pattern 51 are candidate points for positioning the decorative pattern 85 , for example. The CPU 11 positions the decorative pattern 85 such that the center point O of the decorative pattern 85 overlaps a starting point 66 and an ending point 67 of the first character line (m=0) (Step S 42 ). The CPU 11 stores the coordinates of the mask data 85 A of the positioned decorative patterns 85 in the RAM 12 as positioning data for the decorative patterns 85 . The positioning of the decorative patterns 85 is thus completed for the one character line [m]. The CPU 11 adds 1 to the value of the character line counter m and adds 1 to the value of the positioned pattern counter n (Step S 43 ).
Next, the CPU 11 determines whether the value of the character line counter m has reached the value of the total number of character lines mmax (Step S 44 ). In a case where the value of the character line counter m is less than the value of the total number of character lines mmax (NO at Step S 44 ), the CPU 11 returns to Step S 41 and repeats the processing (Steps S 42 to S 43 ) until the positioning of the decorative patterns 85 has been completed for all of the character lines. In a case where the value of the character line counter m has reached the value of the total number of character lines mmax (YES at Step S 44 ), the positioning of the decorative patterns 85 has been completed for all of the character lines. Therefore, the CPU 11 terminates the pattern positioning processing. The CPU 11 processes the character patterns 52 and 53 in the same manner as the character pattern 51 .
At the point when the pattern positioning processing is terminated, the character patterns 51 to 53 become decorated character patterns 251 to 253 , which are shown in FIG. 22 . At this stage, the decorative patterns 85 are positioned at all of the characteristic points of the decorated character patterns 251 to 253 . Therefore, some of the decorative patterns 85 overlap one another. When the decorative patterns 85 overlap one another, the shapes of the decorative patterns 85 may be disfigured, depending on the extent of the overlapping. In such a case, the appearance of the decorated character patterns 251 to 253 therefore may be poorer. Accordingly, the CPU 11 returns to the processing shown in FIG. 4 and performs thinning-out processing (Step S 7 ).
The thinning-out processing will be explained with reference to FIG. 23 . First, the CPU 11 acquires a threshold value Tb from the ROM 13 (Step S 50 ). The threshold value Tb is a threshold value for the ratio of a surface area S where two of the decorative patterns 85 overlap one another to a total surface area of the overlapping decorative patterns 85 . For example, the threshold value Tb in the present embodiment is thirty percent. The threshold value Tb may be modified in accordance with the shape, the size, and the like of the decorative pattern. The threshold value Tb may be stored in a storage medium other than the ROM 13 . For example, the threshold value Tb may be stored in the HDD 15 .
In order to detect overlapping among all of the (fourteen) decorative patterns 85 positioned in the decorated character pattern 251 (refer to FIG. 22 ), the CPU 11 computes the amount of overlap between one target decorative pattern 85 and another of the decorative patterns 85 , then compares the result to the threshold value Tb. In the present embodiment, the one target decorative pattern 85 is defined as a first pattern, and each one of the other decorative patterns 85 is defined as a second pattern. The CPU 11 initializes a first pattern counter v to zero (Step S 51 ). The first pattern counter v counts the first patterns. Next, the CPU 11 initializes a second pattern counter w to zero (Step S 52 ). The second pattern counter w counts the second patterns. The value of each of the counters v and w is stored in the RAM 12 .
First, from among all of the (fourteen) decorative patterns 85 in the decorated character pattern 251 , the CPU 11 selects, as the first pattern, the decorative pattern 85 positioned the earliest. Then, from among the other decorative patterns 85 , the CPU 11 selects, as the second pattern, the decorative pattern 85 positioned the earliest. The CPU 11 computes the surface area S where the rectangular area that is indicated by the mask data for the first pattern overlaps the rectangular area that is indicated by the mask data for the second pattern (Step S 53 ). For example, as shown in FIG. 24 , a portion of the rectangular area that is indicated by mask data 86 A for a decorative pattern 86 , which is selected as the first pattern, overlaps a portion of the rectangular area that is indicated by mask data 87 A for a decorative pattern 87 , which is selected as the second pattern. Based on the coordinates of the mask data 86 A and the mask data 87 A, the CPU 11 computes the surface area S of the rectangular overlapping area (the rectangular area that is filled by diagonal lines in FIG. 24 ). In this manner, the CPU 11 detects that the decorative patterns 86 and 87 overlap. The larger the ratio of the surface area S to the total surface area of the overlapping decorative patterns 85 , the greater the possibility becomes that the stitches of the decorative patterns 86 and 87 is disfigured during the sewing by the sewing machine 3 . The possibility therefore exists that the shapes of the decorative patterns 86 and 87 is not identifiable.
Accordingly, the CPU 11 determines whether the ratio of the surface area S to the total surface area of the overlapping decorative patterns 85 is less than the threshold value Tb (Step S 54 ). The threshold value Tb is the threshold value acquired at Step S 50 . In a case where the ratio of the surface area S to the total surface area of the overlapping decorative patterns 85 is less than the threshold value Tb (YES at Step S 54 ), the first pattern and the second pattern are either separated from one another or the extent of the overlapping of the first pattern and the second pattern is small. Accordingly, the CPU 11 adds 1 to the second pattern counter w without deleting either one of the first pattern and the second pattern (Step S 55 ). The determining of the extent of the overlapping in the combination of the first pattern and the second pattern has thus been completed.
Next, the CPU 11 determines whether the value of the second pattern counter w has reached the value of the positioned pattern counter n (Step S 56 ). The initial value of positioned pattern counter n is the total number of the decorative patterns 85 that are positioned in the decorated character pattern 251 . For example, the value of the positioned pattern counter n when the thinning-out processing starts is 14. In this case, the number of the decorative patterns 85 that are positioned in the decorated character pattern 251 is 14. In a case where the value of the second pattern counter w is less than the value of the positioned pattern counter n (NO at Step S 56 ), the CPU 11 returns to Step S 53 . Then the CPU 11 then repeats the processing for a combination of the same first pattern as in the preceding round of the processing and a different second pattern from the second pattern in the preceding round of the processing.
In a case where the value of the second pattern counter w has reached the value of the positioned pattern counter n (YES at Step S 56 ), the determining of the extent of the overlapping has been completed for all of the combinations of the first pattern and the plurality of the second patterns that are other than the first pattern. Accordingly, the CPU 11 adds 1 to the first pattern counter v (Step S 57 ) and determines whether the value of the first pattern counter v is greater than or equal to value of the positioned pattern counter n (Step S 58 ). In a case where the value of the first pattern counter v is less than the value of the positioned pattern counter n (NO at Step S 58 ), the CPU 11 defines, as the first pattern, a decorative pattern 85 that is different from the first pattern in the preceding round of the processing. The CPU 11 returns to Step S 52 and once again initializes the second pattern counter w to zero. Next, in the same manner as described above, the CPU 11 successively determines the extent of the overlapping between the new first pattern and the second patterns, which are the other decorative patterns 85 .
In a case where the ratio of the surface area S where the first pattern and the second pattern overlap to the total surface area is not less than the threshold value Tb (NO at Step S 54 ), the extent of the overlapping of the first pattern and the second pattern is large. Accordingly, in order to delete the first pattern, which is positioned earlier, the CPU 11 deletes the positioning data for the first pattern (Step S 59 ). As described previously, the positioning data indicate the coordinates of the mask data 85 A for the positioned decorative pattern 85 . In this manner, one of the overlapping decorative patterns 85 on the character pattern is deleted. The CPU 11 then moves up by 1 the positioning order each of the remaining decorative patterns 85 that follow the deleted decorative pattern 85 . The CPU 11 selects, as the first pattern, the decorative pattern 85 positioned the earliest among the decorative patterns 85 that have not yet been selected as the first pattern (Step S 60 ). Furthermore, because one of the decorative patterns 85 has been deleted, the CPU 11 subtracts 1 from the value of the positioned pattern counter n (Step S 61 ). The CPU 11 repeats the processing at Steps S 52 to S 61 for as long as the value of the first pattern counter v has not reached the value of the positioned pattern counter n (NO at Step S 58 ).
In a case where the value of the first pattern counter v has reached the value of the positioned pattern counter n (YES at Step S 58 ), the determining of the extent of the overlapping has been completed for all of the decorative patterns 85 . Furthermore, in a case where two or more of the decorative patterns 85 overlap, the decorative patterns 85 have been thinned out appropriately. The CPU 11 also performs the processing that is described above for the decorated character patterns 252 and 253 , in the same manner as for the decorated character pattern 251 . The CPU 11 then terminates the thinning-out processing.
As shown in FIG. 25 , at the point when the thinning-out processing is completed, the decorative patterns 85 on the decorated character patterns 251 to 253 have been thinned out appropriately. Compared to the decorated character patterns 251 to 253 prior to the performing of the thinning-out processing (refer to FIG. 22 ), the decorative patterns 85 have been thinned out appropriately. Accordingly, the characters in the decorated character patterns 251 to 253 may be more easily visible, and their overall appearance may be improved.
Next, the CPU 11 returns to the decorated character pattern creation processing shown in FIG. 4 and displays the tinned-out decorated character patterns 251 to 253 on the display 21 (Step S 8 ). The user is able to check the decorated character patterns 251 to 253 on the display 21 .
The CPU 11 then generates the sewing data for sewing the decorated character patterns 251 to 253 (Step S 9 ). The sewing data include the character pattern data for each one of the character patterns 51 to 53 , the decorative pattern data for the decorative patterns 85 , the positioning data for the decorative patterns 85 , sewing order data, and the like. The character pattern data are acquired from the character pattern data storage area 152 of the HDD 15 . The decorative pattern data are acquired from the decorative pattern data storage area 153 of the HDD 15 . The positioning data are acquired from the RAM 12 . The sewing order data are data for a sewing order in which the decorative patterns are sewn after the character pattern is sewn. The CPU 11 may store the generated sewing data in the sewing data storage area 154 of the HDD 15 . The CPU 11 may store the generated sewing data in the storage medium 55 through the connector 19 . The CPU 11 terminates the decorated character pattern creation processing.
As explained above, the sewing data generation device 1 of the present embodiment is able to generate the sewing data for the decorated character pattern. The decorated character pattern is a character pattern in which a decorative pattern is combined with a character pattern. The CPU 11 of the sewing data generation device 1 acquires the shape data that are included in the character pattern data for the character pattern 51 , for example, which is the alphabetic character “K”. Based on the shape data, the CPU 11 identifies the characteristic points of the character pattern 51 . The characteristic points are the endpoints and the vertices of the character pattern 51 , for example. The CPU 11 positions the floral decorative patterns 85 , for example, at the characteristic points identified in the character pattern 51 . The CPU 11 defines the coordinates of the characteristic points where the decorative patterns 85 are positioned as the coordinates of the center points of the decorative patterns 85 that are indicated by the mask data. The CPU 11 stores the mask data coordinates in the RAM 12 as the positioning data. The CPU 11 generates the sewing data for the decorated character pattern 251 based on the character pattern data for the character pattern 51 , the decorative pattern data for the decorative patterns 85 , and the positioning data for the decorative patterns 85 . The sewing data include the sewing order data for the sewing order in which the decorative patterns 85 are sewn after the character pattern 51 is sewn.
In this manner, the sewing data generation device 1 is able to identify the characteristic points of the character pattern 51 and automatically position the decorative patterns 85 at the characteristic points. Therefore, the sewing data for sewing the decorated character pattern 251 can be generated easily. Even in a case where the user has selected a different character pattern or decorative pattern, for example, the decorative patterns are automatically positioned in relation to the character pattern. Therefore, it is not necessary for the user to reposition the decorative patterns manually. Furthermore, even in a case where the style of the character pattern is changed, the characteristic points of the character pattern that correspond to the new style are newly identified. The decorative patterns are positioned at the newly identified characteristic points. Therefore, it is not necessary for the user to reposition the decorative patterns manually.
In the present embodiment, in the characteristic point identification processing shown in FIGS. 9 and 10 , the CPU 11 identifies the characteristic points of the character pattern by referring to at least one of the block data and the single-stitch data. The block data and the single-stitch data are the shape data that are included in the character pattern data. By referring to at least one of the block data and the single-stitch data, the CPU 11 is able to identify specifically a pattern shape of the character pattern. The CPU 11 is therefore able to identify the endpoints and the vertex accurately.
In the present embodiment, in the pattern positioning processing shown in FIG. 20 , the CPU 11 stores in the RAM 12 , as the positioning data, the coordinates of the mask data for the decorative patterns that are positioned on the character pattern. Furthermore, in the thinning-out processing shown in FIG. 23 , the CPU 11 detects the overlapping of two or more of the decorative patterns, based on the positioning data for each one of the decorative patterns that are positioned on the character pattern. In a case where the overlapping of two or more of the decorative patterns is detected, the CPU 11 identifies the decorative pattern to be deleted from among of the overlapping decorative patterns, based on a specified condition. The CPU 11 deletes the positioning data for the identified decorative pattern. The decorative patterns may thus be more easily visible, and the overall appearance of the decorated character pattern may be improved.
In the present embodiment, in the thinning-out processing shown in FIG. 23 , the specified condition for deleting a decorative pattern is that, in a case where the ratio of the surface area S where two decorative patterns overlap to the total surface area of the overlapping decorative patterns is not less than the threshold value Tb, one of the overlapping decorative patterns is to be deleted. Thus, in a case where two or more decorative patterns overlap, the CPU 11 is able to thin out the decorative patterns appropriately according to the specified condition. It is therefore possible to improve the balance of the positioning of the decorative patterns in the decorated character pattern.
Various types of modifications can be made to the embodiment that is described above. In the embodiment that is described above, a general-purpose device such as a personal computer or the like is used as the sewing data generation device 1 . However, the sewing data generation device 1 may also be a device that is dedicated to generating the embroidery data. The sewing data generation device 1 may also be incorporated into a sewing machine.
In the embodiment that is described above, a mode is explained in which the decorative patterns are positioned on the character pattern. Instead of the character pattern, a different embroidery pattern, such as a pictorial figure, a symbol, or the like, for example, may be used. Instead of a design (a floral design) such as the decorative pattern 85 in the embodiment that is described above, a different embroidery pattern, such as a text character, a pictorial figure, a symbol, or the like, for example, may be used. Such an embroidery pattern may be selected from among various types of embroidery patterns.
In the decorated character pattern creation processing shown in FIG. 4 in the embodiment that is described above, the thinning-out processing (Step S 7 ) may be omitted. The sewing data generation device 1 may be configured such that the user can select whether or not to perform the thinning-out processing.
In the pattern positioning processing shown in FIG. 20 in the embodiment that is described above, the decorative patterns 85 are positioned at all of the candidate points for the decorative patterns 85 that are identified by the characteristic point identification processing shown in FIGS. 9 and 10 . However, the decorative patterns 85 may be positioned at fixed intervals (such as at every other candidate point, for example). In the embodiment that is described above, the decorative patterns 85 that are positioned on the character pattern are all the same size. However, the sizes of the decorative patterns 85 may be enlarged and reduced according to the locations where the decorative patterns 85 are positioned, for example.
In the embodiment that is described above, the endpoints and the vertex of the character pattern are both identified as the characteristic points. Then the decorative patterns are positioned at the identified characteristic points. However, it is acceptable for only the endpoints or only the vertex of the character pattern to be identified, in accordance with a selection operation by the user, for example. Then the decorative pattern may be positioned at the identified characteristic point. The sewing data generation device 1 may be configured such that the user can use the input portion 20 to delete a decorated pattern manually while checking the decorated character patterns that are displayed on the display 21 .
In the embodiment that is described above, in the characteristic point identification processing shown in FIGS. 9 and 10 , the starting points and the ending points of the line segments that correspond to the center lines of the individual blocks in the block data are determined. However, it is not always necessary for the center lines of the individual blocks in the block data to be identified. It is sufficient for a line segment that indicates the direction of the block data to be identified.
In the embodiment that is described above, in the thinning-out processing shown in FIG. 23 , in a case where the ratio of the surface area S where the first pattern and the second pattern overlap to the total surface area of the overlapping decorative patterns is not less than the threshold value Tb (NO at Step S 54 ), the positioning data for the decorative pattern 85 positioned earlier are deleted. The decorative pattern 85 that was positioned later is given priority and left in place (refer to Step S 59 ). However, it is acceptable to give priority to and leave in place either one of the decorative pattern 85 positioned earlier and the decorative pattern 85 positioned later.
In the embodiment that is described above, at Step S 59 of the thinning-out processing shown in FIG. 23 , the positioning data for the first pattern are deleted in order to delete the positioned decorative pattern 85 . However, processing that invalidates the positioning data, for example, may be performed.
The decorated character pattern creation processing in the embodiment that is described above is not limited to the example of being performed by the CPU 11 . The decorated character pattern creation processing may be performed by a different electronic part (for example, an ASIC). The decorated character pattern creation processing may be performed by distributed processing by a plurality of electronic parts (that is, a plurality of CPUs). For example, a portion of the decorated character pattern creation processing may be performed by a server (not shown in the drawings) that is connected to the sewing data generation device 1 .
The apparatus and methods described above with reference to the various embodiments are merely examples. It goes without saying that they are not confined to the depicted embodiments. While various features have been described in conjunction with the examples outlined above, various alternatives, modifications, variations, and/or improvements of those features and/or examples may be possible. Accordingly, the examples, as set forth above, are intended to be illustrative. Various changes may be made without departing from the broad spirit and scope of the underlying principles.
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An apparatus includes a processor and a memory configured to store computer-readable instructions. The computer-readable instructions, when executed by the processor, cause the apparatus to perform processes of acquiring first pattern data and second pattern data, the first pattern data being data for sewing a first embroidery pattern, and the second pattern data being data for sewing each of at least one second embroidery pattern, identifying, based on the first pattern data, at least one characteristic point of a pattern shape describing the first embroidery pattern, setting positioning data for positioning and sewing the at least one second embroidery pattern at the respective identified at least one characteristic point, and generating sewing data, based on the first pattern data, the second pattern data, and the positioning data. The sewing data is data for sewing the first embroidery pattern and the at least one second embroidery pattern.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an electronic cash register, and more particularly, to an electronic cash register including three printing stations (hereinafter referred to as a three-station printer), whereby different papers are separately printed for their own purpose; one is as a receipt for customers, a second is as a journal for the seller, and a third is as a guest check (hereinafter referred to as a slip). More specifically, the present invention is concerned with the slip printing station adapted for use in an electronic cash register, wherein the slip printer station is located separately from the other two printing stations to ensure practical and physiological convenience for the operator.
2. Description of the Prior Art
A three-station printer cash register per se is known and in wide use; two examples are shown in FIGS. 1 and 2. The cash register illustrated in FIG. 1 has a three-station printer in the left-hand section of the cabinet 1, wherein the printer is provided with a slit 2 through which a slip paper is inserted. In the slit 2 a slip tray 3 is provided to support the slip, wherein a greater part of the slip tray protrudes beyond the cabinet 1 as shown in FIG. 1. The slip paper is fed from the front of the cash register toward the back thereof, during which it is printed. The cabinet 1 has a mark 4 on its left side to indicate a line at which the printing starts. However, this location is inconvenient for the operator, because he must bend his head leftward to align the mark with the desired starting-line. In addition, the operator must insert the slip paper with his left hand. Such physical posture leans to physiological discomfort for the operator. It is also disadvantageous that the cash register requires an extra space for admitting of the protrusion of the slip tray 3.
Another example is illustrated in FIG. 2, in which a two-station printer 6 is mounted in the left-hand section of the cash register while a slip printer 7 is mounted in the right-hand section on the cabinet 10, thereby constituting a three-station cash register as a whole. In this example the slip paper is likewise fed from the front of the cash register toward the back thereof. This latter type of cash register is known as Model 327 manufactured by Data Terminal System Inc. of Massachusetts, U.S.A. As shown in FIG. 2, the top surface of the cabinet 10 is rectangular with a relatively long width and a relatively short depth. The slip tray 8 must be placed in a limited area on the cabinet, and according its length is necessarily shortened in comparison with the width of the cash register. In addition, its extension frontward is not allowable because of a possible hindrance for the operator, nor is its extension backward allowable unless an additional space is provided in the back of the cash register. The mark 11 is also provided on the left side of the printer 7, thereby causing the same inconvenience for the operator. In addition, owning to the shortened slip tray, the slip paper is likely to droop down as shown in FIG. 2, which requires the operator to support it by hand. Likewise, when the printing is finished, the operator also must hold the slip paper from slipping off the cash register. This is troublesome for the operator.
In general, office machines, such as a typewriter with a reader puncher, have such a construction as to feed a tape or card perpendicularly to the operator, and this is no exception to known conventional cash registers.
The present invention is directed toward solving the inconvenience and disadvantages pointed out above, and has for its object to provide an improved three-station electronic cash register in which the slip paper is fed in parallel with the operator's breast who stands in front of the cash register.
Another object of the present invention is to provide an improved three-station electronic cash register in which a slip paper can be inserted and taken out by a normal, easy action of arms, that is, in the operator's natural posture.
A further object of the present invention is to provide an improved three-station electronic cash register occupying as small an installation space as the conventional two-station cash register.
A still further object of the present invention is to provide an improved three-station electronic cash register which can be used in a poor lit room without the use of a special light.
Other objects and advantages of the present invention will be readily understood from the following description and the accompanying drawings.
SUMMARY OF THE INVENTION
The electronic cash register includes a slip printer unit in addition to a two-station printer housed in a main cabinet, wherein the slip printer unit includes a slip printer and a slip feeder both housed in a casing mounted on the long, narrow top surface of the main cabinet, and wherein the slip printer conducts line-by-line printing on the slip paper which is longitudinally fed on the top surface of the main cabinet, thereby enabling the operator to handle the cash register in his easy, natural posture, and additionally admitting of the effective use of the long, narrow top surface of the main cabinet.
BRIEF EXPLANATION OF THE DRAWINGS
FIGS. 1 and 2 are perspective views showing examples of prior art cash registers;
FIG. 3 is a perspective view showing a cash register embodying the present invention;
FIG. 4 is an analytical perspective view of the cash register in FIG. 3;
FIG. 5 is a vertical cross-sectional particularly showing the slip printer unit in FIG. 3;
FIG. 6 is a perspective view showing a modified embodiment;
FIG. 7 is an electric block diagram.
FIG. 8 is a plan view of a slip on which line-by-line printings are made; and
FIG. 9 is a timing diagram illustrating the sequence of the slip printing operation.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 3, the main body of the cash register is covered by a cabinet 11 in which a two-station printer 14 is housed. The cabinet 11 also has a keyboard 12 and a display window 13. A slip printer unit is housed in a casing 15 which is fastened to the frame 22 of the main body by means of fasteners 27. The casing 15 is provided with a slit 16, and the portion of the top surface 25 of the cabinet which corresponds to the slit 16 is cut away at 25' so as to accept the casing 15 as shown in FIG. 5. The cut-away portion 25' of the top surface 25 is covered by a slip tray 24. The slip tray 24 is also provided with its cut-away portion 26, and with a guide 23 at its backward edge. The slit 16 of the casing is engaged with the cut-away portion 26 of the slip tray to allow a feed roller 19 and a pinch roller 20 of a slip feeder 31 to be engageable with each other therein. This will be more particularly described below. The slip printer unit is composed of a slip printer 21 and a slip feeder 31. Reference numeral 18 denotes a mark to indicate a place at which the printing starts. The casing 15 is provided with a window 29 through which an inside lamp 30 throws its light.
Referring to FIG. 5, the slip printer unit will be explained in greater detail:
The slip feeder 31 includes the feed roller 19 and the pinch roller 20, wherein the feed roller is driven by an electric motor 32 through a suitable gear train. The feed roller 19 and pinch roller 20 rotate in the direction indicated by the respective arrows in FIG. 5 to feed the slip paper (A) to the left in the drawing. The pinch roller 20 is carried on a lever 33 whose top end is connected to the casing 15 by means of a coil spring 34. The lever 33 is connected to an electromagnet 35 at the other end. When the electromagnet 35 is energized, the pinch roller 20 is placed into contact with the feed roller 19 against the coil spring 34, and when it is deenergized, the pinch roller 20 comes out of contact with the feed roller 19, and returns to its original position under the urge of the coil spring 34. In order to increase the friction between the feed roller and pinch roller, each roller can be made of rubber, or can be provided with a rubber surfacing on each periphery.
The slip printer 21 is a known stylus printer, consisting of a dot matrix printer head (hereinafter referred to as the head) and a scanner causing the head to scan over the surface of the slip paper to effect line patterns of printing. In FIG. 5 the head travels perpendicular of the plane of the drawing paper, that is, toward and from the operator who stands in front of the cash register. FIG. 8 shows a sample of a printed slip, wherein individual characters are formed by 5×7 dot matrix. The given data is printed in a single line with these characters. The head includes seven needle elements which are selectively driven under the control of a central processing unit 42 (hereinafter referred to as the CPU). The scanner also causes the head to scan over the surface of the slip paper under the control of the CPU. The slip printer 21 is supplied with an ink ribbon from a reel 36. During a single scanning of the head the needle elements are selectively driven to print a line 37. At this stage the pinch roller 20 is kept out of contact with the feed roller 19 under the deenergization of the electromagnet 35. When the line 37 is completely printed, the electromagnet 35 is energized under the control of the CPU, thereby causing the pinch roller 20 to come into contact with the feed roller 19. As a result the slip paper (A) is longitudinally fed merely by the distance of a line, and the next line 38 is printed. In this way the whole desired printing is conducted line by line during the intermittent longitudinal feeding of the slip paper.
Referring to FIG. 9, a typical example of operation will be explained:
The slip paper (A) is inserted by the operator into the slit 16 by setting the desired starting line to the mark 18. This term corresponds to the Slip Paper Handling Stage 44 in FIG. 9. The input signal is transmitted from the keyboard 12 to the CPU 42 (Stage 39), thus initiating the operation of the slip printer unit. The electric motor 32 is energized (Stage 40), and at the same time the head is initiated to scan (Stage 41), while the needle elements are selectively driven under the control of the CPU (Stage 42). In this way the first line 37 (FIG. 8) is printed. Then the head is caused to return to its starting position. The electric motor 32 and the electromagnet 35 are respectively energized, whereby the slip paper (A) is longitudinally fed merely by the distance of a line due to compression between the feed roller 19 and the pinch roller 20 (Stage 43). When the next printing line 38 comes under the mark 18, the feeding of the slip paper stops as a result of the release of pinch roller 20 from the slip paper (A) due to the deenergization of the electromagnet 35. A further input signal is transmitted from the keyboard 12 for printing the second line 38.
In this way the printing is conducted line by line on the slip paper under the control of the CPU 42. When the whole desired printing is finished, the slip paper (A) comes out of contact with the feed roller and the pinch roller.
The embodiment illustrated in FIG. 6 has a cabinet 11 whose top surfaces 25 is slanted rearward. In addition, the top surface 25 is provided with a guide 28 in alignment with the guide 23 of the slip tray 24. Thus, the slip paper (A) can safely rest on the top surface of the cash register after it has been released from the rollers 19 and 20.
Referring to FIG. 7, an input terminal 41 is electrically connected to the keyboard 12 to generate signals. The keyboard includes many keys, that is 0 to 9 numbered keys, a point key, and functional keys, such as an itemizing key and a transaction key.
The CPU 42 includes a read-only memory for storing programs; a random access memory for storing input and output signals and figures under arithmetical operation; an arithmetical circuit, and a timing-signal generator circuit. A display circuit 43 is to indicate the signals of the CPU 42. A two-station printer drive circuit 44 is to impress the output signals provided by the CPU 42 on the two-station printer 14. A slip printer drive circuit 45 is to impress the output signals provided by the CPU 42 on the slip printer 21, in association with which the electric motor 32 and the electromagnet 35 are controlled.
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The electronic cash register includes a slip printer unit in addition to a two-station printer housed in a main cabinet, wherein the slip printer unit includes a slip printer and a slip feeder both housed in a casing mounted on the long, narrow top surface of the main cabinet, and wherein the slip printer conducts line-by-line printing on the slip paper which is longitudinally fed on the top surface of the main cabinet, thereby enabling the operator to handle the cash register in his easy, natural posture, and additionally admitting of the effective use of the long, narrow top surface of the main cabinet.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to an application entitled “RELEASABLE BLOCK FOR ROTATING HOOD HOLSTER” Ser. No. 09/562,085, filed by Norman E. Clifton, Jr. on Apr. 27, 2000; and an application entitled “SUPPORT PLATE FOR A HOLSTER”, Ser. No. 09/696,561, filed by William H. Rogers and Norman E. Clifton, Jr. on Oct. 25, 2000; and is a continuation-in-part of an application entitled, “AUTOMATIC LOCKING HOLSTER”, Ser. No. 09/770,710, filed by William H. Rogers and Norman E. Clifton, Jr. on Jan. 26, 2001.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
Not Applicable.
REFERENCE TO A MICROFICHE APPENDIX
Not Applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to handgun holsters and more particularly a holster with improved features to prevent inadvertent dislodgement, rotation, or withdrawal of the handgun from the holster. The holster is designed to retain the handgun securely and yet to permit rapid withdrawal when required.
2. Prior Art
Most attacks on police officers by assailants trying to remove officer's handguns from holsters have come from the front or side of officers and not from the rear. It is obvious that an assailant has more mechanical leverage as well as an unobstructed path by simply pulling forward and up on the handle of the weapon while standing in front facing the officer or facing him at his side.
Most securing straps of holsters might become unlocked in a violent attack. Because of this possibility, an internal locking method is incorporated in some of the prior art holsters to make it more difficult for the attacker to remove the handgun from the holster in an attack from the rear of the officer. Generally, the internal locking means engages the back recurve of the trigger guard or the top ledge of a cylinder of a revolver. In more recent times the popularity of the semiautomatic pistol has posed a problem in the design of a secure holster because this type of handgun has no cylinder ledges nor trigger guard recurves to serve as a locking point. An attempt to lock upon the forward portion of the trigger guard is not preferred because only a few models of semiautomatics offer a flat ledge at the forward portion of the trigger guard necessary for the locking action.
What is needed is an improved handgun holster which overcomes the deficiencies of the prior art, and is designed to provide a holster which secures the handgun from withdrawal by any but the wearer and yet permits a fast withdrawal upwardly by one trained in using the holster. Further, a holster is needed that provides obstacles to one attempting an unauthorized withdrawal of the handgun from the front or side of the holster.
In addition, an improved holster requires a locking mechanism that prevents rotation of a weapon in the holster, which could dislodge the locking action therein.
In addition, a need exists for apparatus that provides a way to allow a user to rapidly reholster a gun securely and quickly if it is not needed in a particular circumstance. For example, a user may draw a gun and find that deadly force is not required and that hand-to-hand action will suffice against a criminal suspect. A user would then need to rapidly reholster the gun without looking but still have the gun secured by a fast acting, self-locking apparatus in a manner that greatly inhibits its grasp by an assailant.
BRIEF SUMMARY OF THE INVENTION
In one aspect of the present invention there is provided an automatic locking holster comprising a quick release withdrawal restraint, an inner and outer sidewall joined together along front and back portions and sidewalls having interior surfaces defining an inner cavity having an open top shaped to fit a handgun holsterable therein. The restraint includes first blocking means located in the inner cavity to engage a portion of a handgun in the holster to inhibit withdrawal of a handgun upwardly prior to rearward movement of a handgun and second blocking means mounted adjacent the rear portion movable between a first position that engages a portion of a handgun to inhibit rearward movement of a handgun and a second position that permits rearward movement of a handgun to withdraw same from the holster. There is third blocking means located in the cavity adjacent a handgun holstered therein to prevent movement of a holsterable handgun to cause movement of the second blocking means from the first position.
The third blocking means includes a blocking member located between one of the interior surfaces and a portion of a holsterable handgun. The third blocking means also includes biasing means located between one interior surface and the second blocking means for maintaining the second blocking means in the first position until the second blocking means is selectively moved. The biasing means includes spring means to apply force to the second blocking means to bias the second blocking means in the first position. The second blocking means includes a body member and the spring means is located between one of the interior surface of one of the sidewalls and the body member.
The third blocking means includes a horizontally disposed post having opposite end portions located between one of the interior surfaces of one of the sidewalls and a portion of a holsterable handgun. Alternatively, the third blocking means may include an elongate post having an elongate body member and a planar head portion, the head portion being adjacent one of the interior surfaces of one of the sidewalls, the third blocking means further including a spring having opposite end portions and a hollow therein, the spring being located between the head portion and the second blocking means. The post is located inside the hollow of the spring for locating the post closely adjacent a portion of a holsterable handgun. One end portion of the spring is engaged with the head portion of the post to bias the head portion against one interior surface of one sidewall. In addition, the body member of the second blocking means is disposed between the one interior surface of one sidewall and a handgun holsterable in the holster, and having an opening extending therethrough to accommodate the post and to permit contact between one of the end portions of the post and a portion of a handgun holsterable in the holster.
In another aspect of the invention, there is provided an automatic locking holster comprising a quick release withdrawal restraint, an inner and outer sidewall joined together along front and back portions, the sidewalls having interior surfaces defining an inner cavity having an open top shaped to fit a handgun and its trigger guard holsterable therein, the restraint including first blocking means located in the inner cavity to engage a portion of a handgun in the holster to inhibit withdrawal of a handgun upwardly prior to rearward movement of a handgun, second blocking means mounted adjacent the rear portion movable between a first position that engages a portion of a handgun to inhibit rearward movement of a handgun and a second position that permits rearward movement of a handgun to withdraw same from the holster. The second blocking means includes a body member having a portion generally parallel to one of the interior surfaces of the inner sidewall, the portion of the body member and one of the interior surfaces of the outer sidewall forming a channel for receiving a trigger guard of a holsterable handgun. Third blocking means is located in the cavity adjacent a trigger guard of a handgun holstered therein to prevent movement of such handgun to cause movement of the second blocking means from the first position. The third blocking means includes a blocking member located between one interior surface and a portion of a holsterable handgun. The third blocking means includes biasing means located between one interior surface and the second blocking means for maintaining the second blocking means in the first position until the second blocking means is selectively moved.
The holster further includes an elongated restraining strap having opposite ends and a medial portion bridging the sidewalls across the open top, means for pivotal attachment of the opposite ends of the strap to the respective sidewalls to permit movement of the strap from a position across the open top to restrict handgun withdrawal to a position generally forwardly of the holster to permit handgun withdrawal, the means for pivotal attachment for preventing forward pivotal movement of the restraining strap until the strap is moved at the means for pivotal attachment in a predetermined direction. There is also selectively operable blocking means attached to the holster movable between a first position to prevent forward pivotal movement of the strap after the strap has first been moved in the downward direction and a second position to allow forward pivotal movement of the strap after the strap has been moved in the downward direction. The third blocking means includes a horizontally disposed post having opposite end portions located between one interior surface of one of the sidewalls and a portion of a holsterable handgun. The third blocking means may also include an elongate post having an elongate body member and a planar head portion, the head portion being adjacent one of the interior surfaces of one of the sidewalls, the third blocking means further including a spring having opposite end portions and a hollow therein. The spring is located between the head portion and the second blocking means, the post being located inside the hollow of the spring for locating the post closely adjacent a portion of a holsterable handgun. One end portion of the spring is engaged with the head portion of the post to bias the head portion against the interior surface of one sidewall. The third blocking means includes a blocking element positioned horizontally between one interior surface of one sidewall and a trigger guard of a handgun.
The first blocking means includes stop means including an inwardly disposed boss having a front-end portion and a rear end portion. The front-end portion of the boss is shaped to engage an inner surface of an ejection port of a handgun to inhibit upward movement of a handgun.
In a further aspect of the present invention there is provided an automatic locking holster comprising a quick release withdrawal restraint, an inner and outer sidewall joined together along front and back portions, the sidewalls having interior surfaces defining an inner cavity having an open top shaped to fit a handgun having a trigger guard holster therein. The restraint includes first blocking means located in the inner cavity to engage a portion of a handgun in the holster to inhibit withdrawal of a handgun upwardly prior to rearward movement of a handgun, second blocking means including a body member mounted adjacent the rear portion movable between a first position that engages a portion of a handgun to inhibit rearward movement of a handgun and a second position that permits rearward movement of a handgun to withdraw same from said holster. The body member has a channel therein for locating a portion of a trigger guard of a handgun holsterable in the holster to prevent removal of a handgun holstered in the holster unless the body member is in the second position. A third blocking means is located in the cavity adjacent a handgun holstered therein to prevent movement of a handgun in a manner to cause movement of the second blocking means from the first position.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The novel features which are believed to be characteristic of this invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in connection with the accompanying drawings, in which:
FIG. 1 is a side view of the holster according to the present invention with a portion cut away to illustrate the space used to secure stop means to the holster;
FIG. 2 is a top view of the holster of FIG. 1;
FIG. 3 is a perspective of an alternate embodiment of the rearward securing assembly of FIG. 1;
FIG. 4 is a cross-section of the stop means used in the holster;
FIG. 5 is a front elevational view of the stop means of FIG. 4;
FIG. 6 is a side elevational view of the rearward securing assembly of FIG. 1 shown attached to the biasing assembly;
FIG. 7 is a perspective view of the blocking member employed in FIG. 6;
FIG. 8 is another perspective view of the blocking member of FIG. 7 :
FIG. 9 is a side elevational view of another embodiment of the rearward securing assembly;
FIG. 10 is a rear view of the guard block of FIG. 9;
FIG. 11 is a side elevational view of an alternate embodiment of the rearward securing assembly in accord with the present invention;
FIG. 12 is a perspective view of the assembly of FIG. 11;
FIG. 13 is another perspective view of the assembly of FIG. 11 showing the anti-rotation apparatus in accord with the present invention;
FIG. 14 is a partial diagrammatic view of the assembly of FIGS. 11-13 in use securing a handgun in a holster;
FIG. 15 is a side elevational view of an alternative embodiment of the rearward securing apparatus in accord with the present invention;
FIG. 16 is a diagram illustrating the engagement point of the assembly of FIG. 15 with the trigger guard of a handgun in a holster;
FIG. 17 is a perspective view of the assembly of FIG. 15;
FIG. 18 is a partial diagrammatic view of the assembly of FIGS. 15-17 in use securing a handgun in a holster; and
FIG. 19 is a partial cross-sectional exploded diagram showing the relative positioning of the components of the anti-rotation blocking device according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention incorporates features of previous patents and co-pending applications of one or both of the present inventions.
1. The present holster employs the biasing apparatus of Rogers, et al '239 to force a handgun forwardly to position the ejection port of a semi-automatic handgun against a stop in the holster. Once seated in this manner, the gun cannot be withdrawn in a simple vertical manner. Rather, the gun must be forced rearwardly against the biasing means to remove it from the stop means. The stop means is removable in the event it becomes worn down so that a new stop means may be inserted. In addition, the stop means is replaceable by another stop means more appropriate to the handgun being used. In the present invention, the stop means is specifically designed to work with a Glock handgun. If the holster is to be used with another type of handgun, the stop means can be easily replaced with one that provides a better match for the handgun actually being used.
2. The present invention may employ the bridging strap of Rogers, et al '381. The bridging strap rides over the rear of a handgun and includes a hood that is rotatable forwardly thus allowing the gun to be withdrawn. The hood is connected to a vertically movable leg member that must be depressed downwardly to allow for rotation of the hood forwardly.
3. The present holster may also include the hood blocking means of Rogers, et al application '085. A positive locking means is positionable in a manner to prevent downward movement of the leg member unless a blocking member is rotated rearwardly out of the way. Because the blocking member must be rotated rearwardly to allow the leg member to be moved downwardly the required action makes it very difficult for an assailant to withdraw the gun. When used with the biasing element and stop means as discussed above even greater security is achieved.
4. The present holster is designed to be used with the improved holster back plate disclosed in Rogers, et al—appl. Ser. No. 09/696,561. The back plate cooperates with a holster belt to prevent movement of the holster forwardly and rearwardly along the belt. This feature includes greater assurance that the holster remains where the user sets it and provides the security of knowing precisely where the accompanying handgun is located.
5. The present holster provides for an alternative to the rear strap used in Rogers '980. The strap used therein operates to hold the rear of the holster—shaped like a clam shell—to be held tightly together providing additional security against assailant withdrawal.
With reference now to the drawings, FIGS. 1 and 2 illustrate at numeral 10 a side view and rear view respectively of the holster 11 in accordance with the present invention. Biasing apparatus 12 forces a handgun 16 (shown in dotted line in FIG. 1) forwardly against stop means 15 (shown only generally in FIG. 2 ).
Hood strap assembly 13 is shown up in FIG. 1 and rotated forwardly in FIG. 2 . The rearward securing assembly is shown generally at 14 and is movable inwardly (in broken line) from its normal position (shown in solid line) as indicated by arrow 21 .
With reference to FIGS. 1 and 6, forward biasing means 12 includes a support body 22 by which the apparatus 12 is attached to holster 11 . An engaging member 23 is pivotally mounted via pin 24 . Member 23 carries a roller 25 mounted on axle 26 and is internally spring biased to be forced against trigger guard 17 . Flange 27 provides for mounting body 22 to holster 11 via a T-nut 28 or other appropriate means as illustrated in U.S. Pat. No. 5,944,239 incorporated herein by reference. With respect again to FIG. 2, hood strap assembly 13 includes hood strap 29 having a thumb ledge 30 by which leg 31 can be pushed downwardly to allow for strap 29 to be rotated forwardly as shown once the locking mechanism is cleared as clearly illustrated in U.S. Pat. No. 5,501,381 which is herein incorporated by reference.
Releasable blocking apparatus 32 includes a thumb ledge 33 by which a blocking element 34 can be moved rearwardly to allow leg 31 to be pushed downwardly as clearly illustrated in appl. Ser. No. 09/562,085 which is herein incorporated by reference.
FIGS. 4 and 5 illustrate the preferred stop means used in the present invention. Stop means insert 35 includes a series of ribs 36 that match curved interior channel 38 in holster 11 resting on ledges 39 (FIG. 2) which fixes it in place when the holster is closed with screws 45 . Interior upper channel 37 provides clearance for the forward sight 18 of a handgun 16 . Boss 40 includes three portions: a first flat portion 41 fits into the forward portion of an ejection port 19 ; and second and third portions 42 and 43 that “cam up” or guide the muzzle of a handgun 16 when it is inserted into the holster 11 . Biasing apparatus 12 also engages the gun, forcing it upwardly against the forward portion of the holster 11 providing that boss 40 fits into port 19 . Direct rearward (i.e., vertical) movement of the handgun 16 will be blocked by the forward part of the gun 16 adjacent the forward edge of port 19 coming into contact with front portion 41 of boss 40 . Accordingly, rearward motion of the gun 16 against biasing apparatus 12 is required to clear boss 40 and remove the gun 16 from holster 11 .
As also shown in FIG. 2, stop means 35 is a unitary plastic element that fits into interior space 38 and is secured into position when screws 45 are tightened to close the holster 11 without any additional mechanical means and is therefore easily replaceable. The holster 11 is held together rearwardly in a clamshell-like fashion via screws 45 that provide for sufficient closure of the holster side 46 and the two inward overlapping sidewall portions 47 and 48 . Portion 47 is unitary with side 46 and is formed to overlie portion 48 to further provide for security against gun 16 being withdrawn by an assailant a rearward engaging means 14 is employed to prevent rearward movement of the gun 16 unless a blocking element 49 is pushed inwardly and out of the way of the trigger guard 17 by a user.
The blocking element is shown in FIGS. 7-8. Element 49 includes a body 50 having a first end portion 51 to which it is mounted to biasing member body 22 using pin 24 and a second end portion 52 including a finger ledge 57 by which it is moved sideways with a middle finger preferably, or an index finger.
First end portion 51 includes pin (or screw) hole 53 by which it is rigidly attached to body 22 . Another medially located hole 56 in body 22 fits over laterally extending post 55 mounted on body 27 . Hole 54 provides a passageway for a screw or bolt 45 mounting biasing assembly 12 . Flange 58 extends laterally and aids in blocking debris from entering the holster 11 and the associated securing apparatus such as the pivot means. Cavity 59 in ledge 57 reduces weight. Rib sections 60 and 62 cooperate with the specific embodiment of biasing apparatus 12 used in the holster 11 . Rib 61 is preferably in contact with trigger guard 17 . The rib 61 is upraised to fit forwardly of ledge 57 against trigger guard 17 to minimize the allowed rearward movement of handgun 16 before the movement is blocked. When blocking element 49 is moved sideways by finger pressure on ledge 57 , rib 61 is moved away from trigger guard 17 and sufficient room will exist between adjacent flange 63 and surface 63 ′ to allow enough to allow enough rearward movement of the handgun 16 to disengage the ejection port 19 from stop means boss 40 but not enough movement to allow the gun 16 to clear the rotating hood 29 if the hood 29 is upward in its blocking position.
FIG. 6 illustrates an alternative embodiment of a rearward securing assembly 67 . Biasing assembly 68 is substantially the same as the assembly 12 . Housing 69 provides space 70 for spring 71 and guard block 72 that is normally biased to be in contact with trigger guard 17 . Vertical channel 73 is also formed in housing 69 and provides a travel path for holding pin 74 by which block 72 is mounted to spring 71 . Trigger guard arm 75 extends upward on the inward (user's) side of holster 76 and terminates in thumb ledge 77 . Downward pressure on ledge 77 pushes guard block 72 downwardly in space 70 below trigger guard 17 allowing for rearward motion of gun 16 as before. Spring 71 mounted being locating elements 78 and 79 .
FIGS. 9 and 10 illustrate another embodiment of a rearward securing assembly 80 . Biasing assembly 81 is substantially as before and includes a space 82 in housing 83 in which guard block 84 is mounted on spring 85 via pin 86 which moves in vertical channel 87 . Finger ledge 88 is used to depress block 84 downwardly to allow rearward movement of trigger guard 17 for withdrawal of gun 16 as before.
Finger ledge 88 is formed with a medially located channel 89 to keep ledge 88 close to the gun 16 for close to the handgun 16 for increased safety. Spring locating elements 91 , 92 are as before.
To summarize, when handgun 16 is inserted into the holster 11 the tapered portion of stop 15 results in an angled entry of the muzzle with the trigger guard 17 rearwardly. As the handgun 16 is inserted further, biasing means 12 begins to force handgun 16 forwardly as trigger guard 17 makes contact with rear securing means 14 at a rearward portion of cam or flange surface 63 ′ and the trigger guard pushes the blocking element 49 inwardly out of the way to permit handgun 16 to become fully seated, whereupon the blocking element 49 by surface 61 ′ of rib 61 engages the trigger guard 17 to prevent rearward movement and to automatically lock the gun in the holster. Further securing is accomplished by rotating hood 29 over the handgun 16 and further securing by hand lock-blocking element 34 .
With respect to FIG. 11, forward biasing member 99 is comprised of support body 93 , engaging member 94 , pins 95 , roller 96 mounted on axle 96 ′, flange 97 carrying T-nut 98 all substantially identical to the prior members. The mechanical blocking element 100 has been modified to prevent rotation or twisting of a handgun that could be sufficient to dislodge the gun from the rearward securing assembly 14 (FIGS. 1 - 2 ). Body 101 includes a laterally extending post 102 and a boss 104 both of which will engage a trigger guard, and hole 103 for a post, which will be described hereinbelow. Flange 105 finger ledge 106 and surface 107 are as before as is rib 112 .
Flanges 109 and 110 are modifications of the apparatus of FIG. 6 to provide a channel 111 to hold a gun trigger guard therein. The trigger guard is guided by flange 109 and abuts rib 112 and post 102 . The curvature of flange 108 provides an engaging surface for a gun trigger.
Flange 97 is shown removed in FIG. 12 and illustrates that lower end 116 of body 101 includes ribs 113 and 114 , holes 115 and 119 and flange surface 118 are as before.
The reverse of element 100 is shown in FIG. 13 and illustrates anti-rotation apparatus 126 , which consists of two parts: spring 121 and post 125 . Post 125 has top head 124 and fits into smaller upper end 123 of spring 121 , which mounts head 124 against inside surface 47 ′ of sidewall 47 . Larger diameter lower end 122 rests on a portion 127 of body 101 adjacent post hole 103 as indicated by arrow 130 . Post 129 , T-nut hole 128 and cavity 120 are as before.
With regard also to FIG. 14, post head 124 is held against the inside surface 47 ′ of a holster sidewall 47 of holster 149 (shown in dotted line). Excessive lateral movement or rotation of a gun 148 is prevented by the engagement of post 125 with the trigger guard 150 at the area shown in broken line 151 .
The relative positions of post 102 and rib portion 152 of trigger guard 150 which fits into channel 111 is shown in solid line. The rest of apparatus 100 is not shown for purposes of clarity.
Accordingly, gun 148 cannot be moved in a manner to force apparatus 100 out of a locked position into, for example a release position by twisting or other movement.
With regard to FIGS. 15, 16 , and 17 , forward biasing member 131 includes body 132 , engaging member 133 , pins 134 , roller 135 , axle 136 , flange 137 , and T-nut 138 all of which are substantially identical to the apparatus previously described hereinabove.
Mechanical blocking element 100 is substantially identical to element 49 of FIG. 6 with the exception of post hole 141 to accommodate a post 125 as part of apparatus 126 . Body 140 includes flange 142 , finger ledge 143 , surface 144 , flanges 145 and 146 , and rib 147 .
With regard to FIG. 18, gun 154 , mounted in holster 155 , has a slightly different form of trigger guard 156 having a substantially straight lower rib 158 , curved front end 157 . Trigger 159 is also slightly different.
The anti-rotation apparatus used here is identical to apparatus 126 (FIG. 13) and is identically mounted. Post 125 engages area 160 (shown in broken line) spring end 122 rests against body portion 162 via arrow 161 . Here as in FIGS. 11-14, the post 125 engagement will prevent movement of element 139 by rotation or twisting of gun 154 to dislodge the gun 154 from the holster 155 by moving the rearward securing apparatus 14 out of the locked position.
In both embodiments spring 121 provides force against blocking element body 101 , 140 to bias the body 101 , 140 to the locked position and provide further security against withdrawal of a respective handgun 148 , 154 until the proper steps for release are taken.
Rotating hood is illustrated in FIGS. 1 and 2 but is not required for use with anti-rotation blocking apparatus 126 .
While the invention has been described with respect to certain specific embodiments, it will be appreciated that many modifications and changes may be made by those skilled in the art without departing from the spirit of the invention. It is intended, therefore, by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention.
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A holster includes a quick release withdrawal restraint and is constructed of an inner and outer sidewall joined together along a front and back to define an inner cavity with an open top shaped to fit a handgun. The quick restraint includes a mechanical blocking element located in the inner cavity to engage a portion of the handgun adjacent the ejection port to inhibit withdrawal upwardly prior to rearward movement of the handgun. A second mechanical blocking element is also provided adjacent the rear of the trigger guard that is biased into a first position to prevent rearward movement of the gun and a second position that allows for rearward movement of a gun when the second blocking element is moved by pressure on a thumb or finger ledge. A third mechanical blocking element is provided to prevent motion of a handgun when holstered in a manner to cause movement of the second blocking element from the first position.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of U.S. Ser. No. 12/647,318, entitled “Loop Rope Assembly”, filed Dec. 24, 2009, now U.S. Pat. No. 8,590,116 which application is hereby incorporated by reference for all purpose.
FIELD OF THE INVENTION
The disclosure generally relates to devices for securing an object on a transporting vehicle or the like. More particularly, the disclosure relates to a loop rope assembly which includes a pair of end loops and multiple intermediate loops that can be used as attachment points to secure an object such as during transport of the object, for example.
BACKGROUND OF THE INVENTION
Various techniques are known for securing objects on a transport vehicle or a tarp or cover on an object such as a boat, for example, during transport of the object. One of the most common methods for securing an object includes tying ropes to attachment points on the transport vehicle and attaching the ropes to the object or tightening the ropes against the object. Bungee cords or the like may be attached to the ropes and to attachment points on the transport vehicle to additionally secure the object on the vehicle. In some applications, tie-down straps fitted with ratchet mechanisms adapted to tighten the straps may be used to secure the object to the vehicle.
One of the drawbacks of using conventional ropes and bungee cords to secure an object on a transport vehicle is that the ropes must be tied securely to prevent the ropes from inadvertently becoming detached during transport. Therefore, proper securing of the object on the vehicle may require knowledge of how to correctly tie the knots in the ropes to prevent the ropes from inadvertently becoming untied. Furthermore, the bungee cords may not be securely attached to the ropes since the ropes typically lack suitable attachment points for the bungee cords between the ends of the ropes. Moreover, the ratchet mechanisms on many tie-down straps may be complicated and difficult to operate.
Accordingly, a loop rope assembly is needed which is simple and easy to use and includes a pair of end loops and multiple intermediate loops that can be used as attachment points for bungee cords, ropes or tie-down straps to secure an object on a transport vehicle or a tarp or cover on an object during transport of the object, for example.
SUMMARY OF THE INVENTION
The disclosure is generally directed to a loop rope assembly. An illustrative embodiment of the loop rope assembly includes a main rope segment having a plurality of rope strands and first and second ends, a first end loop provided on the first end of the main rope segment, a second end loop provided on the second end of the main rope segment and at least one intermediate loop defined by at least one of the rope strands.
In some embodiments, the loop rope assembly may include a main rope segment having a plurality of rope strands and first and second ends; a first end loop provided on the first end of the main rope segment; a second end loop provided on the second end of the main rope segment and at least one intermediate loop defined by at least one of the rope strands. At least one of the rope strands can be selectively pulled away from remaining ones of the rope strands to define and adjust the size of the at least one intermediate loop.
In some embodiments, the loop rope assembly may include a main rope segment having a pair of rope strands and first and second ends; a first end loop provided on the first end of the main rope segment; a second end loop provided on the second end of the main rope segment; a plurality of spaced-apart strand sleeves provided on the main rope segment; and at least one intermediate loop defined by one of the rope strands between the strand sleeves.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosure will now be made, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view, partially in section, of an illustrative embodiment of the loop rope assembly;
FIG. 2 is a perspective view of an illustrative embodiment of the loop rope assembly in the securing of a load (illustrated in phantom) in an exemplary application of the loop rope assembly;
FIG. 3 is a perspective view, partially in section, of an illustrative embodiment of the loop rope assembly, more particularly illustrating attachment of one end of the loop rope assembly to a truck bed side (illustrated in phantom) of a pickup truck in an exemplary application of the loop rope assembly;
FIG. 4 is a perspective view of an alternative illustrative embodiment of the loop rope assembly;
FIG. 5 is a perspective view of the illustrative embodiment of the loop rope assembly illustrated in FIG. 4 in the securing of a load (illustrated in phantom) in an exemplary application of the loop rope assembly; and
FIG. 6 is a perspective view, partially in section, of the illustrative embodiment of the loop rope assembly illustrated in FIG. 4 in the securing of a tarp or boat cover (illustrated in phantom) on a boat (illustrated in phantom) in an exemplary application of the loop rope assembly.
DETAILED DESCRIPTION
The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to practice the disclosure and are not intended to limit the scope of the claims. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.
Referring initially to FIGS. 1-3 of the drawings, an illustrative embodiment of the loop rope assembly is generally indicated by reference numeral 1 . The loop rope assembly 1 may include multiple rope strands 2 which are wound in a braided configuration. In some embodiments, the loop rope assembly 1 may include three braided rope strands 2 , as illustrated. In other embodiments, the loop rope assembly 1 may include four or more braided loop strands 2 . In some embodiments, the rope strands 2 may be a single continuous rope. Each rope strand 2 may be nylon or other suitable material. The loop rope assembly 1 may include a generally elongated main rope segment 3 . A pair of end loops 4 may terminate the respective ends of the main rope segment 3 . In some applications, each end loop 4 may be inserted through the opposite end loop 4 to define an attachment loop 5 in one or both ends of the main rope segment 3 . As illustrated in FIG. 2 , each rope strand 2 can be selectively pulled away from the other rope strands 2 of the main rope segment 3 or either or both of the end loops 4 to define one or multiple intermediate loops 8 each having an adjustable size. Each intermediate loop 8 may be in-plane (the rope strands 2 which define each intermediate loop 8 may be disposed within the same plane).
As illustrated in FIG. 2 , in an exemplary application the loop rope assembly 1 can be used to secure a load 16 to a support surface (not illustrated) which in some applications may be a support surface on a transport vehicle (not illustrated) such as a pickup truck or trailer, for example and without limitation. Multiple anchor plates 12 , each having an anchor hook 13 , may be provided on the support surface in proximity to the load 16 . Accordingly, the main rope segment 3 of the loop rope assembly 1 may be extended generally around the lower portion of the load 16 and the end loops 4 ( FIG. 1 ) attached to one of the anchor hooks 13 . One of the rope strands 2 may then be pulled away from the other rope strands 2 at the appropriate locations along the length of the main rope segment 3 to form the intermediate loops 8 , which may be attached to the remaining anchor hooks 13 . One or multiple bungee cords 14 (illustrated in phantom) may then be used to additionally secure the load 16 by forming additional intermediate loops 8 in the main rope segment 3 , attaching a bungee cord hook 15 on one end of each bungee cord 14 to an intermediate loop 8 on one side of the load 16 , extending the bungee cord 14 over the top of the load 16 and attaching the bungee cord hook 15 on the other end of the bungee cord 14 to an intermediate loop 8 on the opposite side of the load 16 . Thus, the load 16 is secured for transport of the load 16 on the transport vehicle or for other purposes. The load 16 can be unsecured, as desired, by detaching each bungee cord 14 from the corresponding pair of intermediate loops 8 ; detaching the intermediate loops 8 from the respective anchor hooks 13 ; and detaching the end loops 4 ( FIG. 1 ) from the anchor hook 13 .
As illustrated in FIG. 3 , in some applications of the loop rope assembly 1 , each end loop 4 may be inserted through the opposite end loop 4 to define an attachment loop 5 in one or both ends of the main rope segment 3 . The attachment loop or loops 5 may be used to fasten the loop rope assembly 1 to one or more attachment points on a transport vehicle or on the object or load which is to be secured. Accordingly, as illustrated in FIG. 3 , in an exemplary application, a first end loop 4 on one end of the main rope segment 3 can be extended through a conventional fastener opening 22 which is provided in a truck bed side 21 of a pickup truck 20 . The opposite end loop 4 ( FIG. 1 ) can then be extended through the first end loop 4 to form the attachment loop 5 which secures the loop rope assembly 1 to the truck bed side 21 , as illustrated. The end loop 4 on the unsecured end of the main rope segment 3 can be fastened to another attachment point (not illustrated) on the pickup truck 20 or to the object or load (not illustrated) which is to be secured. Additional attachment points for bungee cords 14 ( FIG. 2 ) or the like can be provided by forming the intermediate loops 8 in the main rope segment 3 and/or in either or both of the end loops 4 , as was heretofore described with respect to FIG. 2 .
Referring next to FIGS. 4-6 of the drawings, another illustrative embodiment of the loop rope assembly is generally indicated by reference numeral 24 . The loop rope assembly 24 may include a pair of adjacent rope strands 26 which define a main rope segment 27 and a pair of end loops 30 at respective ends of the main rope segment 27 . Each rope strand 26 may be nylon or other suitable material. In some embodiments, the rope strands 26 may be a single continuous rope. The rope strands 26 may extend through a pair of adjacent openings (not illustrated) provided in each of multiple strand sleeves 28 . The strand sleeves 28 may be provided at spaced intervals with respect to each other along the main rope segment 27 . Accordingly, between each pair of adjacent strand sleeves 28 , one rope strand 26 can be selectively pulled through the strand sleeves 28 and away from the other rope strand 26 to form an intermediate loop 32 having an adjustable size. Each intermediate loop 32 may be in-plane (the rope strands 26 which define each intermediate loop 32 may be disposed within the same plane). One or multiple strand sleeves 28 may be provided at each end of the main rope segment 27 to define the end loop 30 in each corresponding end of the main rope segment 27 .
As illustrated in FIG. 5 , in an exemplary application the loop rope assembly 24 can be used to secure a load 16 to a support surface (not illustrated) which in some applications may be a support surface on a transport vehicle (not illustrated) such as a pickup truck or trailer, for example and without limitation. Multiple anchor plates 12 , each having an anchor hook 13 , may be provided on the support surface in proximity to the load 16 . Accordingly, the main rope segment 27 of the loop rope assembly 24 may be extended generally around the lower portion of the load 16 and the end loops 30 ( FIG. 4 ) attached to one of the anchor hooks 13 . One of the rope strands 26 may then be pulled through a pair of adjacent strand sleeves 28 and away from the other rope strand 26 at the appropriate locations along the length of the main rope segment 27 to form the intermediate loops 32 , which may be attached to the remaining anchor hooks 13 . One or multiple bungee cords 14 (illustrated in phantom) may then be used to additionally secure the load 16 by forming additional intermediate loops 32 in the main rope segment 27 , attaching a bungee cord hook 15 on one end of each bungee cord 14 to an intermediate loop 32 on one side of the load 16 , extending the bungee cord 14 over the top of the load 16 and attaching the bungee cord hook 15 on the other end of the bungee cord 14 to an intermediate loop 32 on the opposite side of the load 16 . Thus, the load 16 is secured for transport of the load 16 on the transport vehicle or for other purposes. The load 16 can be unsecured, as desired, by detaching each bungee cord 14 from the corresponding pair of intermediate loops 32 ; detaching the intermediate loops 32 from the respective anchor hooks 13 ; and detaching the end loops 30 ( FIG. 4 ) from the anchor hook 13 .
Another exemplary application of the loop rope assembly 24 is illustrated in FIG. 6 . Accordingly, the loop rope assembly 24 can be used to secure a tarp or boat cover 37 on a boat 36 (illustrated in phantom). After the boat cover 37 is placed over the boat 36 , the main rope segment 27 may be extended around the edges of the boat cover 37 and against the boat 36 . The end loops 30 ( FIG. 4 ) on the respective ends of the main rope segment 27 may then be attached to suitable attachment points (not illustrated) provided on the boat 36 or on a trailer (not illustrated) on which the boat 36 is supported. Intermediate loops 32 may be formed at selected points along the main rope segment 27 on each side of the boat 36 to provide attachment points for 14 which can be used to additionally secure the boat cover 37 on the boat 36 . Thus, the bungee cord hook 15 on one end of a bungee cord 14 can be attached to an intermediate loop 36 on one side of the boat 36 ; the bungee cord 14 extended over the top of the boat cover 37 ; and the bungee cord hook 15 on the other end of the bungee cord 14 attached to an intermediate loop 36 on the other side of the boat 36 . The bungee cord hook 15 on one end of another bungee cord 14 can be attached to an intermediate loop 36 on one side of the boat 36 ; the bungee cord 14 extended beneath the boat 36 ; and the bungee cord hook 15 on the other end of the bungee cord 14 attached to an intermediate loop 36 on the other side of the boat 36 . The adjacent bungee cords 14 which extend over the boat cover 37 and under the boat 36 may alternate with one another along the length of the boat 36 . Accordingly, the boat cover 37 is securely attached to the boat 36 for transport and/or storage of the boat 36 . The loop rope assembly 24 can be selectively detached from the boat 36 by detaching the bungee cord hooks 15 of the bungee cords 14 from the intermediate loops 32 and detaching the end loops 30 ( FIG. 4 ) from the attachment points (not illustrated) on the boat 36 or trailer (not illustrated) on which the boat 36 is supported.
It will be appreciated by those skilled in the art that the loop rope assemblies of the disclosure are effective for tying down tarps or covers or light- to medium-duty loads on a support for transport, storage or other purposes. The loop rope assembly may enable a user to maintain a tight fit of the assembly without the use of hooks or ratcheting-type devices. One size of the loop rope assembly may fit any desired application. Moreover, a user need not have the knowledge or ability to tie secure knots in order to facilitate securing of a cover or load. Using the loop rope assembly, one user can easily secure virtually any size load without assistance. Under circumstances in which a greater length of the loop rope assembly is needed, a pair of the assemblies can be looped together for the purpose.
While the preferred embodiments of the disclosure have been described above, it will be recognized and understood that various modifications can be made in the disclosure and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the disclosure.
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A loop rope assembly includes a main rope segment having a plurality of rope strands and first and second ends, a first end loop provided on the first end of the main rope segment, a second end loop provided on the second end of the main rope segment and at least one intermediate loop defined by at least one of the rope strands.
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TECHNICAL FIELD
[0001] The invention relates generally to medical devices and, more specifically, to communication between modular components of a medical device.
BACKGROUND
[0002] Ventricular fibrillation and atrial fibrillation are common and dangerous medical conditions that cause the electrical activity of the human heart to become unsynchronized. Loss of synchronization may impair the natural ability of the heart to contract and pump blood throughout the body. Medical personnel treat fibrillation by using a defibrillator system to apply a relatively large electrical charge to the heart. If successful, the charge overcomes the unsynchronized electrical activity and gives the natural pacing function of the heart an opportunity to recapture and reestablish a normal sinus rhythm.
[0003] Defibrillator systems are medical instruments that may have multiple components, including, for example, a defibrillator to apply an electrical shock to the heart of a patient, and an electrocardiogram (ECG) monitor to evaluate the condition of the patient. More particularly, the monitor records and analyzes an ECG signal from the patient, while the defibrillator produces a high-energy defibrillation pulse to terminate ventricular or atrial fibrillation.
[0004] One or more of these components may incorporate several modules. The defibrillator, for example, may include modules for obtaining information from the patient, interacting with the operator of the defibrillator, and delivering therapy to the patient. This modular approach facilitates customization of the defibrillator to the needs of the particular application. For example, a user interface module may be selected based on the level of experience of the expected operator of the defibrillator.
[0005] The defibrillator modules typically communicate with each other using a serial data connection. In some conventional defibrillators, inter-module communication occurs over an RS-232 connection. Other conventional defibrillators use various types of serial data connections, including, for example, I 2 C, Microwire, or SPI connections. These types of connections have a number of disadvantages. For example, the bandwidth realized by these connections may be too low for certain applications. In addition, these connections lack extensibility. That is, flexibility in allocating functionality among various modules is limited.
SUMMARY
[0006] In general, the invention facilitates improved inter-module communication within a medical device system, such as an automated external defibrillator (AED), by using a serial data interface based on the USB specification to transfer data between modules. USB-type interfaces have conventionally been used to connect devices externally, e.g., to connect various types of peripheral devices to a personal computer. According to the principles of the invention, however, a USB-type interface connects devices or modules internally within a medical device system. This interface transfers data using the USB data communication protocol and complies with USB specifications with respect to signal integrity and impedances, but employs a physical connector module designed for the space-limited environment within a medical device system.
[0007] The invention may offer several advantages. For instance, data transmission rates may be improved significantly, thereby providing ample communication bandwidth for a variety of medical device applications. Further, the serial interconnect nature of the USB interface reduces the number of physical interconnects that are needed to support the interface, thereby reducing the design constraints on the medical device system. Costs associated with manufacturing the medical device system may also be reduced.
[0008] One embodiment is directed to a method for transferring data between modules of a medical device using a USB protocol. A USB token packet is transmitted to a first module of a medical device system. When the first module has a USB data packet to transfer, the data packet is received from the first module. The data packet is transferred to a second module of the medical device system. Modules of the medical device may be programmed or upgraded in this manner.
[0009] Other implementations include defibrillators that carry out these methods, as well as processor-readable media containing instructions that cause a processor within a medical device to perform these methods. For example, in one embodiment, a medical device includes a system control module, functional modules, and a system bus coupled to the system control module and to the plurality of functional modules. The system bus transfers data packets between the functional modules and the system control module according to the USB protocol. The functional modules may include, for example, a therapy control module that controls a therapy device, such as a set of defibrillator electrodes, a user interface module, and a patient parameters module.
[0010] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF DRAWINGS
[0011] [0011]FIG. 1 is a block diagram illustrating a defibrillating system configured according to an embodiment of the invention.
[0012] [0012]FIG. 2 is a plan view of a connector module for connecting a device or module to the system controller of FIG. 1.
[0013] [0013]FIG. 3 is a flow diagram illustrating an example mode of operation of the defibrillator system of FIG. 1.
DETAILED DESCRIPTION
[0014] [0014]FIG. 1 is a block diagram illustrating a defibrillating system in which the invention may be practiced. When activated by an operator 10 , a defibrillator 12 administers one or more electric shocks via defibrillator electrodes to a patient 16 . Defibrillator 12 may be implemented, for example, as an automated external defibrillator (AED).
[0015] Operation of defibrillator 12 is controlled by a system controller 18 that is connected to a system bus 20 . System controller 18 may be implemented as a microprocessor that communicates control and data signals with other components of defibrillator 12 using the USB protocol via system bus 20 . These components may include functional modules, such as therapy control module 14 or other therapy control modules, a patient parameters module 22 , and a user interface module 24 .
[0016] Therapy control module 14 causes defibrillator electrodes (not shown) to deliver electric shocks to patient 16 in response to control signals received from system controller 18 via system bus 20 . Therapy control module 14 may include, for example, charging circuitry, a battery, and a discharge circuit. Any or all of these components can be controlled by system controller 18 .
[0017] Patient parameters module 22 may include electrocardiogram (ECG) leads or other inputs. Patient parameters module 22 collects information from patient 16 , including, for example, vital signs, non-invasive blood pressure (NIBP) measurements, and SpO 2 information. Other information relating to patient 16 may be collected by patient parameters module 22 , including, but not limited to, EEG measurements, invasive blood pressure measurements, temperature measurements, and ETCO 2 information.
[0018] User interface module 24 receives input from operator 10 and outputs information to operator 10 using any of a variety of input and output devices. For example, operator 10 may use keys to input commands to defibrillator 12 and receive prompts or other information via a display screen or LED indicators. As an alternative, the display screen may be implemented as a touch-screen display for both input and output. In addition, user interface module 24 may print text reports or waveforms using a strip chart recorder or similar device. User interface module 24 may also interface with a rotary encoder device.
[0019] User interface module 24 provides input received from operator 10 to an operating system 26 that controls operation of defibrillator 12 via system controller 18 . Operating system 26 may be implemented as a set of processor-readable instructions that are executed by system controller 18 . When defibrillator 12 is activated, operating system 26 causes therapy control module 14 to deliver therapeutic shocks to patient 16 via defibrillator electrodes according to an energy protocol.
[0020] As described above, system controller 18 , therapy control module 14 , patient parameters module 22 , and user interface module 24 are connected to each other via system bus 20 . According to an embodiment of the invention, system bus 20 is compatible with the USB standard. Implementing system bus 20 as a USB-compatible bus offers several benefits. Advantageously, these modules may communicate with each other using significantly fewer interconnects compared to other communication schemes. For example, one conventional interconnect technique uses a peripheral component interconnect (PCI) bus that, in some implementations, uses more than one hundred interconnects. As a result, systems using a PCI bus must satisfy strict design constraints, such as size and power constraints. By contrast, USB-compatible system bus 20 may use only four interconnects, facilitating implementation within significantly fewer design constraints. Moreover, the USB communication protocol is simple, reducing the complexity of the logic required in USB support chips. The reduced constraints and simple communication protocol lead to lower costs of production, as well as improved reliability.
[0021] For purposes of inter-module communication, system controller 18 , therapy control module 14 , patient parameters module 22 , and user interface module 24 may be considered USB devices. System controller 18 acts as a host controller that initiates all data transfers between the other modules. In addition to system controller 18 , therapy control module 14 , patient parameters module 22 , and user interface module 24 , other modules or devices can also be connected to system bus 20 . For example, an expansion module 28 may allow system controller 18 to control a device 30 external to defibrillator 12 . External device 30 may be a USB root hub or a USB hub connected to other devices, such as data acquisition devices or other USB-compatible devices. Using a USB hub, many devices can be connected to defibrillator 12 for a variety of purposes. Some such devices include, but are not limited to, a printer, a bar code scanner, a computer keyboard, or a data transfer device. These devices may either be simple devices or complex devices as defined in the USB specification.
[0022] [0022]FIG. 2 is a plan view of a connector module 50 for connecting a device or module to system controller 18 . Connector module 50 includes a number of pins 52 , 54 , 56 , and 58 that may be inserted into appropriate receptacles in devices or modules to transfer ground and data signals. For example, in one embodiment, pins 52 and 54 may be used for ground, while pins 56 and 58 may be used to transfer data signals. The allocation of ground and data lines among pins 52 , 54 , 56 , and 58 may be selected to satisfy impedance requirements. Allocating two pins to ground connections allows greater flexibility in impedance matching, potentially improving signal integrity. As an alternative, a single pin may be allocated to ground, such that connector module 50 may include only three pins, rather than four as shown. In addition, one or more of system controller 18 , therapy control module 14 , patient parameters module 22 , and user interface module 24 may incorporate impedance matching circuitry to satisfy the impedance requirements of the USB standard, thereby meeting USB signal integrity requirements.
[0023] Connector module 50 may be used to connect any of the devices or modules internal to defibrillator 12 , e.g., system controller 18 , a therapy control module 14 , patient parameters module 22 , user interface module 24 , and expansion module 28 , to system bus 20 . Expansion module 28 has a USB port for connecting an external USB-compatible device to system bus 20 via a conventional flex circuit cable that meets USB specifications for impedance and signal integrity. The flex cable allows expansion module 28 to reside within defibrillator 12 at some distance, e.g., approximately 2-12 inches (5-30 cm) away from system controller 18 . In addition to carrying the USB-standard signals, the flex cable may also carry several additional signals that do not relate to USB communication. While not required, the flex cable may also be used to connect other devices or modules internal to defibrillator 12 , such as user interface module 24 . External devices 30 may be connected to expansion module 28 via a conventional USB cable.
[0024] While the physical interface between the various devices or modules and system bus 20 differs from the USB standard, communication between the devices conforms to the USB communication protocol, as well as USB specifications relating to impedance and signal integrity. Accordingly, conventional software and hardware development tools designed for the USB standard can be used with little, if any, modification to develop additional devices for use in conjunction with defibrillator 12 . Development costs are thereby reduced.
[0025] Software for transferring data between devices or modules of defibrillator 12 may incorporate conventional USB software with slight modifications. For example, the lower levels of the communication stack may be modified to support the particular processor and system controller 18 used in defibrillator 12 . The software may be implemented as a set of computer-executable instructions stored in some form of computer readable media. Computer readable media can be any available media that can be accessed by defibrillator 12 . By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. Computer storage media includes volatile and nonvolatile, removable and nonremovable media implemented in any method or technology for storage of information, such as computer readable instructions, data structures, program modules, or other data. Computer storage media includes, but is not limited to, random access memory (RAM), read only memory (ROM), EEPROM, flash memory or other memory technology, CD-ROM, digital versatile discs (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store the desired information and that can be accessed by defibrillator 12 . Communication media typically embodies computer readable instructions, data structures, program modules, or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media, such as a wired network or other direct-wired connection, and wireless media, such as acoustic, RF, infrared, and other wireless media. Combinations of any of the above computer storage media and communication media are also included within the scope of computer-readable media.
[0026] [0026]FIG. 3 is a flow diagram illustrating an example mode of operation that may be implemented by the USB software. Before any data is transferred, system controller 18 assigns USB addresses to devices or modules as they are connected to system bus 20 during a process known as enumeration ( 70 ). These addresses are subsequently used to address individual devices. In addition, when a device is connected to system bus, associations between system controller 18 and one or more endpoints of the device are established ( 72 ). These associations are known as pipes. A given device may have multiple pipes. For example, user interface module 24 may have an endpoint that supports a pipe for transferring data to user interface module 24 and another endpoint that supports another pipe for transferring data from user interface module 24 . When multiple pipes are established, the available bandwidth of system bus 20 is allocated among the pipes ( 74 ). For some pipes, bandwidth is allocated when the pipe is established.
[0027] All devices must support a specially designated control pipe. All devices support a common access mechanism for accessing information through the control pipe. For example, system controller 18 can access device information via the control pipe. This device information may be categorized as standard information whose definition is common to all devices, as class information specific to the type or class of the device, or as vendor-specific information. In addition to device information, system controller 18 may access USB control and status information via the control pipe.
[0028] Other pipes may be used to transfer functional data and control information between system controller 18 and other devices via system bus 20 . Such pipes may be either unidirectional or bidirectional. Generally, data movement through one pipe is independent from data movement in other pipes.
[0029] System bus 20 is a polled bus. That is, system controller 18 periodically polls ( 76 ) the devices connected to system bus 20 to determine whether a device has data to be transferred to system controller 18 or to another device connected to system bus 20 . If there is no data to be transferred, system controller 18 repeats polling the devices ( 76 ) until a device indicates that it has data to transfer.
[0030] When a device indicates that it has data to transfer, system controller 18 begins a transaction to transfer the data. Data transfers may involve the transmission of up to three packets. Each transaction begins when system controller 18 sends a USB packet, known as a token packet ( 78 ), describing the type and direction of transmission, an address designating a device or module, and an endpoint number that designates a specific endpoint associated with the device. The device or module designated by the address selects itself by decoding the appropriate address fields. In a given transaction, data is transferred either from system controller 18 to the selected device or from the selected device to system controller 18 . The token packet specifies the direction of data transfer. The source of the transaction then either sends a data packet ( 80 ) or indicates that the source has no data to transfer. The destination may then respond with a handshake packet that indicates whether the transfer was successful ( 82 ).
[0031] System bus 20 may transfer data in a number of different modes. Control data, for example, is transferred in a control mode to configure a device when it is initially connected to system bus 20 . Another transfer mode, known as a bulk data transfer mode, is used to transfer data that is generated or consumed in relatively large and bursty quantities, e.g., data transferred to a strip chart recorder. Bulk data is sequential. Reliable exchange of data is ensured at the hardware level by using error detection and correction techniques. The bandwidth taken up by bulk data may depend on other data transfer activities occurring on system bus 20 .
[0032] Some devices or modules that send relatively small amounts of data may transfer data in an interrupt mode. In the interrupt mode, data may be presented for transfer to or from a device at any time and is delivered by system bus 20 at a rate no slower than is specified by the device. Interrupt data typically consists of event notifications or characters that are organized as one or more bytes. One example of interrupt data is characters input via the keys connected to user interface module 24 .
[0033] Other devices or modules may transfer data in an isochronous mode. Isochronous data is continuous and real-time in creation, delivery, and consumption. To the extent that patient parameters module 22 collects real-time vital sign measurements from patient 16 , for example, patient parameters module 22 may transfer data in the isochronous mode. In this mode, data streams between the device and system controller 18 in real-time without error correction. Timing-related information does not need to be explicitly transferred, as this information is implied by the steady rate at which the isochronous data is received and transferred. To maintain correct timing, isochronous data must be delivered at the same rate at which it is received. Accordingly, isochronous data is sensitive to the delivery rate. In addition, isochronous data may also be sensitive to delivery delays. For isochronous pipes, the bandwidth required may be based on the sampling characteristics of the associated function. The latency required may be related to the buffering available at each endpoint of the pipe.
[0034] Regardless of the data transfer mode, data transferred via system bus 20 may be encoded using a conventional inverted non return to zero (NRZI) encoding scheme. In this scheme, a value of “0” is indicated by a transition in the data signal, while a value of “1” is indicated by the absence of a transition in the data signal. Thus, for example, a string of 1's would result in a long period without signal transitions. In order to force transitions in the data signal, a bit stuffing technique is used to insert a zero after a sequence of consecutive 1's of a prescribed length, e.g., after a sequence of six consecutive 1's. Accordingly, if a device receives a sequence of consecutive 1's that exceeds the prescribed length, the device may conclude that an error has occurred and ignore the data packet.
[0035] By way of example, the data transfer technique of FIG. 3 may be used to reprogram a processor embedded in system controller 18 , therapy control module 14 , patient parameters module 22 , or user interface module 24 . Program data, such as a software upgrade, may be transferred via system bus 20 to the device to be reprogrammed. The software upgrade may then be stored using, for example, a RAM device or a flash memory.
[0036] The data transfer technique of FIG. 3 can also be used to control the functions of the various modules of defibrillator 12 . For example, system bus 20 can be used to effect the delivery of therapeutic shocks to patient 16 via defibrillator electrodes. In this mode of operation, operator 10 uses the external keys to activate defibrillator 12 . Operator 10 may use the external keys, for example, to select an energy protocol to be applied to patient 16 . User interface module 24 transfers the key input to system controller 18 via system bus 20 .
[0037] System controller 18 then generates the appropriate control signals for controlling the defibrillator electrodes to deliver the electric shock or shocks to patient 16 as specified by the selected energy protocol. System controller 18 transfers the control signals to therapy control module 14 . These control signals may include control signals for controlling the charging circuitry, the discharge circuitry, or both. Therapy control module 14 operates the charging and discharge circuitry as directed by the control signals, thereby causing the defibrillator electrodes to deliver the correct electric shock or shocks to patient 16 .
[0038] Various embodiments of the invention have been described. The invention may be used in AEDs as well as other types of defibrillators. In addition, while several embodiments of the invention have been described in the context of a defibrillator, the principles of the invention may be practiced in other types of medical devices, including, but not limited to, defibrillator/pacemakers and therapy devices for other medical conditions, such as stroke and respiratory conditions. These and other embodiments are within the scope of the following claims.
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In general, the invention facilitates improved inter-module communication within a medical device system, such as an automated external defibrillator (AED), by using a serial data interface based on the USB specification to transfer data between modules. As a result, data transmission rates may be improved significantly, thereby providing ample communication bandwidth for a variety of medical device applications. Further, the serial interconnect nature of the USB interface reduces the number of physical interconnects that are needed to support the interface, thereby reducing the design constraints on the medical device system.
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PRIORITY CLAIM
This application claims priority of U.S. Provisional Patent Application Serial No. 60/279,213, filed Mar. 27, 2001.
FIELD OF THE INVENTION
This invention relates to flame arrestors equipped with reflection suppressors.
BACKGROUND OF THE INVENTION
Flame arrestors are passive devices designed to prevent propagation of gas flames through pipelines. A flame arrestor incorporates a permeable barrier known as an element which is usually a matrix of metallic, ceramic or mixed materials that define a permeable barrier containing narrow channels. An element removes heat and free radicals from a flame at a rate which is fast enough to quench the flame and to prevent reignition of the hot gas on the protected side (downstream relative to the direction of flame propagation along a pipe) of the arrestor.
A flame arrestor is located in a pipeline carrying a flammable gas, and the design of a flame arrestor can vary greatly depending upon application, location and use conditions. For example, a best design for a particular installation may take into account flow resistance, maintainability and cost.
For purposes of evaluating efficacy of a particular flame arrestor for particular flame arrestor applications, various testing protocols have been developed that aim to address most adverse conditions encountered. In, for example, the case of marine vapor control systems in the United States, the testing and application of flame arrestors is regulated by the U.S. Coast Guard.
A flame arrestor can be used to arrest deflagrations and detonations. A deflagration is a combustion wave propagating at less than the speed of sound as measured in unburned gas immediately ahead of the flame front. Flame speed relative to unburned gas is typically 10-100 m/s (meters per second), but, owing to expansion of hot gas behind the flame, several hundred meters per second may be achieved relative to a pipe wall. Although the pressure peak coincides with the flame front, a marked pressure rise precedes it, so that the unburned gas is compressed as the deflagration proceeds, depending upon flame speed and available vent paths. The precompression of gas ahead of the flame front establishes the gas conditions in the arrestor when the flame enters it and hence affects both the arrestment process and the maximum pressure generated in the arrestor body.
As a deflagration travels through piping, its speed increases due to flow-induced turbulence and compressive heating of unburned gas ahead of the flame front. At a flame speed approaching sonic velocity, a deflagration-to-detonation transition (DDT) can occur with associated abnormally high velocities and pressures. At the instant of transition, a transient state of overdriven detonation is achieved and persists for a few pipe diameters. After the decay of such conditions, a stable detonation state is attained. A detonation is a combustion-driven shock wave propagating at the speed of sound, as measured in the burned gas immediately behind the flame front. Stable detonations propagate at sonic velocities relative to an external fixed point. A wave is sustained by chemical energy released by shock compression and ignition of unreacted gas. The flame front is coupled in space and time with the shock front, with no significant pressure rise ahead of the shock front.
The high velocities and pressures associated with detonations require special element design to quench the high-velocity flames plus superior arrestor construction to withstand the associated impulse loading. In practice, this entails narrower and/or longer element channels plus bracing of the element facing.
The problem of flame arrestment, either of deflagrations or detonations, depends on the properties of the gas mixture plus the initial pressure. Since gas mixture combustion properties cannot be quantified for direct use in flame arrester selection, flame arrester performance must be demonstrated by realistic testing.
A severe deflagration arrestment test involves placing a restricting orifice behind the arrestor (that is, upstream relative to the direction of wave propagation). Such a restriction produces a so-called reflection wave that travels back to the flame arrestor from the restriction and increases the degree of precompression. Such “restricted end” deflagration testing constitutes a severe deflagration arrestment test, yet such testing is believed to represent an operating environment that can exist in fact from various conditions, such as when, for example, a closed or partially closed valve in a pipe is located upstream from a functioning arrestor in the pipeline. Such testing has demonstrated that arrestors capable of stopping even overdriven detonations may fail under restricted end deflagration test conditions.
The art of flame arrestors needs improved apparatus and methods for achieving arrestment in environments where reflection waves can be generated upstream relative to the direction of wave propagation and be propagated back to a flame arrestor. The present invention provides such improvements.
SUMMARY OF THE INVENTION
More particularly, this invention is directed to a combination of a flame arrestor with a reflection suppressor, and to a process for using same.
The invention aims to control, including minimize and suppress, reflection waves produced in a pipeline.
The invention can be practiced with various types of flame arrestors, and is suitable for use in various flame arrestor applications. The reflection suppressor that is provided in accord with the present invention is located adjacent to an interior end region of an arrestor in a common housing. This end region is chosen so as to be an end of the arrestor that is downstream relative to the direction of flame and pressure wave propagation, but that is upstream relative to the direction of reflection wave propagation.
The flame arrestor can be either of the deflagration arresting type or of the anti-detonation (or so-called detonation arresting) type. A detonation flame arrestor may also be usable as a deflagration flame arrestor. Preferably, in the practice of this invention, the inventive combination employs a flame arrestor of the detonation type and that has opposite end portions that adapt the combination to be mounted in a pipeline.
Preferably, in the inventive combination, a reflection suppressor is provided adjacent each opposite end portion of the combination, whereby the combination is adapted to suppress a reflected wave that reaches either end portion of the combination.
The reflection suppressor employed in the combination is a body having tapered sidewalls. The body has a longitudinal length such that it is axially positionable in an end region of a housing that also holds the flame arrestor, and the body is centered and longitudinally adjacent to the flame arresting housing. The tapered body has an apex end portion and a base end portion that is longitudinally spaced from the apex end portion. In a housing, the base end portion has a substantially larger cross-sectional area than the apex end portion. The longitudinal length of the tapered body is preferably such that the base end portion is located approximately adjacent to an outlet aperture of the common housing while the apex end portion is located approximately adjacent to an end region of the flame arrestor. Preferably, the flame arrestor is located in a mid-region of the common housing.
Preferably the combination is easy to assemble and maintain.
Other and further aims, purposes, objects, features, advantages, embodiments and the like will be apparent to those skilled in the art from the present specification taken with the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a longitudinal, medial, partial sectional view through an embodiment of the inventive combination of a flame arrestor with a reflection suppressor, some parts being broken away and some parts being shown in section;
FIG. 2 is a vertical sectional view taken along the line II—II of FIG. 1;
FIG. 3 is a view similar to FIG. 1 but showing the combination with two reflection suppressors;
FIG. 4 is a diagrammatic view of another embodiment of a combination of a flame arrestor with a reflection suppressor; some parts being broken away and some parts being shown in section;
FIG. 5 is a side elevational view of the reflection suppressor such as employed in the embodiments of FIGS. 1 and 4;
FIG. 6 is an apex end elevational view of the reflection suppressor of FIG. 5;
FIG. 7 is a side elevational view similar to FIG. 5 but showing an alternative embodiment of a reflection suppressor;
FIG. 8 is an apex end elevational view of the reflection suppressor of FIG. 7;
FIG. 9 is a side elevational view similar to FIG. 5 but showing an alternative embodiment of a reflection suppressor;
FIG. 10 is an apex end elevational view of the reflection suppressor of FIG. 9; and
FIG. 11 is a diagrammatic, fragmentary vertical sectional view through an end region of an inventive combination that is similar to the FIG. 1 embodiment but that illustrates an alternative embodiment that incorporates two reflection suppressors in an inward end region of the common housing.
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2, there is seen an illustrative embodiment 50 of the inventive combination of a detonation flame arrestor 51 with a reflection suppressor 52 . The combination 50 is comprised of metal components, preferably steel or steel alloy. The combination 50 employs a common housing 53 for the flame arrestor 51 and for the reflection suppressor 52 .
The housing 53 is cross-sectionally circular and axially elongated, and has a generally circular aperture 55 and 56 defined at each respective opposite end thereof. The mid-region 57 of the housing 53 is diametrically enlarged, has a generally uniform diameter, and has side wall portions defined by a circumferentially extending sleeve 58 . Transversely across but within each respective opposite end 67 , 68 of sleeve 58 (and mid-region 57 ) a circular, apertured retaining wall 59 and 60 , respectively, is located. The walls 59 and 60 are supported and connected by an axially extending elongated bolt 62 whose respective opposite ends are each threadably associated with a nut 63 .
The apertured walls 59 and 60 can be comprised of plate stock, but, preferably are alternatively fabricated of cross bars that are welded together at abutting and cross-over regions. Other constructions can be employed, as those skilled in the art appreciate.
Longitudinally adjacent each respective opposite end 67 , 68 of sleeve 58 is located a frusto-conical section 64 and 65 of housing 53 . Each section 64 and 65 provides a longitudinally tapered region that declines in cross-sectional area proceeding from each opposite end 67 , 68 of sleeve 58 to an adjacent aperture 55 , 56 , respectively. In the region of each aperture 55 , 56 , each section 64 , 65 defines a terminal cylindrical portion 69 , 70 , respectively, and each cylindrical portion 69 , 70 is joined at its outer end, by welding or the like, to a pipe connecting flange 72 , 73 , respectively. The sleeve 58 adjacent end portion of each frusto-conical section 64 , 65 terminates in an integrally associated, longitudinally short, cylindrical flange 74 , 75 , respectively. Outer surface portions of each flange 74 , 75 are joined preferably by welding to a sleeve abutting flange 76 , 77 , respectively.
During assembly of the combination 30 , each flange 76 , 77 is longitudinally abutted against an opposite end 67 , 68 of the sleeve 58 . In aligned relationship with one another, apertures (not shown) defined in the outstanding portions of each respective flange 76 , 77 have extended therethrough a plurality of circumferentially preferably equally spaced tie rods 80 . The respective opposite ends of the tie rods 80 are threadably associated with nuts 81 , so that longitudinal compressive force exerted by the rods 80 and their associated nuts 81 hold the housing components in assembled relationship.
Positioned between the walls 59 , 60 within the sleeve 58 is a fill of crimped steel plates or the like (not detailed but conventional). Various flame arrestor fill media are known to the prior art and can be employed, including fill structures having a honeycomb configuration (in cross section), packed steel or ceramic spheres (or other spherical media) parallel or stacked crimped metal plates, stacked wire mesh (such as disclosed in U.S. Pat. No. 4,909,730), and the like.
The walls 59 , 60 taken with the fill material can be considered to comprise the “element” of a flame arrestor, as those skilled in the art will readily appreciate. The element is porous and adapted for the passage of a gas therethrough that is flowing a rate within a predetermined range in the pipeline across which the inventive combination 50 is connected. The design of the element varies from one intended installation to another. Also, the element design may be influenced and sometimes controlled by the criteria specified in a test protocol to which the element has been subjected (or could be subjected) and passed. As those skilled in the art will appreciate, many variations in the design of a particular element are possible and are used. It is an important feature and advantage of the present invention that the reflection suppressor can be associated with a flame arrestor virtually without regard to the structure or operating characteristics of an element without detracting from the capacity of the reflection suppressor to reduce or eliminate the effect of a reflection wave upon the element.
In the frusto-conical section 65 of the housing 53 , the reflection suppressor 52 is located. The reflection suppressor 52 has side wall portions 86 that extend between a base portion 87 and an apex portion 88 thereof. The reflection suppressor 52 has a longitudinal or axial length 89 (see FIG. 5) that is shorter than the distance between the orifice or aperture 56 and the adjacent wall 60 of the element. Also, the reflection suppressor 53 has a cross-sectional area along its length between the base portion 87 and the apex portion 88 that generally declines with increasing distance from the base portion 87 . Further, the base portion 87 has a cross-sectional area that is less than the cross sectional area of the orifice or aperture 56 . While the reflection suppressor 52 has side wall portions 86 that are here conically tapered which is preferred, a reflection suppressor, as below described, can have other side wall configurations, if desired.
Mounting means is provided for mounting (including holding and supporting) the reflector suppressor 52 in the frusto-conical section 65 . The reflection suppressor 52 is preferably (and as shown) centrally positioned in the section 65 . The base portion 86 is located adjacent to the orifice 56 in section 65 . In embodiment 50 , the mounting means is achieved by mounting the apex portion 88 , by welding or the like, to the adjacent nut 63 and by positioning a spider 90 (shown in FIGS. 1 and 2) circumferentially about side wall portions 86 adjacent to the base portion 87 . The spider 90 is sized to fit in the neck region of the terminal cylindrical portion 65 . However, various convenient alternative mounting means may be employed for a reflection suppressor as those skilled in the art will readily appreciate.
Optionally, the housing 53 is provided with fittings 78 for drains, pressure taps, or temperature probes.
In the combination 50 , normal gas flow in a pipeline to which the combination 50 is connected can proceed in either direction (relative to the apertures 55 and 56 ) through the housing 53 , including through the element as defined by walls 59 , 60 and the fill therebetween, and around the reflection suppressor 52 . However, when a flame front and associated pressure wave occur in the associated pipeline at a location at a distance from the combination 50 , the flame front and associated pressure wave propagate towards the combination 50 and reach the combination 50 through the input pipe 91 , the combination becomes operational. Owing to the design of the detonation flame arrestor 51 , the flame front is suppressed upon reaching and entering the arrester 51 owing to the relationship between the passageways through the element and the heat sink capacity of the element. However, the pressure wave passes through the element and the arrestor 51 and around the reflection suppressor 52 and moves into and onwards in the output pipe 92 . Upon reaching a restriction (not shown in FIG. 1) in the output pipe 92 , a reflection pressure wave is generated that moves in the opposite direction and so travels back in the output pipe 92 to the combination 50 .
As those skilled in the art will appreciate, and as the results of various studies and tests have ascertained and confirmed, a restriction in a pipe can be caused by various factors and pipe discontinuities, such as a bend in the pipeline, a coupling, a valve that perhaps is not fully closed or open, and other flow path changes. Theoretically, if the pressure wave encounters no restriction, then no reflection pressure wave is produced. When a reflection pressure wave is produced and enters a flame arrestor, a sudden pressure increase occurs therein causing a so-called over-pressure situation within the flame arrestor 51 , which can result in a re-ignition and propagation of a new flame front and pressure front outwardly from the region of the flame arrestor in the pipeline.
The reflection suppressor 52 , when the reflection wave reaches the combination 50 , restricts the flow of the high pressure reflection wave front back into the housing 53 of the combination 50 . The reflection wave is either reflected back harmlessly into the output pipe 92 or the pressure is absorbed by the reflection suppressor 52 and the adjacent portions of the housing 53 .
By retaining the base portion 87 in an open configuration, some energy of the reflection wave is resultingly absorbed by the open base upon reaching the reflection suppressor 85 .
Since it is not always possible to predict that a wave front and associated pressure wave will approach a combination 50 from only one direction along the associated pipeline, it is advisable and indeed preferred to provide a combination 100 that is similar to the combination 50 but that contains a second reflection suppressor 85 located in the frusto-conical section 64 , as illustrated in FIG. 3, where components similar to those in FIGS. 1 and 2 are similarly numbered but with the addition of prime marks thereto for convenient identification purposes. The reflection suppressor 85 is similar to the reflection suppressor 52 , but is oriented in a reverse direction, and operates similarly but with gases moving in an opposite direction.
By suppressing or diverting a reflection wave, the reflection suppressor avoids potentially catastrophic results in the region of the combination 50 .
Another embodiment of a combination of flame arrestor 10 and reflection suppressor 30 is illustrated in FIG. 4, this arrangement being similar to that of FIG. 1, but is adapted for testing in accord with a test protocol.
This embodiment has the combination associated with an inlet pipe 12 and an outlet pipe 14 in a pipeline. The configuration shown in FIG. 4 includes a restricted end 16 on outlet pipe 14 . It is understood, however, that flame arrestors such as flame arrestor 10 can be installed in multiple pipeline configurations. Restricted end 16 is depicted in FIG. 4 for convenience in describing a reflective pressure front (below). Inlet pipe 12 is secured to the inlet side 18 of the flame arrestor 10 in a known manner. Likewise, outlet pipe 14 is secured to the outlet side 20 of the flame arrestor in a known manner.
The precise internal configuration of flame arrestor 10 varies with the type of fill media inserted which may be determined by the desired application. It is understood that known internal configurations for a flame arrestor 10 are acceptable for the present invention, such as for example, the flame arrestor apparatus disclosed in U.S. Pat. No. 5,415,233. Additional known flame arrestor fill media include structures having a honeycomb configuration (in cross section), packed steel or ceramic spheres (or other spherical media), parallel or stacked plates, stacked wire mesh (such as disclosed in U.S. Pat. No. 4,909,730) or the like. It is understood that flame arrestor 10 of FIG. 4 and of the present invention could be configured to include such fill media, and other known configurations, within its internal cavity 11 .
Flame arrestor 10 as depicted in FIG. 4 includes a pair of perforated or apertured end plates, each 22 , which support a central bolt 24 secured by nuts 26 and 28 for the purpose of description herein. However, it is understood that the combination of the invention utilizes a common housing for the flame arrestor and the reflection suppressor. In place of end plates 22 , other apertured wall means can be used such as welded cross bars or the like. Also, in place of central bolt 24 , and nuts 26 and 28 other mounting and supporting arrangements can be used.
Flame arrestor 10 includes in the outlet end 20 of the common housing a reflection suppression device 30 of the present invention. Reflection suppressor 30 is positioned on the outlet side 20 of flame arrestor 10 between the fill media contained within internal cavity 11 and outlet pipe 14 . In a construction such as depicted in FIG. 4 wherein the flame arrestor 10 includes a center bolt 24 , reflection suppressor 30 is fitted with a nut 28 which threads onto center bolt 24 in the same manner as bolt 26 threads onto the opposite end of center bolt 24 . In an embodiment where a center bolt is omitted, reflection suppressor 30 may be affixed to the outlet side 20 of flame arrestor 10 by other known means, most commonly welding.
Referring to FIGS. 5 and 6, views of the reflection suppressor 30 are provided. As shown, reflection suppressor 30 , in its preferred embodiment is of a conical or frusto-conical longitudinal geometry. The nut 28 is secured to the tapered end (vertex) of the reflection suppressor 30 . Nut 28 may be secured by any known means, but is preferably welded thereon. As stated above, it is understood that reflection suppressor 30 may be configured without nut 28 and welded directly to the end plate 22 on the outlet side of flame arrestor 10 or affixed directly to the fill media contained within internal cavity 11 .
FIGS. 7 and 8 show an alternate reflection suppressor 34 of the present invention. In this alternate preferred embodiment, reflection suppressor 34 has a pyramidal geometry. As with the embodiment 30 , the alternate embodiment 34 of FIG. 4 is secured to nut 28 in the manner described above in embodiment 30 .
FIGS. 9 and 10 show an alternate reflection suppressor 35 which has a hemispherical geometry.
The geometries of the present embodiments of FIGS. 5, 7 and 9 can each be considered to include a vertex 32 , an altitude 36 , and a base 38 .
The side walls of a reflection suppressor 30 , 34 or 35 can be, if desired, porous or perforated. The bases of such reflectors can be continuous, porous, perforated or open.
A reflection suppressor in the inventive combination may incorporate, if desired, two successive, serially arranged and centrally positioned tapered bodies that are preferably each conically configured, such as the bodies 94 and 95 in the fragmentary alternative embodiment shown in FIG. 11 . Both bodies 94 and 95 are located in a single end region, such as in frusto-conical section 65 ′ of the housing 53 ′ combination 50 ′ illustrated in FIG. 11 and both bodies are frusto-conically configured. The outward body 95 , against which an advancing reflection wave first impinges, preferably has smaller dimensions than the inward body 94 against which the advancing reflection wave secondarily impinges. To mount the bodies 94 and 95 , a plurality of spiders 90 ′ are illustratively employed, with the apex of the body 95 being illustratively received in and mounted across the base of the body 94 ; however, alternative arrangements can be employed.
The significance of the geometry of a reflection suppressor, such as suppressor 30 , is next described. Referring to FIG. 4 and as stated above, reflection suppressor 30 is positioned on the outlet side 20 of flame arrestor 10 such that vertex 32 is positioned adjacent the fill media contained within internal cavity 11 and base 38 is positioned toward outlet pipe 14 in the direction of flow within the pipeline. The configuration (shape) and position of reflection suppressor 30 is important. The shape of reflection suppressor 30 may be such that the vertex end 32 does not unduly impede the gas flow through and away from flame arrestor 10 in the direction of flow in the pipeline, yet restricts the flow in the opposite direction back into the flame arrestor 10 from the outlet side 20 .
In other words, the size of base 38 and the length of altitude 36 are such that reflective wave fronts traveling counter-flow relative to an initiating pressure wave within outlet pipe 14 are restricted from re-entering flame arrestor 10 through outlet side 20 . The shape, the reflection suppressor which is preferably conical preferably offers little or no flow restriction to a pressure wave leaving the flame arrestor but preferably offers a significant flow impediment or restarting effect on a reflection wave that would, but for the reflection suppressor enter the flame arrestor. As a reflection suppressor configured, a pressure front which may cause flame arrestor 10 to fail is restricted. Although the conical geometry of FIG. 5 and the pyramidal geometry of FIG. 7 and the hemispherical geometry of FIG. 9 may be considered to be preferred embodiments of reflection suppressors, it is understood that other geometries are contemplated provided that flow in the desired direction on the outlet side 20 from flame arrestor 10 is not undesirably impeded while the reverse flow in the counter-direction into the outlet side 20 is desirably restricted. In order to accomplish this, a reflection suppressor such as suppressor 30 , should be configured to taper from base 38 down to vertex 32 along altitude 34 .
With reference to FIG. 4, the direction of flow within the pipeline is shown by arrow 40 within inlet pipe 12 . Arrow 40 depicts the direction of flow into the inlet side 18 of flame arrestor 10 . Flow continues through the internal cavity 11 of flame arrestor 10 containing the fill media and exits flame arrestor 10 through outlet side 20 past reflection suppressor 30 as shown by arrows, collectively 42 . Flow continues through outlet pipe 14 and impinges upon restricted end 16 .
FIG. 4 is depicted with restricted end 16 for convenience and for test protocol purposes in order to show a reflection directed back toward flame arrestor 10 as depicted by arrow 44 . The reflected wave front then travels counter-flow through outlet pipe 14 back toward the outlet side 20 of flame arrestor 10 . As shown by arrow 46 , the reflected pressure front contacts reflection suppressor 30 through base end 38 and is restricted from reentering the internal cavity 11 of flame arrestor 10 . Reflection suppressor 30 then re-deflects the pressure front back toward restricted end 16 .
In the case where the material within the pipeline is ignited and traveling through inlet pipe 12 , the fill media contained within internal cavity 11 of flame arrestor 10 , when acting correctly and as designed, extinguishes the flame in the manner described above. However, the heated combustion gases contained within internal cavity 11 of flame arrestor 10 will exit through outlet side 20 past reflection suppressor 30 creating a pressure head directed down the length of outlet pipe 14 . When the high pressure front is reflected by restricted end 16 back toward the outlet side 20 of flame arrestor 10 , the reflection suppressor 30 , positioned therein restricts the flow of the pressure front back into the internal cavity 11 and reflects it back harmlessly toward restricted end 16 within outlet pipe 14 . Reflection suppressor 30 restricts the flow of the high pressure front back into internal cavity 11 which has been otherwise known to cause an over-pressure situation within internal cavity 11 causing flame arrestor 10 to fail which may cause catastrophic results.
As stated above, FIG. 4 depicts a restricted end 16 for the convenience of illustrating the reflection of the pressure front back toward flame arrestor 10 to illustrate the effectiveness of reflection suppressor 30 . It is understood, however, that in a pipeline design, reflected pressure wave fronts can be caused by a variety of discontinuities such as a bend in the pipeline, a coupling, a valve and many other such flow-path changes.
A combination of the invention can be used with a wide variety of pipes, for example with pipes having inside diameters ranging from about 2 to about 24 inches. Typically and preferably, the mid-region of the housing of a combination of the invention ranges from about 1.5 to about 4 times the average cross-sectional area of a pipeline with which the combination is associated although larger and smaller such ratios can be employed if desired.
Although the reflection wave suppression capability of a combination of this invention is very useful at relatively low pipe internal gas operating pressures, an inventive combination is particularly advantageous at relatively high pipe internal gas operating pressures, where elevated pressures of dangerous levels can be quickly attained when a flame front and associated pressure wave occur, and the necessity to dissipate or reduce such elevated pressures becomes necessary to avoid catastrophic consequences. So far as is known, no other passive device is known which has the pressure dissipating capacity of the present invention particularly at high operating pipe pressures.
EXAMPLES
A number of tests were conducted using a combination of a flame arrestor with a reflection suppressor in a configuration as illustrated in FIG. 4 .
The pipe diameter was 8 inches. The test protocol was as provided in 33 Code of Federal Regulations (CFR) Part 154-Appendix A—“Guidelines for Detonation Flame Arrestors” involving restricted outlet deflagration arrestor testing. The gas mixture was 7% ethylene plus air.
In each of the tests, a flame arrestor, including a crimped ribbon fill media design, was employed with the difference only being the use of the reflection suppressor in Tests 1-10. In these tests, a flame was generated at an ignition point located 20 feet from the inlet side of the flame arrestor. The results of the tests are depicted in Table I. In Table I, Po is the initial pressure, P2 is the maximum final explosion pressure and P2/Po is a calculated pressure ratio. All measured pressures were expressed in absolute psi values. As illustrated, Table I includes a total of seventeen (17) tests, ten (10) with the reflection suppressor of the present invention and seven (7) without. For each test, the pressure (P2) was measured at the inlet side of the flame arrestor.
As reflected in Table I (below), of the ten (10) tests of the flame arrestor including the reflection suppressor of the present invention, the flame arrestor passed. In contrast, as depicted in Tests 11-15, the flame arrestor without the reflection suppressor of the present invention failed in 3 out of 5 tests. In Tests 16 and 17, a different flame arrestor of the same design (as Tests 11-15) was employed in order to be certain that the flame arrestor of Tests 11-15 was not defective. As shown in Table I, Tests 16 and 17, the flame arrestor failed in each test.
TABLE I
With/Without
Pressure at
Pass/
Reflection
Ignition
Test No.
arrestor (P2)
P2/Po
Fail
Suppressor
Point***
1
35
2
Pass
with
20
2
51.42
3.49
Pass
with
20
3
19.19
1.3
Pass
with
20
4
28.7
1.95
Pass
with
20
5
16
1.23
Pass
with
20
6
27.83
1.89
Pass
with
20
7
39.9
2.7
Pass
with
20
8
39.7
2.7
Pass
with
20
9
44.82
3.04
Pass
with
20
10
37.65
2.56
Pass
with
20
11
5.27
0.35
Fail
without
20
12
7.178
0.488
Fail
without
20
13
25.78
1.75
Pass
without
20
14
7.178
0.488
Fail
without
20
15
43.8
2.97
Pass
without
20
16*
22
1.5
Fail
without
20
17**
24
1.6
Fail
without
20
*Same design different arrestor
**Same design different arrestor
***Location 20 forward of this entrance to the flame arrestor/reflection suppressor combination
Other and further embodiments, applications, features and the like will be apparent to those skilled in the art.
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A combination of a flame arrestor with a reflection suppressor is provided which not only arrests an advancing flame front, but also suppresses or mitigates a reflection wave that is generated by a pressure wave that passes through the combination and continues on to a pipe restriction what generates a reflection wave that proceeds back to the combination. At the combination, the reflection suppressor suppresses and/or mitigates the reflection wave, thereby avoiding a heightened pressure in the combination that could cause a re-ignition and a new flame front and pressure front. The reflection suppressor has a tapered profile that permits a pressure wave to pass along and past the reflection suppressor as it leaves the combination but that impedes and mitigates a returning reflection wave produced by the pressure wave striking a pipe restriction and causing such a returning reflection wave.
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BACKGROUND OF THE INVENTION
This invention relates a device for preventing reverse gear buzzing upon reverse shifting operation in a manual transmission or to a synchronizing device for reverse shifting operation.
As reverse shifting operation in a manual transmission is conducted in principle when the vehicle is stopped, gears are designed to be slidingly meshed with each other without provision of a synchronizing device, in general. However, recently a low-viscosity lubricating oil for the manual transmission has been often employed in order to reduce fuel consumption of an engine of the vehicle and improve a speed change operation at low temperatures. As a result, even when the clutch is released, the input shaft in the transmission continues to inertially rotate under no-load conditions, thereby causing poor manipulation upon the reverse shifting operation as well as creating reverse gear buzzing. This noise will make the driver unpleasant, and in the worst case, the gears may be damaged. Such a noise tends to be created especially when the engine idling speed is required to be set to a higher value because of operation of an air-conditioning or cooling device in summer.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide a device for improving a speed change operation as well as preventing a gear buzzing upon reverse shifting operation in order to eliminate unpleasant feeling of the driver and failure of the gear.
According to the present invention, in combination with a manual transmission provided with a synchromesh mechanism and including a transmission casing, a shaft rotatably disposed in the transmission casing, a clutch hub mounted on the shaft and adapted to rotate synchronously with the shaft, said clutch hub having a spline on its outer circumference, a forward gear mounted on the shaft and adapted to rotate relatively to the shaft, said forward gear being arranged on the front side of the clutch hub, a hub sleeve engaged with the outer circumference of the clutch hub by a spline to be movable in the axial direction of the shaft, a synchronizing cone mounted on the boss portion formed at the rear side of the forward gear and adapted to rotate synchronously with the forward gear, said synchronizing cone having a spline with which the hub sleeve is engaged and a frusto-conical surface converging toward the clutch hub, a synchronizer ring adapted to be press-fitted on the conical surface of the synchronizing cone, a shifting key provided at the spline engaged portion between the hub sleeve and the clutch hub and adapted to engage with the synchronizer ring, wherein upon forward shifting operation, the hub sleeve is engaged with the clutch hub and the synchronizing cone, and the forward gear rotates synchronously with the shaft, and upon reverse shifting operation, the hub sleeve is idly moved in the opposite direction to that in the forward shifting operation; a device for preventing reverse gear buzzing is disclosed herein, which comprises an irrotational cone or rotationally limited cone mounted on the boss portion formed on the rear side of the clutch hub and adapted to rotate relative to the clutch hub, said irrotational cone having a frusto-conical surface diverging rearwardly on its outer periphery, means for stopping rotation of the irrotational cone and a friction ring adapted to be press-fitted on the conical surface of the irrotational cone and engaged with the shifting key, wherein upon reverse shifting operation, the friction ring is urged rearwardly by the shifting key to press the outer circumference of the irrotational cone, thereby reducing or stopping inertial rotation of the shaft.
In particular, since the irrotational cone is relatively rotatably mounted on the shaft and the rotation of the irrotational cone is stopped by the projection formed on the transmission casing, the irrotational cone and the friction ring may be assembled coaxially with the shaft, and thereby there remains no fear of noises made by the loose rotation of the friction ring which results from the eccentric arrangement between the shaft and the irrotational cone, and their assembling may be improved.
The present invention will become more fully apparent from the claims and the description as it proceeds in connection with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary sectional view of a manual transmission of an embodiment according to the present invention;
FIG. 2 is a fragmentary view illustrating the relationship between a stopper and a catch projection in FIG. 1; and
FIG. 3 is a fragmentary sectional view of the essential part of a manual transmission according to another embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 in which a part of a manual transmission is shown, an input shaft 2 and an output shaft 3 are rotatably disposed in a transmission casing 1 and are arranged in parallel relation with each other. A forward gear 4 is rotatably mounted on the input shaft 2 through a bearing. A driven gear 5 is fixed on the output shaft 3 in such a manner as to be always meshed with the forward gear 4. A clutch hub 6 is secured to the input shaft 2 by means of serration engagement or others, being arranged adjacent to the left-hand side or the rear side of the forward gear 4. A hub sleeve 7 is slidably engaged through a spline with the outer periphery of the clutch hub 6. There is provided, as is known in the art, a shifting key 8 between the clutch hub 6 and the hub sleeve 7 in such a manner as to be urged by a key spring 9 against the hub sleeve 7. A synchronizing cone 10 is secured to a left-hand side hub portion 4a of the forward gear 4 by means of serration engagement or others. The cone 10 includes a spline with which the hub sleeve 7 is engaged and a frusto-conical surface. A synchronizer ring 11 is mounted on the frusto-conical surface of the synchronizing cone 10, being arranged oppositely to the hub sleeve 7. The shifting key 8 is inserted into a key way (not shown) of synchronizer ring 11, and acts to bring a spline of the hub sleeve 7 into opposed relation with a spline of the synchronizer ring 11, which opposed condition is referred to as "index". The ring 11 is engaged with the shifting key 8 and is rotated together with the hub sleeve 7. When the hub sleeve 7 moves toward the forward gear 4, the ring 11 is pressed against the synchronizing cone 10 through the shifting key 8. A shift fork 12 is engaged with the hub sleeve 7 in such a manner as to allow rotation of the hub sleeve 7 as well as axial movement thereof. The shift fork 12 is carried by a fork shaft 20 which is axially movably mounted on the transmission casing 1, and a shift arm (not shown) is attached to the right-hand portion of the fork shaft 20. When the fork 12 is leftwardly or rearwardly moved as viewed in FIG. 1, the reverse shift position is obtained through the conventinal sliding mesh mechanism. An irrotational cone 13 or rotationally limited cone is mounted on a boss portion 6a of the clutch hub 6 on the left-hand side of the clutch hub 6 through a ball bearing 14, so as to rotate relative to the clutch hub 6. The cone 13 has a frusto-conical surface diverging toward the left-hand end thereof as viewed in FIG. 1. The bearing 14 may be replaced by a bushing. There is provided a friction ring 15 between the clutch hub 6 and the irrotational cone 13. The tapering angle of the inner circumference of the friction ring 15 is identical with that of the outer circumference of the cone 13. The friction ring 15 is settled in the same manner as the synchronizer ring 11 arranged between the clutch hub 6 and the synchronizing cone 10. In other words, the friction ring 15 is provided with a key way 15a extending in the axial direction thereof on the outer periphery for receiving the sliding shifting key 8. The key way 15a has a stepped portion 15b for permitting abutment of the friction ring 15 against the tapering surface of the irrotational cone 13 by movement of the shifting key 8. The friction ring 15 is engaged with the shifting key 8 and is rotated together with the hub sleeve 7. When the hub sleeve 7 moves leftwardly as viewed in FIG. 1, the ring 15 is pressed against the outer circumference of the irrotational cone 13 through the shifting key 8. Therefore, the friction ring 15 may be regarded as a synchronizer ring without a chamfer. In a modified embodiment, a synchronizer ring with a chamfer may be used in place of the friction ring 15. There are provided stoppers 16 projecting from the left end surface of the irrotational cone 13 toward the inner surface 1a of the transmission casing 1, which stoppers 16 are arranged 180° spaced apart from each other. A bracket 17 is attached to the inner surface 1a of the transmission casing 1 by means of a bolt 18. The bracket 17 has catch projections 19 opposite to the irrotational cone 13 and arranged on the same circumference as that of the stoppers 16 and arranged 180° spaced apart from each other in such a manner that the stoppers 16 may be butted against the catch projections 19 so as to permit limited rotation of the cone 13, but, prevent the rotation of the irrotational cone 13 upon engagement of stopper 16 and projection 19. (See FIG. 2.)
In operation, when the forward shifting operation is conducted, the fork shaft 20 is moved rightwardly as viewed in FIG. 1, and the hub sleeve 7 is also moved rightwardly through the shift fork 12. As a result, synchronous rotation is achieved through the shifting key 8, the synchronizer ring 11 and the synchronizing cone 10, and the hub sleeve 7 is engaged with the synchronizing cone 10, and then the input shaft 2 is connected with the forward gear 4, thereby permitting their synchronous rotation.
To the contrary, when the reverse shifting operation is conducted, the fork shaft 20 is moved leftwardly as viewed in FIG. 1 to obtain a reverse shift position. During the reverse shifting operation, the hub sleeve 7 is moved leftwardly through the shift fork 12. As a result, the friction ring 15 which rotates synchronously with the clutch hub 6 through the shifting key 8 is urged leftwardly as viewed in FIG. 1 by the shifting key 8 and is frictionally abutted against the outer circumferential surface of the irrotational cone 13, resulting in brakeage with respect to the input shaft 2 which will inertially rotates after releasing the clutch. Thus, the rotation of the input shaft 2 is reduced or stopped. At the beginning of the reverse shifting operation, the shifting key 8 serves to make the friction ring 15 pressed against the irrotational cone 13, but during the reverse shifting operation, the axial engagement of the shifting key 8 and the hub sleeve 7 is released, and as a result, the pressure of the friction ring 15 against the irrotational cone 13 is released, thereby creating almost no load during reverse driving.
Though the transmission casing 1 carries the bracket 17 having the catch projections 19 in the above embodiment, the catch projection 19 may be integrally formed on the inner surface 1a of the transmission casing 1 as shown in FIG. 3.
While the invention has been described with reference to a few preferred embodiments thereof, it is to be understood that modifications or variations may be easily made without departing from the scope of the present invention which is defined by the appended claims.
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The invention relates to a device for preventing reverse gear buzzing in a manual transmission. The device includes an irrotational or rotationally limited cone supported on a shaft rotatably disposed in a transmission casing. The irrotational cone is coaxial with the shaft and adapted to rotate relative thereto. Means are provided for limiting and stopping rotation of the irrotational cone and a friction ring adapted to be fitted on the conical surface of the irrotational cone. In the preferred embodiment, the rotational stopping means comprises a stopper provided on the irrotational cone and a member provided on the transmission casing for abuttedly engaging the stopper.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image processing apparatus.
2. Description of the Related Art
In recent years, image processing apparatus such as multifunction devices that manage the functions of a printer, a copying machine, a scanner, and a fax machine in one housing generally incorporate a CPU similar to a computer and their functions are realized by controlling applications.
For example, an image forming device described in Japanese Patent No. 3679349 (Patent Document 1) includes functions used in common by applications as a platform. The applications can be implemented by using an API (Application Programming Interface) of this platform. According to this image forming device, with the commonly used functions provided as a platform, redundant implementation of functions in the applications can be avoided, which improves development efficiency of the applications as a whole.
With the related art structures, however, the development efficiency of the applications is sometimes not improved as much as expected if the granularity of the functions or the interface provided by this platform is not appropriately designed.
If this granularity is too high, the API is called too often even though the application provides merely a simple service. As a result, the source code becomes complicated.
If the granularity is too low, on the other hand, the platform is required to be modified internally when an application providing a partly modified service is required to be implemented, which leads to an increase of development steps. In particular, when modules in the platform depend largely on each other, not only is a new function required to be added to the platform but an existing part may also require modification. Thus, the development process becomes more complicated.
In the case of implementing an existing application with a partly modified service (for example, an input process of an image), it is impossible to call the unmodified part of the application for the unmodified function. Therefore, a new application is required to be implemented by writing new source code.
SUMMARY OF THE INVENTION
It is an object of at least one embodiment of the invention to provide an image processing apparatus which can simplify customization, extension, and the like of the functions.
According to one aspect of the invention, an image processing apparatus includes an input unit configured to obtain image data and to perform an input process on the image data to produce input image data, an input filter configured to control the input process performed by the input unit, an output unit configured to perform an output process on processed image data, an output filter configured to control the output process performed by the output unit, a process filter connecting between the input filter and the output filter to control processing of the input image data, and another output filter configured to control an output process for storing given image data and conditions concerning outputting of the given image data in a storage unit. The other output filter is coupled to one of the input filter and the process filter in response to receiving an instruction to store the given image data.
According to another aspect of the invention, an image processing apparatus includes an input unit configured to obtain image data and to perform an input process on the image data to produce an input image data, an input filter configured to control the input process performed by the input unit, an output unit configured to perform an output process on processed image data to produce output image data, an output filter configured to control the output process performed by the output unit, a process filter connecting between the input filter and the output filter to control processing of the input image data to produce the processed image data, and another input filter configured to control an input process for reading out image data stored in a storage unit storing the image data and conditions concerning outputting of the image data. The other input filter is coupled to one of the process filter and the output filter in response to receiving an instruction to read the image data stored in the storage unit.
According to another aspect of the invention, an image processing apparatus includes an input unit configured to obtain image data and to perform an input process on the image data to produce an input image data, an input filter configured to control the input process performed by the input unit, an output unit configured to perform an output process on processed image data to produce output image data, an output filter configured to control the output process performed by the output unit, a process filter connecting between the input filter and the output filter to control processing of the input image data to produce the processed image data, another output filter configured to control an output process for storing given image data and conditions concerning outputting of the given image data in a storage unit, and another input filter configured to control an input process for reading out the image data stored in the storage unit. The other output filter is coupled to one of the input filter and the process filter in response to receiving an instruction to store the given image data. The other input filter is coupled to one of the process filter and the output filter in response to receiving an instruction to read the image data stored in the storage unit.
According to at least one embodiment of the invention, customization and enhancement of the functions can be simplified and stored image data can be easily re-outputted.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing the idea of pipes & filters;
FIG. 2 is a configuration diagram showing a software configuration of an image processing apparatus of a first embodiment;
FIG. 3 is a diagram showing a printing process of the image processing apparatus of the first embodiment;
FIG. 4 is a configuration diagram showing a software configuration of an image processing apparatus of a second embodiment;
FIG. 5 is a diagram showing a storing process of image data in the image processing apparatus of the second embodiment;
FIG. 6 is a diagram showing a re-output of the image data in the image processing apparatus of the second embodiment;
FIG. 7 is a diagram showing a configuration of each filter;
FIG. 8 is a sequence diagram showing a setting of document registration in the image processing apparatus of the second embodiment;
FIG. 9 is a sequence diagram showing a storing process of output conditions in the image processing apparatus of the second embodiment;
FIGS. 10A through 10C are diagrams showing settings of the output conditions;
FIG. 11 is a diagram showing an example of the output conditions;
FIG. 12 is a diagram showing the output conditions when image data are outputted through plural output filters;
FIG. 13 is a sequence diagram showing a selecting process of image data to be re-outputted in the image processing apparatus of the second embodiment;
FIGS. 14A and 14B are diagrams showing examples of a display of an operating device of the image processing apparatus of the second embodiment;
FIGS. 15A and 15B are diagrams showing other examples of the display of the operating device of the image processing apparatus of the second embodiment;
FIG. 16 is a sequence diagram showing a selecting process of image data to be re-outputted in the image processing apparatus of the second embodiment;
FIG. 17 is a diagram showing an example of an operations display displayed on the operating device;
FIG. 18 is a diagram showing another example of an operations display displayed on the operating device;
FIG. 19 is a flowchart showing a process to determine existence of a filter in the second embodiment;
FIG. 20 is a flowchart showing an operation when there is a change in output conditions in the image processing apparatus of the second embodiment;
FIG. 21 is a diagram showing an example of an operations display asking whether to keep the changed output conditions;
FIG. 22 is a flowchart showing an operation when a part of output conditions cannot be executed in the image processing apparatus of the second embodiment;
FIG. 23 is a diagram showing an example of an operations display asking whether to restore the output conditions;
FIG. 24 is a diagram showing an operation when image data before processing are retained in the image processing apparatus of the second embodiment; and
FIG. 25 is a diagram showing a memory medium storing a program to realize various functions described in each embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention employs a software architecture based on an idea called pipes & filters in the image processing apparatus, thereby the customization, enhancement, and the like of the functions are simplified. Moreover, the invention easily realizes a re-output of stored image data.
Hereinafter, the idea of pipes & filters employed in the image processing apparatus of the invention is described, prior to describing the embodiments of the invention. FIG. 1 is a diagram showing the idea of pipes & filters. “P” shown in FIG. 1 denotes a pipe and “F” denotes a filter.
The filter is a program which applies a predetermined process to inputted data and outputs a process result. The pipe is a unit which connects the filters. The pipe temporarily holds the process result outputted from the filter connected on an input side of the pipe and then transfers the data to the filter connected on an output side of the pipe. In this manner, according to the idea of pipes & filters, the processes of the filters can be continuous through the pipes.
In the invention, the predetermined processes performed by the filters are considered to apply a predetermined conversion to the inputted data. That is, each function realized by the image processing apparatus is considered to be continuous “conversion processes” applied to a document (input data) in the image processing apparatus of this embodiment. Each function of the image processing apparatus is thought to include input, processing, and output of the document, which is data. In this embodiment, each of the “input process”, “processing” and “output process” is considered to be a “conversion process” and a software component which realizes one conversion process is a filter.
In the invention, a filter which controls a data input process is called an input filter, a filter which controls data processing is called a processing filter, and a filter which controls a data output process is called an output filter. Each of these filters is an independent program without dependence among them. Therefore, each filter can be independently added (installed) or deleted (uninstalled) as a filter unit in the image processing apparatus.
Embodiment 1
Hereinafter, an image processing apparatus 100 of Embodiment 1 of the invention is described with reference to the drawings.
FIG. 2 is a configuration diagram showing a software configuration of the image processing apparatus 100 of Embodiment 1 of the invention. The image processing apparatus 100 is a complex machine which manages plural functions of a printer, a copying machine, a scanner, a facsimile machine, or the like in one housing.
Software realizing the functions of the image processing apparatus 100 has a hierarchical structure including a user interface layer 110 , a control layer 120 , an application logic layer 130 , a device service layer 140 , and a device layer 150 . The hierarchical relationship of these layers is based on the relationship of calling between the layers. That is, an upper layer calls a lower layer in the drawing.
When a user sends an instruction for the execution of various functions by the user interface layer 100 in the image processing apparatus 110 , the user interface layer 110 calls the control layer 120 and controls the application logic layer 130 based on this execution instruction. The application logic layer 130 executes an application which realizes the requested function based on the instruction from the control layer 120 . Based on this execution result, the device service layer 140 and the device layer 150 control a hardware resource of the image processing apparatus 100 . In this manner, the image processing apparatus 100 obtains an output result corresponding to the function that the user interface layer 110 has received.
Each layer is described below.
The user interface layer 110 incorporates, for example, a local UI (user interface) unit 111 to receive an execution instruction to realize various functions of the image processing apparatus 100 . The various functions here are a copying function, a printing function, a scanning function, a facsimile function, and the like. The local UI unit 111 may be provided, for example, in an operating unit (not shown) where processes executed in the image processing apparatus 100 are operated. This operating unit may be realized by an operations panel or the like having a display area. In the user interface layer 110 , the execution instruction received in the local UI unit 111 is transferred to the control layer 120 .
The control layer 120 incorporates functions for controlling the processes to realize each function of the image processing apparatus 100 . In specific terms, execution of each filter in the application logic layer 130 is controlled in accordance with the requested function. It is to be noted that a function of the image processing apparatus 100 described in the following embodiments is one service unit (from a request input to a final output) that the image processing apparatus 100 provides to the user and software-wise is the same as an application which provides one service unit.
The application logic layer 130 incorporates various filters as a component group which realizes a part of the functions provided in the image processing apparatus 100 . In the application logic layer 130 , one function is realized by using plural filters in combination with control of the control layer 120 . The application logic layer 130 in this embodiment incorporates an input filter 131 , a process filter 132 , an output filter 133 , and an activity unit 134 . Each filter incorporated in the application logic layer 130 is operated and controlled based on the definition of that filter itself. The activity unit 134 is a component which connects each filter in accordance with the function requested in the user interface layer 110 and controls the execution of each filter.
The device service layer 140 incorporates a lower function used in common by each filter incorporated in the application logic layer 130 . The device service layer 140 of this embodiment incorporates an image pipe 141 . The image pipe 141 which realizes the pipe function transfers an output result of one filter to another filter among the filters incorporated in the application logic layer 130 . Here, the image pipe 141 may connect, for example, the input filter 131 with the process filter 132 , or the process filter 132 with the output filter 133 .
The device layer 150 incorporates a driver as a program which controls hardware. The device layer 150 of this embodiment incorporates a scanner unit 151 , a plotter unit 152 , and the like. Each of these control units controls a device of its name.
Hereinafter, each filter incorporated in the application logic layer 130 is further described.
The input filter 131 of this embodiment controls an input process of data inputted externally to the image processing apparatus 100 . The input filter 131 includes a read filter, an email receive filter, a facsimile receive filter, a PC document receive filter, and the like (not shown). The read filter, for example, controls reading of image data by a scanner and outputs the read image data. The email receive filter receives an email in the image processing apparatus 100 and outputs data included in the received email. The facsimile receive filter controls receiving of facsimiles and outputs the received data. The PC document receive filter receives print data from a client PC or the like that is not shown and outputs the print data. A report filter (not shown) organizes setting data, history data, or the like of the image processing apparatus 100 into, for example, a table format and outputs the organized data.
The process filter 132 of this embodiment applies a predetermined process to the image data inputted from the filter on the input side of the process filter 132 and outputs the process result to the filter on the output side of the process filter 132 . The process here is aggregation, expansion, shrinking, rotation, or the like of the inputted data.
The output filter 133 controls an output process of the inputted data and outputs the data outside the image processing apparatus 100 . The output filter 133 includes a print filter, a preview filter, and the like. The output filter 133 shown in FIG. 2 includesan email send filter, a facsimile send filter, a PC document send filter, and the like.
The print filter outputs (prints) the inputted data to the plotter unit 152 . The preview filter causes an operating unit or the like which is not shown included in the image processing apparatus 100 to preview the inputted data. Further, the email send filter attaches the data to an email and sends it. The facsimile send filter sends the inputted data by facsimile. The PC document send filter sends the inputted data to a client PC or the like which is not shown.
An instruction inputted from the local UI unit 111 in the user interface layer 110 is transferred through the control layer 120 to the activity unit 134 . The activity unit 134 controls execution of jobs in the input filter 131 , the process filter 132 , and the output filter 133 .
In the application logic layer 130 , each function of the image processing apparatus 100 is realized by using the filters 131 to 134 in combination. According to this configuration, various functions can be realized by using the filters and pipes in combination in the image processing apparatus 100 . In specifics, the read filter included in the input filter 131 , the process filter 132 , and the print filter included in the output filter 133 are to be used in combination to realize a copying function, for example.
Hereinafter described is a printing process in the image processing apparatus 100 of this embodiment. FIG. 3 is a diagram showing a printing process in the image processing apparatus of Embodiment 1.
The control layer 120 in the image processing apparatus 100 in this embodiment sends a job to the activity unit 134 to control execution of a process of each filter (S 31 ). The image processing apparatus 100 of this embodiment may generate and send a job to this activity unit 134 when, for example, power of the image processing apparatus 100 is turned on.
Here, when an execution request of a printing process is made in the local UI unit 111 , the local UI unit 111 transfers this request to the control layer 120 (S 32 ). Note that the description in this embodiment is made based on the premise that a copying process as one of the printing processes is selected. In this case, an operation to select reading and printing of a paper document is performed in the local UI unit 111 .
The activity unit 134 connects a read filter 131 a , the process filter 132 , and a print filter 133 a through the image pipes 141 . Note that a read filter included in the read filter 131 a is connected to the process filter 132 in actuality. Subsequently, the control layer 120 generates a job (S 33 ) to be executed by the read filter 131 a , a job (S 34 ) to be executed by the process filter 132 , and a job (S 35 ) to be executed by the print filter 133 a.
When the jobs to be executed by filters 131 a , 132 , and 133 a are sent from the control layer 120 , the activity unit 134 sends an instruction to each filter to execute the corresponding job. Then, the read filter 131 a reads the paper document from the scanner unit 151 as an input unit and thus the paper document is read in as image data. These image data are outputted from the read filter 131 a and transferred to the process filter 132 through the image pipe 141 .
In the process filter 132 , a predetermined process set in advance is applied to these image data and the data are outputted as the processed image data. The processed image data are then transferred to the print filter 133 a as one of the output filters 133 . In the print filter 133 a , the processed image data are outputted from the plotter unit 152 as an output unit to realize a copying process.
In this manner, the input filter 131 , the process filter 132 , and the output filter 133 are each independently controlled and no dependence exists among the filters in this embodiment. Therefore, when the functions are customized, expanded, or the like, the appropriate filter is to be customized or the like in this embodiment. According to this embodiment, customization, expansion, or the like of the functions can be simplified.
Embodiment 2
Embodiment 2 of the invention is hereinafter described. Embodiment 2 of the invention is the same as Embodiment 1 with improvement. Thus, components with similar functional structures to those in Embodiment 1 are denoted by the same or similar reference numerals, and their descriptions are not repeated.
Prior to describing this embodiment, problems to be solved in this embodiment are described.
In Embodiment 2, the case of re-outputting image data stored in a hard disk or the like in the image processing apparatus 100 is considered (see FIG. 4 ). Note that re-outputting in this embodiment means, for example, when the image data outputted by the print filter 133 a are to be re-outputted, to read out and re-print the image data. When the image data outputted by an email send filter are to be re-outputted, re-outputting means to read out and re-send these image data by an email.
Assuming that the image data are to be re-outputted, the image processing apparatus 100 A is required to retain the image data at the same time as outputting the image data so that they can be re-outputted anytime. To be specific, the image processing apparatus 100 A is required to retain output conditions such as setting conditions or the like with the image data when the image data are outputted. With the output conditions of the image data being retained, the image data can be restored to be re-outputted based on the output conditions.
A feature of pipes & filters is that various functions can be freely realized by using the filters in combination. In this embodiment, an image processing apparatus is provided which can retain image data capable of being re-outputted without spoiling the freedom of filter combinations, and easily re-output the retained image data.
The image processing apparatus 100 A of this embodiment includes a document register filter 133 b which relates the image data outputted from the output filter 133 with the output conditions of the image data and stores them and a read-out filter 131 b which reads out the stored image data together with the output conditions of the image data; thereby the stored image data can be easily re-outputted.
FIG. 4 is a configuration diagram showing a software configuration of the image processing apparatus 100 A of Embodiment 2 of the invention.
The image processing apparatus 100 A of this embodiment includes an input filter 131 A, a process filter 132 , an output filter 133 A, and a bibliographic data management service unit 135 in an application logic layer 130 A. Moreover, the image processing apparatus 100 A of this embodiment includes a request management unit 142 in a device service layer 140 A and a data management unit 153 in a device layer 150 A.
The image processing apparatus 100 A of this embodiment does not include the control layer 120 included in the image processing apparatus 100 of Embodiment 1. In the image processing apparatus 100 A of this embodiment, the role of the control layer 120 included in the image processing apparatus 100 of Embodiment 1 is shared by an activity unit 134 A of the application logic layer 130 A and the request management unit 142 of the device service layer 140 A. That is to say, the activity unit 134 A of this embodiment originates instructions for connection between the filters and execution of jobs of the filters while the request management unit 142 generates jobs to be executed by the filters and connects between the filters as instructed by the activity unit 134 A.
The input filter 131 A includes the read-out filter 131 b in addition to the read filter 131 a . The read-out filter 131 b reads out and outputs image data and output conditions of the image data from a storage device such as a hard disk which is described below. The read-out filter 131 b is described in detail below.
The output filter 133 A includes the document register filter 133 b in addition to the print filter 133 a . The document register filter 133 b outputs the image data and the output conditions of the image data to a storage device and stores the image data and the output conditions of the image data. The document register filter 133 b is described in detail below.
The bibliographic data management service unit 135 controls a data management memory or the like which temporarily holds image data and output conditions when the document register filter 133 b stores the image data and the output conditions.
The data management unit 153 in the device layer 150 controls the retaining of data in a storage device such as a hard disk included in the image processing apparatus 100 A.
Hereinafter described is an outline of the image data keeping process and the re-output process of the image data in the image processing apparatus 100 A of this embodiment. First, the image data keeping process in the image processing apparatus 100 A is described. FIG. 5 shows the image data keeping process in the image processing apparatus 100 A of Embodiment 2.
In the image processing apparatus 100 A of this embodiment, output conditions of image data are retained with the image data when retaining the image data. As a result, the image data reflecting the same conditions as set when outputting the image data can be outputted based on the output conditions when re-outputting the image data.
Here, the document register filter 133 b in the image processing apparatus 100 A of this embodiment is further described.
The document register filter 133 b of this embodiment includes an output condition generating unit 136 and a relating unit 137 . The output condition generating unit 136 generates output conditions of the image data to be retained. Generation of the output conditions is described in detail below. The relating unit 137 relates the image data to be stored with the output conditions generated by the output condition generating unit 136 . The relating process is described in detail below.
FIG. 5 shows the case of retaining the image data to be printed. When the local UI unit 111 makes an instruction to print and keep the image data in the image processing apparatus 100 A, the local UI unit 111 transfers this instruction to the activity unit 134 (S 51 ).
Receiving this instruction, the activity unit 134 A selects a filter to generate a job and connects the filters in accordance with the user's settings to realize the requested function. The activity unit 134 A then transfers this setting information to the request management unit 142 for job generation.
The request management unit 142 generates a job to be executed in each filter based on filter connection settings received from the activity unit 134 A and connects the filters. In the read filter 131 a , a job to read the image data is generated. In process filters 132 A and 132 B, jobs to perform a process required to print the image data are generated. In the print filter 133 a , a job to print the image data is generated. In the document register filter 133 b , a job to keep the image data in a storage device HDD which is described below is generated.
In the example shown in FIG. 5 , the activity unit 134 A sends instructions to connect the print filter 133 a to the process filter 132 A through the image pipe 141 a and to connect the process filter 132 A to the read filter 131 a through the image pipe 141 b . The request management unit 142 connects the filters based on these connection instructions.
The activity unit 134 A sends instructions to connect the document register filter 133 b to the process filter 132 B through the image pipe 141 c and to connect the process filter 132 B to the read filter 131 a through the image pipe 141 d . The request management unit 142 connects the filters based on these connection instructions.
When the filters are connected by the request management unit 142 , the activity unit 134 A then instructs the filters 131 a , 132 A, 133 a , 132 B, and 133 b to execute the jobs S 52 , S 53 , S 54 , S 55 , and S 56 , respectively. At this time, the output condition generating unit 136 of the document register filter 133 b generates output conditions based on the connecting relationships between the filters and the setting conditions of the filters, which are described below.
When the jobs are executed, the read filter 131 a writes out the read image data to the image pipes 141 b and 141 d . The process filter 132 A reads out the image data written out to the image pipe 141 b , applies a predetermined process, and writes out the image data to the image pipe 141 a . The print filter 133 a reads out and prints the processed image data written out to the image pipe 141 c.
The process filter 132 B reads out the image data from the image pipe 141 d , processes the image data, and writes the processed image data out to the image pipe 141 c . When the document register filter 133 b reads out the processed image data from the image pipe 141 c , the image data are read out and related with the output conditions by the relating unit 137 and stored in the storage device HDD.
Note that the process filters 132 A and 132 B apply similar processes to the image data written out from the image pipe 141 b and the image data written out from the image pipe 141 d , respectively. Therefore, the image data written out from the image pipe 141 a by the print filter 133 a and the image data written out from the image pipe 141 c by the document register filter 133 b are similar. As a result, the document register filter 133 b can retain the image data to be printed.
With reference to FIG. 6 , the re-output of image data by the image processing apparatus 100 A of this embodiment is described. FIG. 6 shows the re-output of image data by the image processing apparatus 100 A of Embodiment 2.
FIG. 6 shows the case of re-reading and printing the image data printed by the print filter 133 a . The read-out filter 131 b of this embodiment restores the output conditions related to the image data to be re-outputted. The restoring of the output conditions are described in detail below.
In the image processing apparatus 100 A, when the local UI unit 111 receives an instruction to re-output the image data, this instruction is transferred to the activity unit 134 (S 61 ).
Here, the re-output instruction transferred to the activity unit 134 A is a re-output instruction of the printed image data.
When the output conditions are restored by the read-out filter 131 b in the image processing apparatus 100 A, the activity unit 134 A generates jobs to be executed in the read-out filter 131 b , the process filter 132 A, and the print filter 133 a in order to execute the process to re-print the image data. When the jobs are generated, the activity unit 134 A connects the filters based on the relationships between the jobs. Here, the read-out filter 131 b and the process filter 132 A are connected while the process filter 132 A and the print filter 133 a are connected.
When the filters 131 b , 132 A, and 133 a are connected, the activity unit 134 A instructs the filters to execute the jobs S 62 , S 63 , and S 64 , respectively. When the jobs are executed in the filters, the read-out filter 131 b writes the image data out from the storage device HDD to the image pipe 141 e . The process filter 132 A reads out the image data from the image pipe 141 e , applies a process to print the image data, and writes the processed image data out to the image pipe 141 f . The print filter 133 a writes out the image data from the image pipe 141 f and prints it.
In this manner, the image data stored in the storage device HDD can be re-outputted by receiving a re-output instruction for the image data.
Here, a keeping process of the image data and the output conditions are described more specifically.
Each of the filters included in the application logic layer 130 A of this embodiment has a configuration shown in FIG. 7 . That is, each filter included in the application logic layer 130 A of this embodiment is formed of a setting UI where settings of the filter are performed and a logic unit to control job execution.
FIG. 8 is a sequence diagram showing settings of document registration in the image processing apparatus 100 A of Embodiment 2.
In the image processing apparatus 100 A of this embodiment, the image data and the output conditions are retained after the settings of document registration are made in the document registration filter 133 b . Note that the settings of document registration here mean settings of the output conditions and bibliographic data of the image data.
First, a setting process of the output conditions in the image processing apparatus 100 A is described. In the example of FIG. 8 , the output conditions are to aggregate a document of two pages into one page and print both sides.
In the image processing apparatus 100 A, an edit setting of the image data is performed in the process UI 132 Aa as a setting UI of the process filter 132 A by an operating device which is described below (S 801 ). Note that the process filter 132 A is connected between the read filter 131 a and the print filter 133 a . In step S 801 , the edit condition of “2 in 1” (two pages are aggregated into one page) is set.
When the edit condition is set in the process UI 132 Aa, this edit condition is set in the process logic unit 132 Ab as well (S 802 ). Then, the process logic unit 132 Ab advises the activity logic unit 134 Ab that the edit condition is changed into “2 in 1” (S 803 ).
The activity logic unit 134 Ab also causes the process filter 132 B to set a similar edit condition based on the edit condition set in the process UI 132 Aa (S 804 ). Note that the process filter 132 B is connected between the read filter 131 a and the document register filter 133 b . The process logic unit 132 Bb of the process filter 132 B advises the activity logic unit 134 Ab that the edit condition is changed into “2 in 1” (S 805 ).
Subsequently, a print condition is set in a print UI 133 aa as a setting UI of the print filter 133 a by the operating device (S 806 ). The print condition set here is to print both sides. When the print condition is set, the print UI 133 aa sets this print condition in a print logic unit 133 ab as well (S 807 ). The print logic unit 133 ab tells the activity logic unit 134 Ab that the print condition is changed into “print both sides” (S 808 ).
Here, the edit condition and the print condition of the image data, that is the output conditions of the image data are set in the image processing apparatus 100 A.
Next, setting the bibliographic data of the image data by the document register filter 133 b is described. After the output conditions are set, the bibliographic data of the image data to be retained with the output conditions can be set in the image processing apparatus 100 A of this embodiment.
When an instruction to set the bibliographic data in a document register UI 133 ba of the document register filter 133 b (S 809 ) is made by the operating device, the document register UI 133 ba sends an instruction to set the bibliographic data to a document register logic unit 133 bb (S 810 ). Note that in this embodiment the bibliographic data are set when a file name of the image data is set as the bibliographic data of the image data.
In this manner, the bibliographic registration is set in the image processing apparatus 100 A of this embodiment.
When the output conditions and the document registration are set in the image processing apparatus 100 A, the activity unit 134 A generates a job to be executed in each filter. The process as shown in FIG. 5 is performed after the jobs to be executed in the filters are generated by the activity unit 134 A.
Next, keeping of the output conditions in this embodiment is described.
The document register filter 133 b of this embodiment performs a process to relate the image data with the output conditions and store them in the storage device HDD through the bibliographic data management service unit 135 . Hereinafter, the keeping process of the output conditions is described with reference to FIGS. 9 and 10 . FIG. 9 is a sequence diagram showing the keeping process of the output conditions in the image processing apparatus 100 A of Embodiment 2. FIG. 10 is a diagram showing settings of the output conditions.
When the document registration is set in the image processing apparatus 100 A, the activity logic unit 134 Ab transfers an instruction to keep the output conditions to the document registration logic unit 133 bb (S 901 ). Receiving this keeping instruction, the output condition generating unit 136 generates a keeping table 10 which is described below and tells the activity logic unit 134 Ab about the table generation (S 902 ).
Here, the keeping table 10 is described with reference to FIG. 10 .
The keeping table 10 shown in FIG. 10A is generated and stored on a storage device included in the image processing apparatus 100 A. The keeping table 10 contains a file name of the image data, which is set in the document register UI 133 ba , a filter name through which filter the image data pass during the interval from input to output in the image processing apparatus 100 A and a filter ID. Note that in FIG. 10A the process filter 132 A, the print filter 133 a , and the filter ID are stored, however, only the process filter 132 A is retained in the keeping table 10 at the point of S 901 in FIG. 9 . Moreover, the filter name and ID of each filter may be set in advance in the image processing apparatus 100 A. In this embodiment, the process filter 132 A has a filter ID of 65 and the print filter 133 a has a filter ID of 52.
In FIG. 9 , the activity logic unit 134 Ab instructs the process logic unit 132 Bb to keep the edit condition set in the process UI 132 Aa (S 903 ). Receiving this instruction, the process logic unit 132 Ba generates an edit condition table 12 which is described below (S 904 ) and stores the edit condition set in the process UI 132 Aa in the bibliographic data management service unit 135 (S 905 ).
FIG. 10B shows the edit condition table 12 . The edit condition table 12 stores the edit condition set in the process filter 132 A. In the example of FIG. 10B , the edit condition of “2 in 1” is stored.
In FIG. 9 , when the process logic unit 132 Bb is instructed to retain the edit condition (S 906 ), the process logic unit 132 Bb reports to the activity logic unit 134 Ab that the edit condition is retained (S 907 ).
The activity logic unit 134 Ab sends a registration instruction to the document register logic unit 133 bb to relate the ID of the process filter 132 A stored in the keeping table 10 and the edit condition stored in the edit condition table 12 (S 908 ). Here, the relating unit 137 of the document register filter 133 b relates the process filter 132 A and the edit condition set in the process filter 132 A.
The activity logic unit 134 Ab sends an instruction to the print logic unit 133 ab to retain the print condition set in the print UI 133 aa (S 909 ). Receiving this instruction, the print logic unit 133 ab generates a print condition table which is described below (S 910 ) and retains the print condition set in the print UI 133 aa in the bibliographic data management service unit 135 (S 911 ). Note that the filter name and the filter ID of the print filter 133 a may be stored in the keeping table 10 .
FIG. 10C shows a print condition table 14 . The print condition table 14 stores the print condition set in the print filter 133 a . In the example of FIG. 10C , the print condition of “print both sides” is stored. The print condition table 14 may store, for example, the number of prints, a paper size, a color mode, and the like as shown in FIG. 10C .
In FIG. 9 , when the print logic unit 133 ab is instructed to retain the print condition (S 912 ), the print logic unit 133 ab advises the activity logic unit 134 Ab that the print condition is retained (S 913 ).
The activity logic unit 134 Ab sends a keeping instruction to the document register logic unit 133 bb to relate the ID of the print filter 133 a stored in the keeping table 10 with the print condition stored in the print condition table 14 (S 914 ) and retain them. Here, the print filter 133 a and the print condition set in the print filter 133 a are related.
As described above, the edit condition related to the process filter 132 A and the print condition related to the print filter 133 a are used as output conditions in this embodiment. Here, the document register filter 133 b relates the keeping table 10 , the edit condition table 12 , and the print condition table 14 by using the relating unit 137 .
FIG. 11 shows an example of output conditions. In the output conditions shown in FIG. 11 , a file name of image data, a filter name and a filter ID through which the image data pass, and a condition set in each filter are related to each other based on the keeping table 10 , the edit condition table 12 , and the print condition table 14 . Therefore, the file name (bibliographic data), the edit condition, and the print condition (output condition) of the image data are related to each other.
The document register filter 133 b of this embodiment stores and retains the output conditions and the image data with a set file name in the storage device HDD through the bibliographic data management service 135 . In this embodiment, therefore, the output conditions of the image data can be read out as well when reading out the stored image data. Thus, the image data reflecting the conditions set in each filter when outputting the image data can be restored in this embodiment.
Note that the description has been made on the case where the image data are outputted only from the print filter 133 a , however, the invention is not limited to this. In the case where there are plural output filters 133 which output the same image data, the paths through which the image data are outputted from the output filters 133 may be stored as output conditions.
FIG. 12 shows the output conditions in the case where the image data are outputted from plural output filters.
FIG. 12 shows the case where the image data read out by the read filter 131 a are outputted from the print filter 133 a and the email send filter 133 c.
For example, in a path through which the image data are outputted from the print filter 133 a , the edit condition set in the process filter 132 A and the print condition set in the print filter 133 a are stored as output conditions ( 1 ). In a path through which the image data are outputted from the email send filter 133 c , the edit condition set in the process filter 132 C and the email send condition set in the email send filter 133 c are stored as output conditions ( 2 ).
In this manner, output conditions of each path can be retained when there are plural output paths of the image data in the image processing apparatus 100 A of this embodiment.
In this embodiment, therefore, the image data can be restored based on the output conditions of each path.
Hereinafter described is the restoring of the image data in the image processing apparatus 100 A of this embodiment. In this embodiment, the image data start being re-outputted when the image data to be re-outputted are selected.
First, a selecting process of the image data to be re-outputted in the image processing apparatus 100 A of this embodiment is described with reference to FIGS. 13 and 14 . In this embodiment, the image data selected from the image data stored in the storage device HDD can be re-outputted.
FIG. 13 is a sequence diagram showing a selecting process of the image data to be re-outputted in the image processing apparatus 100 A of Embodiment 2. FIG. 14 shows an example of a display of the operating device included in the image processing apparatus 100 A of Embodiment 2.
When an instruction to select the image data to be re-outputted in the read-out filter 131 ba of the read-out UI 131 b is made through the operating device (S 1301 ), the read-out UI 133 ba sends the selection instruction to the read-out logic unit 133 bb.
In the image processing apparatus 100 A of this embodiment, when the instruction to re-output the image data is received through the operating device, all the image data stored in the storage device HDD may be displayed. An operations display 14 A shown in FIG. 14A listing all the stored image data is displayed on the operating device. Note that a re-output instruction button 14 a to re-output the image data is not visible on the operations display 14 A since the image data to be re-outputted have not been selected.
In FIG. 13 , when the image data to be re-outputted are selected, a read-out logic unit 131 bb searches for the selected image data in the storage device HDD by using the bibliographic data management service unit 135 (S 1303 ). When the image data are found, the read-out logic unit 131 bb compares the image data with the related output conditions (S 1304 ). The read-out logic unit 131 bb determines if the set output conditions include the re-output of the image data to be re-outputted (S 1305 ).
In the case where the output conditions including the re-output of the image data are set in step S 1305 , the read-out logic unit 131 bb advises the read-out UI 131 ba about it (S 1306 ). The read-out UI 131 ba updates the operations display 14 A of the operating device so that a re-output instruction can be made (S 1307 ).
The operations display 14 B shown in FIG. 14B indicates that the re-output instruction can be made. In the operations display 14 B, an image data set 2 is selected as an object to be re-outputted. As the image data set 2 can be re-outputted in the example shown here, the re-output instruction button 14 a to generate a re-output instruction of the image data set 2 is visible. Pressing (or touching) the re-output instruction button 14 a on the operations display 14 B starts the re-output process of the selected image data set 2 .
In this manner, the image data as an object to be re-outputted are selected in this embodiment.
With reference to FIGS. 15 and 16 , restoring the output conditions of the image data as an object to be re-outputted is described. FIG. 15 shows another example of a display of the operating device included in the image processing apparatus 100 A of Embodiment 2. FIG. 16 is a sequence diagram showing the restoring process of the output conditions in the image processing apparatus 100 A of Embodiment 2.
When the re-output instruction for the selected image data is made, the operating device of the image processing apparatus 100 A of this embodiment displays an operations display 15 A showing output paths capable of being restored as shown in FIG. 15A . The operations display 15 A shows that it is possible to restore a path to re-output the image data from the print filter 133 a and a path to re-output the image data from the email send filter 133 c . When the operations display 15 A is displayed on the operating device, the image processing apparatus 100 A starts the restoring process of the output conditions shown in FIG. 16 .
FIG. 16 shows the case where the image data are re-outputted from the print filter 133 a among the output paths displayed; the operations display 15 A shown in FIG. 15A .
When the output conditions of the image data to be re-outputted are displayed on the operating device, the image processing apparatus 100 A instructs the read-out UI 131 ba to expand the output conditions (S 1601 ). The read-out UI 131 ba sends this instruction to the read-out logic unit 131 bb (S 1602 ).
The read-out logic unit 131 bb advises the activity logic unit 134 Ab about receiving the instruction to expand the output conditions (S 1603 ). The activity logic unit 134 Aa restores the output condition of each filter based on the output conditions compared when searching for the image data to be re-outputted (see S 1304 in FIG. 13 ).
In FIG. 16 , the activity logic unit 134 Ab restores the edit condition of the process filter 132 A from the output conditions. The activity logic unit 134 Ab once again causes the process logic unit 132 Ab to restore the edit condition related to the filter ID of the process filter 132 A included in the output conditions (S 1604 ). Receiving the instruction to restore the edit condition from the activity logic unit 134 Ab, the process logic unit 132 Ab checks the edit condition related to the filter ID of the process filter 132 A stored in the storage device HDD through the data management unit 153 (S 1605 ). Then, the process logic unit 132 Ab sets the edit condition checked in the storage device HDD and advises the process UI 132 Aa that the edit condition is changed (S 1606 ).
Subsequently, the activity logic unit 134 Ab restores the print condition of the print filter 133 a from the output conditions. The activity logic unit 134 Ab causes the print logic unit 133 ab to restore the print condition related to the filter ID of the print filter 133 a included in the output conditions (S 1607 ). Receiving the instruction to restore the print condition from the activity logic unit 134 Ab, the print logic unit 132 ab checks the print condition related to the filter ID of the print filter 133 a stored in the storage device HDD through the data management unit 153 (S 1608 ). Then, the print logic unit 133 ab sets the print condition checked in the storage device HDD and advises the print UI 133 aa that the print condition is changed (S 1609 ).
In the image processing apparatus 100 A of this embodiment, the output conditions are restored as described above. When the output condition of each filter is restored in the image processing apparatus 100 A, the operations display 15 B shown in FIG. 15B is displayed on the operating device. The operations display 15 B displays the edit conditions restored in the process filter 132 A and the print conditions restored in the print filter 133 a.
When the output conditions are restored and the condition of each filter is set, jobs to be executed in the filters are generated by the activity unit 134 A and a re-output process of the image data is performed in the image processing apparatus 100 A of this embodiment. The re-output process of the image data after the jobs are generated to be executed in the filters is as shown in FIG. 6 .
According to this embodiment, the output conditions set for each output path of the image data are related to the image data when the image data are retained. Therefore, the image data reflecting the output conditions can be re-outputted by only reading out the image data to be re-outputted and the output conditions related to the image data. According to this embodiment, an image processing apparatus can be provided which can maintain image data in a state capable of being re-outputted and can easily re-output the stored image data without spoiling the freedom of filter combination.
The image processing apparatus 100 A of this embodiment can select the output condition to retain when storing the image data with the output conditions. In this embodiment, for example, an operations display 17 A shown in FIG. 17 may be displayed on the operating device before the keeping process of the output conditions shown in FIG. 9 starts. FIG. 17 shows an example of the operations display 17 A displayed on the operating device.
The operations display 17 A shows the case where there are two output paths of the image data. One path is a print path where the image data are to be outputted from the print filter 133 a and the other path is an email send path where the image data are to be outputted from the email send filter 133 c . In the operations display 17 A in this case, the user can select to keep both the output conditions of the print path and those of the email send path, keep one of these, or keep none of these. In the image processing apparatus 100 A, the image data can be related and retained with the output conditions selected on the operations display 17 A. Thus, the user can retain only the necessary output conditions.
The image processing apparatus 100 A of this embodiment can restore only the selected output conditions from the stored conditions when restoring the output conditions. For example, in this embodiment, the operations display 18 A shown in FIG. 18 may be displayed on the operating device before the restoring process of the output conditions shown in FIG. 16 starts. FIG. 18 shows another example of an operations display 18 A displayed on the operating device.
The operations display 18 A shows the case where there are two output conditions related to one image data set. One output condition is set in the print path where the image data are to be outputted by the print filter 133 a and the other output condition is set in the email send path where the image data are to be outputted by the email send filter 133 c . In this embodiment, only the output conditions selected on the operations display 18 A can be restored.
Note that when the output conditions to be restored are selected on the operations display 18 A, only the data of the selected output condition may be displayed on the operations displays 15 A and 15 B shown in FIGS. 15A and 15B , respectively.
Moreover, when re-outputting the image data through plural paths, a judgment by a human can be made whether the image data are to be re-outputted through each of the selected paths or not.
When the idea of pipes & filters is applied as in the image processing apparatus 100 A of this embodiment, filters can be easily installed or uninstalled. Therefore, when the image data are to be re-outputted, there is a possibility that a filter set as an output condition has been uninstalled.
In the image processing apparatus 100 A of this embodiment, a determination is made whether all the filters set as the output conditions exist when outputting the image data. FIG. 19 is a flowchart describing a process to determine the existence of the filters of Embodiment 2.
Reading out the output conditions set in all the paths requested to re-output the image data (S 1901 ), the image processing apparatus 100 A determines whether all the filters included in the output conditions of all the paths exist (S 1902 ). When all the filters included in the output conditions in all the paths do not exist (NO in step S 1902 ), the output conditions are not restored and the image data are not re-outputted.
The image processing apparatus 100 A of this embodiment includes an application management unit (not shown) where the activity unit and the filters are registered. The application management unit is incorporated in the application logic layer 130 A and manages the activity unit and the filters. The activity unit and the filters are registered in the application management unit when the image processing apparatus 100 A is activated and the registration is deleted from the application management unit when the power of the image processing apparatus 100 A is shut down. In this embodiment, therefore, the determination can be made whether all the filters included in the output conditions exist by searching the application management unit when activating the image processing apparatus 100 A.
When all the filters included in the output conditions in all the paths are determined to exist in step S 1902 , the image processing apparatus 100 A performs the restoring process of the output conditions (S 1903 ). The restoring process of the output conditions is performed as described above. In this embodiment, the processes of S 1902 and S 1903 are performed for each output path of the image data (S 1904 ).
In this manner, the image data are restored only when the restoration is possible with settings similar to the output conditions of storing the image data. Therefore, the output conditions can be restored without mistakes and an improper output such as re-outputting the image data with wrong conditions can be prevented.
When the output condition is changed during the re-output of the image data in the image processing apparatus 100 A of this embodiment, the user can select whether to keep the changed output conditions.
The case where the output condition is changed during the re-output is, for example, the case where a part of the output conditions is canceled while continuing the output. For a specific example, for example, when a re-output of the image data is performed with the output conditions to perform a staple process after printing by the image processing apparatus 100 A, the staple process only is temporarily cancelled as the staples run out.
FIG. 20 is a flowchart showing an operation when the output condition of the image processing apparatus 100 A of Embodiment 2 is changed.
When the output process of the image data starts to be executed in the image processing apparatus 100 A (S 2001 ), the image processing apparatus 100 A determines whether there is a change in the output conditions during execution of the process (S 2002 ). The change in the output conditions here means a change of a setting for a filter in a path through which the image data are to be outputted, for example. To be specific, there are examples such as a change in an edit setting of the process filter 132 A and a change in a print setting in the print filter 133 a . When there is a change in the output conditions in step S 2002 , the image processing apparatus 100 A sets a flag signaling that there is a change in the output conditions (S 2003 ).
Subsequently, the image processing apparatus 100 A determines whether the flag of the change in the output conditions is set when storing the image data (S 2004 ). When there is a flag of the change in the output conditions set in step S 2004 , the image processing apparatus 100 A displays an operations display 21 A on the operating device asking whether to keep the changed output conditions (S 2005 ). FIG. 21 shows an example of the operations display 21 A asking whether to keep the changed output conditions.
In FIG. 20 , when the user selects to keep the changed output conditions on the operations display 21 A in step S 2005 , the image processing apparatus 100 A retains the changed output conditions.
In step S 2005 , when the user selects not to keep the changed output conditions, the image processing apparatus 100 A deletes the settings set in the filters where the output conditions have been changed, and displays a message of deletion on the operations display 21 A of the operating device (S 2006 ).
In this manner, when there is a change in the output conditions during the re-output process of the image data, the user can select whether to keep the changed output conditions in this embodiment. Therefore, it is possible to prevent an improper operation cancelling a part of the output conditions by mistake during the re-output process of the image data.
In this embodiment, even when a part of the restored output conditions cannot be executed when re-outputting the image data, the re-output can be performed by executing the other output conditions.
To be specific, a case where a part of the output conditions cannot be executed is, for example, where staples are not supplied in the image processing apparatus 100 A when a staple process after printing is set as an output condition. In this case, the staple process as a part of the output conditions cannot be executed.
In the image processing apparatus 100 A of this embodiment, the output conditions can be executed except for the output conditions which cannot be executed. FIG. 22 is a flowchart showing an operation of the case when a part of the output conditions cannot be executed in the image processing apparatus 100 A of Embodiment 2.
When the output conditions are restored (S 2201 ), the image processing apparatus 100 A determines whether the re-output can be executed based on the restored output conditions (S 2202 ). In the case where there is an output condition which cannot be executed in step S 2202 , the image processing apparatus 100 A sets a flag of impossible execution (S 2203 ). The image processing apparatus 101 A performs the processes of S 2201 through S 2203 on all the filters of each output path.
Next, the image processing apparatus 100 A determines whether a flag signaling that the output condition cannot be executed is set (S 2204 ). When there is a flag in step S 2204 , the image processing apparatus 100 A displays on the operating device an operations display 23 A as shown in FIG. 23 asking a question whether to restore the output condition which cannot presently be executed (S 2205 ). The image processing apparatus 100 A performs the processes of S 2201 through S 2206 on all the output paths.
In this manner, even when a part of the output conditions cannot be executed, the other output conditions can be executed to perform a re-output in the image processing apparatus 100 A of this embodiment. In the image processing apparatus 100 A of this embodiment, it is possible to retain the output condition which cannot be executed. Therefore, the output conditions can be retained without a change when the impossible execution problem can be easily solved; for example, cases where no staples are supplied, no printing paper is supplied in a paper tray, and the like. In such cases, the impossible execution problem can be solved by supplying staples or printing paper.
In the image processing apparatus 100 A of this embodiment, the image data before processing by the process filter 132 , that is the image data right after the output from the input filter 131 A, can be stored as well.
FIG. 24 shows an operation to store the image data before processing in the image processing apparatus 100 A of Embodiment 2.
FIG. 24 shows the case where the image data are outputted from the print filter 133 a and the email send filter 133 c.
In the image processing apparatus 100 A, the activity unit 134 A connects the document register filter 133 b in a subsequent stage of the read filter 131 a when the image data before processing are set to be retained. The document register filter 133 b reads out and stores the image data read by the read filter 131 b.
At this time, the document register filter 133 b is required to store only the conditions set in the print filter 133 a and the email send filter 133 c as the output filters through which the image data are to be outputted. Therefore, in the example shown in FIG. 24 , the document register filter 133 b stores in the keeping table 100 A the filter names and filter IDs of the print filter 133 a and the email send filter 133 c as the output filters through which the image data are to be outputted. The document register filter 133 b forms a print condition table (not shown) set for the print filter 133 a and an email send condition table (not shown) set for the email send filter 133 c , which are related to the image data and stored.
Thus, in this embodiment, image data before being processed can be maintained as it is.
In this embodiment, when re-outputting the image data stored before being processed, either of the read-out filter 131 b and the output filter 133 may be connected without interposing the process filter 132 . For example, the email send filter 133 c is connected in a subsequent stage of the read-out filter 131 b . In this case, the image data read out from the storage device HDD by the read-out filter 131 b may be outputted from the output filter 133 .
Further, the procedures to realize the various functions in the embodiments may be stored in a memory medium as a program which can be read and executed by computers.
FIG. 25 shows a memory medium 410 storing a program 400 which realizes various functions of the embodiments. When the program 400 stored in the memory medium 410 is read in the image processing apparatus 100 A and executed, the functions described in the embodiments can be realized.
The image processing apparatus 100 A, for example, includes a CPU 510 , a hard disk 520 , a memory 530 , an operating unit 540 , a scanner unit 550 , a communicator unit 560 , a memory medium read-in unit 570 , and a plotter unit 580 . The CPU 510 is an arithmetic processing unit which performs operations and processes executed in the image processing apparatus 100 A. The hard disk (HDD) 520 is a storage device which stores data, which are an application operating in the image processing apparatus 100 A, data formed by this application, and the like. The storage device described in this embodiment may be the hard disk 520 . The memory 530 holds various set values related to the image processing apparatus 100 A, operating results of the CPU 510 , and the like.
The operating unit 540 is an operations panel or the like having a display function, at which operations, display of operating states, and the like of the image processing apparatus 100 A are performed. Note that the operating device of this embodiment may be the operating unit 540 .
The scanner unit 550 , which reads in a document to form image data, is formed of a scanner engine, an engine controller, and the like. The communicator unit 560 is a network control unit or the like, through which the image processing apparatus 100 A communicates with external devices. The memory medium read-in unit 570 reads in data, programs, and the like stored in various memory media, which is a floppy (registered trademark) disk drive, for example. The plotter 580 is formed of a plotter engine, an engine controller, and the like, which prints out the image data.
The memory medium 410 stores the image processing program 400 which realizes various functions of this embodiment. This image processing program 400 is read in by the memory medium read-in unit 570 and executed by the CPU 510 . The memory medium 410 may be, for example, a floppy (registered trademark) disk, a CD-ROM (Compact Disk Read Only Memory), or any medium which can be read by the image processing apparatus 100 A. Further, the image processing program 400 may be received by the communicator unit 560 through a network and stored in the hard disk 520 or the like.
Although the invention has been described with respect to specific embodiments for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art that fairly fall within the basic teachings herein set forth.
This patent application is based on Japanese Priority Patent Application No. 2007-276729 filed on Oct. 24, 2007, the entire contents of which are hereby incorporated herein by reference.
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An image processing apparatus includes an input unit configured to obtain image data and to perform an input process on the image data to produce input image data, an input filter configured to control the input process performed by the input unit, an output unit configured to perform an output process on processed image data, an output filter configured to control the output process performed by the output unit, a process filter connecting between the input filter and the output filter to control processing of the input image data, and another output filter configured to control an output process for storing given image data and conditions concerning outputting of the given image data in a storage unit. The other output filter is coupled to one of the input filter and the process filter in response to receiving an instruction to store the given image data.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser. No. 13/692,139, filed on Dec. 3, 2012, entitled GUSSETED FLEXIBLE PACKAGE WITH SHAPED SIDES AND METHODS OF MAKING THE SAME, which in turn claims priority from Provisional Application Ser. No. 61/566,847, filed on Dec. 5, 2011, entitled GUSSETED FLEXIBLE PACKAGE WITH SHAPED SIDES AND METHODS OF MAKING THE SAME, both of which applications are assigned to the same assignee as this application and whose disclosures are specifically incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] This invention relates to flexible packages and more particularly to gusseted flexible packages and methods of making the same.
[0003] Various types of stand-up flexible packages are known for storing liquids, granular, powders and the like. One such package is the so-called side-gusseted package. It is typically formed from a web of flexible stock material, e.g., polyethylene, polyester, polypropylene, metal foil, and combinations thereof in single or multiple plies, into a tubular body, having a front panel, a back panel, and a pair of gusseted sides. Each gusseted side is formed by a pair of gusset sections and a central fold edge. The lower end of the package is commonly permanently sealed, e.g., heat sealed, along a line extending transversely across the width of the bag close to its bottom edge. The top of the package is commonly sealed transversely across the entire width of the package in a number of ways to maintain the contents under vacuum until the package is opened. One example of a side-gusseted package is a bag typically used for packaging coffee. That side-gusseted bag is made from a flexible packaging laminate composed of various layers of plastic films, metal foils and papers bonded together using adhesives and extrusions. The flexible packaging laminate is generally printed or labeled for the package contents and other consumer information. The flexible packaging laminate is normally produced as sheeting wound onto a roll or rolls which is used to form many packages. The flexible package is formed from the laminate using conventional equipment such as pre-made bag machines, vertical form-fill-seal machines, horizontal form-fill-seal machines and other well known equipment. These machines fold a sheet or sheets of the flexible laminate and seal together some of the edges and leaving a filling mouth. The package is then filled through the mouth and then sealed across the filling mouth to complete the package. The formed and filled side-gusseted package generally takes the shape of a parallelepiped or six-faced polyhedron, though at times the package top may also take the form of a triangular prism.
[0004] As is known package retailers tend to keep the package height at a maximum of 12-14 inches in order to maximize the number of shelves for product display. In order to meet the height restriction, package designers must increase the package width and depth in order to hold the required package contents. The problem with these packages is the difficulty in handling the package by the consumer, especially when attempting to pick the package up using one hand.
[0005] Other types of flexible packages are available to provide easier handling. For example, flat pouches have been made in die-cut shapes. These flat pouches can also have a gusset inserted into the bottom to form a shaped stand-up pouch. However, such shaped flat and bottom gusseted stand-up pouches do not provide the volume or depth that is provided by a side-gusseted package.
[0006] Thus, there is a need for a side-gusseted package which can be permit simple one-handed grasping of the package and still keep the package height restricted as required by retailers. The subject invention addresses that need.
SUMMARY OF THE INVENTION
[0007] One aspect of this invention constitutes methods of making a plurality of side-gusseted flexible packages. One such method basically entails forming a web of flexible material into a tubular member having a central longitudinal axis and a plurality of sequentially located sections extending along the central longitudinal axis. Each of the sections is arranged to be formed into a respective one of the side-gusseted flexible packages (e.g., is a precursor of the package). Each of the side-gusseted flexible packages comprises a front panel, a back panel, and a pair of gusseted side panels, with the front panel having a first side edge, a second side edge, a top edge and a bottom edge, and with the back panel having a first side edge and a second side edge, a top edge and a bottom edge. Each of the gusseted side panels comprises pair of gusset sections connected to each other by a fold line, with one of the pair of gusseted side panels being connected between the first side edge of the front panel and the first side edge of the back panel, with the other of the pair gusseted side panels being connected between the second side edge of the front panel and the second side edge of the back panel. Portions of the front panel are sealed to portions of the gusseted side panels along respective front panel seal lines at the front panel side edges. Each of the front panel seal lines has an end edge portion and an intermediate edge portion. The intermediate edge portions of the front panel seal lines are located closer to the central longitudinal axis than the end edge portions thereof. Portions of the back panel are sealed to portions of the gusseted side panels along respective back panel seal lines at the back panel side edges. Each of the back panel seal lines has an end edge portion and an intermediate edge portion, with the intermediate edge portions of the back panel seal lines being located closer to the central longitudinal axis than the end edge portions thereof. Portions of the package are cut immediately outside the front and back panel seal lines to produce the side edges of the package and the bottom edges of the front and real panels are sealed together along a bottom seal line. The package may be filled with a product and then sealed by a seal line extending across the top edges of the front and back panels.
[0008] Another method of making a side-gusseted flexible package in accordance with this invention entails forming a front panel and a back panel from a web of flexible material. The front panel has a first side edge, a second side edge, a top edge a bottom edge and a central longitudinal axis located midway between the first and second side edges of the front panel. The back panel has a first side edge and a second side edge, a top edge, a bottom edge and a central longitudinal axis located midway between the first and second side edges of the back panel. A pair of tubes is formed from a web of flexible material, with each of the tubes of the pair having a longitudinal axis and an outer surface. A portion of the outer surface of the pair of tubes is adhesively secured to the back panel with the tubes being spaced from each other and with the longitudinally axes of the tubes extending parallel to the central longitudinal axis of the back panel. The front panel is disposed over the back panel and on portions of the pair of tubes to form a pair of gusseted side panels. Portions of the front panels are sealed to portions the tubes along a pair of front panel seal lines and portions of the back panels are sealed to portions of the tubes along a pair of back panel seal lines to form a body having a pair of gusseted side panels and a central longitudinal axis. The central longitudinal axis is located midway between the gusseted side panels. Each of the gusseted side panels comprises a pair of gusset sections connected to each other by a fold line. Each of the front panel seal lines has an end edge portion and an intermediate edge portion with the intermediate edge portions of the front panel seal lines being located closer to the central longitudinal axis than the end edge portions thereof. Portions of the package immediately outside the front and rear panel seal lines are cut to form the side edges of the package. The bottom edges of the front and back panels are sealed together along a bottom seal line to form a hollow, side-gusseted package having an open top. The package may be filled with a product and then sealed by a seal line extending across the top edges of the front and back panels.
DESCRIPTION OF THE DRAWING
[0009] FIG. 1 is a front isometric view of one exemplary side-gusseted package constructed in accordance with this invention;
[0010] FIG. 2 is a rear isometric view of the package shown in FIG. 1 ;
[0011] FIG. 3 is an isometric view of the package of FIG. 1 , but shown from the bottom;
[0012] FIG. 4 is a flow diagram showing the steps of one method of making a series of packages like shown in FIGS. 1-3 ;
[0013] FIG. 5 is a plan view of a portion of a web of flexible packaging material which has been formed into a folded tube having plural sequentially located sections, each of which is arranged to be formed into a respective side-gusseted flexible package, with each of those packages having a front panel, a pair of side gussets, and a back panel, in accordance with a method step shown in the flow diagram of FIG. 4 ;
[0014] FIG. 5A is a cross sectional view of the folded tube taken along lines 5 A- 5 A of FIG. 5 ;
[0015] FIG. 6 is a plan view of the folded tube shown in FIG. 5 , but after the front and back panels and interposed side gussets of a series of sequentially located sections have been sealed along respective seal lines in accordance with a method step shown in the flow diagram of FIG. 4 ;
[0016] FIG. 7 is a plan view of the folded, sealed tube shown in FIG. 6 , but after portions of the front, back and side gussets of the series of sequentially located sections have been die-cut along lines immediately outside of the seal lines in accordance with a method step shown in the flow diagram of FIG. 4 ;
[0017] FIG. 8 is a plan view of the folded, sealed tube shown in FIG. 7 , but after the die-cut portions of the sequentially located sections of the tube have been discarded in accordance with a method step shown in the flow diagram of FIG. 4 ;
[0018] FIG. 9 is a plan view of the die-cut sealed tube shown in FIG. 8 , but after a bottom seal line has been formed between two sequentially located die-cut sections of the tube in accordance with a method step shown in the flow diagram of FIG. 4 ;
[0019] FIG. 10 is a plan view of the die-cut sealed tube shown in FIG. 9 , but after a the tube has been die cut below the bottom seal line of the upper section to thereby separate a section from the tube to form a package to be filled with a product in accordance with a method step shown in the flow diagram of FIG. 4 ;
[0020] FIG. 11 is a plan view of the separated package of FIG. 10 which is filled with a product through its open top in accordance with a method step shown in the flow diagram of FIG. 4 ;
[0021] FIG. 12 is a plan view of the filled package shown in FIG. 11 after its top end has been sealed to close off the package in accordance with a method step shown in the flow diagram of FIG. 4 ;
[0022] FIG. 13 is a plan view of the filled, sealed package shown in FIG. 12 but after portions of the front, back and side gussets of that package have been die-cut along lines immediately outside of the top end seal line and discarded to complete the package in accordance with a method step shown in the flow diagram of FIG. 4 ;
[0023] FIG. 14 is a flow diagram showing the steps of another method of making a series of packages like shown in FIGS. 1-3 ;
[0024] FIG. 15 is a plan view of a portion of a web of flexible packaging material which has been slit into two web sections for forming a series of front and back panels for a series of packages in accordance with a method step shown in the flow diagram of FIG. 14 ;
[0025] FIG. 16 is a combined plan and isometric view of a portion of a web of flexible packaging material shown forming one tube of a plurality of tubes for use with the front and back panels shown of FIG. 15 for producing a series of package in accordance with a method step shown in the flow diagram of FIG. 14 ;
[0026] FIG. 17 is a combined plan and isometric view of a portion of the web of flexible packaging material making up a series of sequentially located back panels on which a plurality of tubes like that shown in FIG. 16 have been disposed, and a portion of the web of flexible packaging material making up a series of sequentially located front panels arranged for disposition over the web of back panels to produce a series of packages in accordance with a method step shown in the flow diagram of FIG. 14 ;
[0027] FIG. 18 is an isometric view of a portion of the web of sequentially located front panels disposed over the portion of the web of sequentially located back panels with the plural tubes interposed therebetween and tacked thereto to produce an assembly from which a series of packages are produced in accordance with a method step shown in the flow diagram of FIG. 14 ; and
[0028] FIG. 19 is a plan view of the assembly of FIG. 18 but showing that assembly after the sequentially located sections forming the front and back panels and interposed tubes (which form the side gussets) have been sealed along respective seal lines in accordance with two method steps shown in the flow diagram of FIG. 14 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] Referring now to the various figures of the drawing wherein like reference characters refer to like parts, there is shown at 20 in FIG. 1 one exemplary embodiment of a side-gusseted package constructed in accordance with this invention. The package has a central longitudinal axis A and basically comprises a front panel 22 , a back or rear panel 24 , a first side gusset panel 26 and a second side gusset panel 28 which are fixedly secured, e.g., heat or ultrasonically sealed, to one another. In particular, as best seen in FIGS. 1 and 2 , one side edge of the front panel 22 is fixedly secured to a front edge of the first side gusset panel 26 along a seal line 30 and another side edge of that front panel is fixedly secured to a front edge of the second side gusset panel 28 along a seal line 32 . The back panel 24 is of the same shape and size as the front panel 22 . One side edge of the back panel 24 is fixedly secured to a rear edge of the first side gusset panel 26 along a seal line 34 and another side edge of that back panel is fixedly secured to a rear edge of the second side gusset panel 28 along a seal line 36 . The front panel 22 , the back panel 24 and the lower edges of the two side gusset panels 26 and 28 are fixedly secured along a bottom seal line 38 ( FIG. 3 ), which is preferably linear. The front panel 22 , the back panel 24 and the upper edges of the two side gusset panels 26 and 28 are fixedly secured along a top seal line 40 . The top seal line is shown as being arcuate, but could if desired be of any other shape, e.g., linear, so long as it extends across the top of the package.
[0030] As will be seen in the discussion to follow, when the package 20 is made, there will be a point where all of its side seals and its bottom seal will have been completed, to thereby create a hollow body having an open top. It is through that open top that the contents of the package, e.g., any product, such as coffee, etc., can be introduced. Once the package is filled with the product the top portion of the package is sealed to enclose the product within the package.
[0031] In order to render the package suitable to be readily grasped by a user, the side seals lines 30 , 32 , 36 and 26 are not linear (as has characterized prior art side-gusseted packages), but rather are somewhat necked down at approximately their mid-portion. To that end, the seal line 30 includes a pair of end edge portions 30 A and an intermediate edge portion 30 B. The end edge portions 30 A are preferably linear (but may be arcuate), while the intermediate edge portion 30 B is preferably concave, e.g., an inwardly extending arcuate shape, but can be of other shapes. In a similar manner the seal line 32 includes a pair of linear end edge portions 32 A and a concave intermediate edge portion 32 B. Thus, the intermediate edge portions 30 B and 32 B of the two front panel side seals are located closer to the central axis A, than the end edge portions 30 A and 32 A of those seal lines. In a similar manner, the seal line 34 includes a pair of linear end edge portions 34 A and a concave intermediate edge portion 34 B, while the seal line 36 includes a pair of linear end edge portions 36 A and a concave intermediate edge portion 36 B. Thus the intermediate edge portions 34 B and 36 B of the two back panel side seals are located closer to the central axis A, than the end edge portions 34 A and 36 A of those seal lines.
[0032] As best seen in FIGS. 1 and 2 each of the gusseted side panels comprises pair of gusset sections connected to each other by a fold line. In particular, the gusset panel 26 includes a gusset section 26 A and a gusset section 26 B connected to each other by a fold line 26 C. In a similar manner the gusset panel 28 includes a gusset section 28 A and a gusset section 28 B connected to each other by a fold line 28 C.
[0033] Turning now to FIGS. 4-13 , one exemplary embodiment of a method of producing plural side-gusseted packages 20 will now be described. The entire method is depicted in the flow or block diagram of FIG. 4 and in the corresponding FIGS. 5-13 , showing the sequential steps in the process. To that end, a web of any suitable flexible packaging material, e.g., a laminate, is unwound from a supply of that material and is formed into a folded tube like shown in FIGS. 5 and 5A . The tube includes a front face 122 (which will become the front panels 22 of the series of packages), a back face 124 (which will become the back panels 24 of the series of packages), a first gusseted side 126 (which will become the first side gusset panels 26 of the series of packages), and a gusseted side 128 (which will become the second side gusset panels 28 of the series of packages).
[0034] Portions of the front face 122 are then sealed to the adjacent portions of the gusseted sides 126 and 128 along seal lines 130 and 132 , respectively, (which will become the seal lines 30 and 32 of the series of packages). At the same time portions of the back face 124 are sealed to the adjacent portions of the gusseted sides 126 and 128 along similar seal lines (not shown, and which will become the seal lines 34 and 36 of the series of packages). Once the seals are completed the sealed tube is die cut along die-cut lines 100 , which are immediately adjacent and outside of the side seal lines as shown in FIG. 7 . The portions of the tube located outside of the seal line are designated by the reference number 102 and serve as the trim, so that they are discarded leaving the tube as shown in FIG. 8 . A transverse seal 38 , which serves as the bottom seal line of the package, is then applied across the width of the tube at longitudinally spaced locations along the central longitudinal axis A as shown in FIG. 9 . The spacing between the transverse seal lines effectively establishes a series of sequentially located tube sections, each of which is the precursor to the formation of a respective package 20 . The tube is then die-cut along a line immediately below each transverse seal line as shown in FIG. 10 . This results in a hollow body 20 ′, like shown in FIG. 11 . The top portion 20 A of the hollow body 20 ′ is open, i.e., unsealed at this time, so that it serves as a mouth through which a product (not shown) can be introduced into the hollow interior of the body. Once the body 20 ′ is filled, the top portion is sealed by the top seal line 40 (which extends transversely across the body) to enclose the product within the body as shown in FIG. 12 . Once the product is sealed within the body, the portions of the body immediately above the top seal line are die-cut and discarded as trim, resulting in a completed package 20 , such as shown in FIG. 13 .
[0035] Turning now to FIGS. 14-22 , another exemplary embodiment of a method of producing plural side-gusseted packages 20 will now be described. The entire method is depicted in the flow or block diagram of FIG. 14 and in the corresponding FIGS. 15-19 and 11-13 , showing the sequential steps in the process. To that end, a web of any suitable flexible packaging material 10 , e.g., a laminate, is unwound from a supply of that material and is slit longitudinally in half along line 10 A as shown in FIG. 15 to result in two web sections 222 and 224 . Each of these sections is the precursor of a series of front and back panels to form a series of packages 20 , thus the sections 222 and 224 of indeterminate length. Another web of any suitable flexible packaging material 10 , e.g., a laminate, is unwound from a supply of that material and as shown in FIG. 16 is formed into a plurality of tubes 226 and 228 . These tubes serve as precursors of the side gusset panels 26 and 28 of the package. As can be seen in FIG. 16 an adhesive strip 200 , e.g., tape, is unwound from a supply reel and applied to the outer surface of the tubes 226 / 228 along the abutting longitudinal marginal edges of those tubes to hold the tubes together. The tubes are then disposed on the back web section 224 at spaced locations therealong and are tacked thereon to hold the tubes in place as shown in FIG. 17 . The front web section 222 is then juxtaposed over the back rear section and is tacked in place thereon to result in an assembly like shown in FIG. 18 .
[0036] The assembly of FIG. 18 is then sealed along plural seal lines 130 , 132 to join the front web section to the underlying portions of the gusset sections (the contiguous portions of the tubes 226 and 228 ). At the same time plural seal lines (not shown) are produced joining the back web section to the overlying portions of the gusset sections (the contiguous portions of the tubes 226 and 228 ). These seal lines are the precursors of the side seals 30 , 32 , 34 and 36 of the package. After the precursors of the side seal lines are produced a seal line 128 extending along one side of the assembly is formed. The seal line 128 is the precursor of the bottom seal 38 of the package.
[0037] After the bottom seal line 128 has been made, the sequentially located sections of the assembly are die-cut from each other to result in a body like shown in previously described FIG. 11 . The top portion 20 A of the hollow body 20 ′ is open, i.e., unsealed at this time, so that it serves as a mouth through which a product (not shown) can be introduced into the hollow interior of the body. Once the body 20 ′ is filled the top portion is sealed by the top seal line 40 (which extends transversely across the body) to enclose the product within the body as shown in previously described FIG. 12 . Once the product is sealed within the body, the portions of the body immediately above the top seal line are die-cut and discarded as trim, resulting in a completed package 20 , such as shown in previously described FIG. 13 .
[0038] It should be pointed out at this juncture that this invention contemplates a variety sizes and shapes of side-gusseted packages which are configured to enable ready manual handling. The packages of this invention can be used to hold any type of product and may, if desired, include a one-way valve (not shown). Such valves are commonly used in flexible packaging holding coffee to enable the coffee to degas through the valve, while preventing the ingress of air into the package.
[0039] Without further elaboration the foregoing will so fully illustrate my invention that others may, by applying current or future knowledge, adopt the same for use under various conditions of service.
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A flexible side-gusseted package and methods of making the same are disclosed. The package has a central longitudinal axis, a front panel, a back panel, and a pair of gusseted side panels. The front panel is secured to the gusseted side panels along a pair of side seal lines. The back panel is secured to the gusseted side panels along a pair of side seal lines. Each of the seal lines includes a pair of end portions and an intermediate portion. The intermediate portion, e.g., a concave recessed portion, of each side seal line is located closer to the central longitudinal axis than the end portions of the side seal lines to provide a package which is somewhat necked-down at its middle, to facilitate grasping of the package by users.
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BACKGROUND
[0001] Typical bathing installations such as spa systems employ a control system that operates the spa equipment and a control panel that allows the user to input user commands and data. Some programming features may be programmed by the user with the control panel, e.g., filter cycles, temperature settings, lighting settings, panel and/or temperature locking. Specific buttons on the control panel are actuated to operate the equipment, or to program features.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] Features and advantages of the disclosure will readily be appreciated by persons skilled in the art from the following detailed description when read in conjunction with the drawing wherein:
[0003] FIG. 1 is a diagrammatic view of an exemplary spa installation, with enhanced security and control features.
[0004] FIG. 2 is a diagrammatic view of an exemplary embodiment of a transponder or tag for activating features of the spa installation of FIG. 1 .
[0005] FIG. 3 diagrammatically illustrates an exemplary embodiment of a card key with a bar code for activating features of the spa installation of FIG. 1 .
[0006] FIG. 4 diagrammatically illustrates an exemplary embodiment of a finger print scanner for activating features of the spa installation of FIG. 1 .
[0007] FIG. 5 is a schematic block diagram of an exemplary embodiment of a spa installation.
[0008] FIG. 6 illustrates an exemplary control method RFID use with a spa, pool or other bathing installation.
[0009] FIG. 7 illustrates an exemplary control method employing bar code or other optical code control with a bathing installation such as a spa or hot tub.
[0010] FIG. 8 illustrates an exemplary method employing a finger print or other biometric scanner with a bathing installation such as a spa or hot tub.
[0011] FIG. 9 depicts a flow diagram of an exemplary production technique employing an RFID tag to facilitate production.
DETAILED DESCRIPTION
[0012] In the following detailed description and in the several figures of the drawing, like elements are identified with like reference numerals. The figures are not to scale, and relative feature sizes may be exaggerated for illustrative purposes.
[0013] An exemplary embodiment of a bathing installation 200 is illustrated in FIG. 1 . In this exemplary embodiment, the bathing installation is a spa system, but other exemplary bathing installations may include a pool installation, including a large municipal or school pool installation, or a whirlpool bath installation. The spa system 200 includes a spa tub 202 , and an electronic spa control system 206 for controlling the spa systems and features, including, for example, a spa water heater 212 , pump, air blower (the water pump and blower are not shown in FIG. 1 ) and spa operated accessories including yard or decorative lighting 210 . The spa system includes a spa cover 204 , which may be locked in a closed position by an electronically-controlled cover lock system 214 . A control panel 216 may be situated adjacent to or supported by the spa tub to provide user interaction with the control system 206 to set parameters, and initiate some activities.
[0014] The spa control system may include one or more personalized mobile information bearing devices whose sensed presence or absence may enable features of the spa system to be activated. The personalized mobile information bearing device may be sensed or read by a sensor or reader comprising the control system. In one exemplary embodiment, the sensor is a Radio Frequency Identification (RFID) reader or sensor 220 that can interact with a mobile RFID tag 222 ( FIG. 2 ) as the personalized mobile information bearing device. In other embodiments, the personalized mobile information bearing device may be a card or a biometric characteristic of a user, such as a thumb or finger print or an eye.
[0015] The RFID tag 222 is encoded with information which may be read by the sensor 220 when the tag is within range of the sensor 220 . The information may be read and interpreted by the sensor or the control system. The RFID tag may be a passive, active, or semi-passive RFID device. For some bathing installation applications, it may be preferred to use an RFID tag with a limited range so that the RFID tag must be within a few feet of the sensor 220 for the tag information to be read by the sensor.
[0016] The coded information carried by the RFID tag is programmed or stored in a memory of the spa control system, e.g. in a location which identifies a given set of coded information as an authorized user of the spa installation. The RFID tag may be used in conjunction with the spa control system so that the sensed presence or absence of the RFID tag inside a certain distance from the spa control system will cause or allow certain spa functions to operate. These functions may include one or more of the following functions.
[0017] Security Functions:
[0018] 1. The cover locks 214 automatically unlock when the RFID tag 222 is present.
[0019] 2. The control panel 216 will unlock, i.e. be rendered responsive to user inputs on the control panel, when the RFID tag is present.
[0020] 3. The control panel 216 is locked when the RFID tag is removed from the spa area.
[0021] 4. The cover locks 214 are armed when the RFID tag is removed from the area.
[0022] 5. A cover alarm is armed when the RFID tag is not present, so that an alarm will be sounded, broadcast, or signaled when the cover is opened and the RFID tag is not present.
[0023] Product Use:
[0024] 1. Configurations may be stored in the system controller memory, and which run when the RFID tag is present. For example, these configurations can be programmed so that, when the RFID tag is present, the jets, light and blower will activate automatically. These activities are exemplary, and other programmed activities that are available to the spa can be programmed to activate when the RFID tag is present.
[0025] 2. Different RFID tags can be associated with different programmed activities and for different preset actions, e.g. one RFID tag for daytime activities, a second RFID tag for night time activities, a third RFID tag for a parent, and a fourth RFID tag for children. Each tag has encoded therein a different code.
[0026] Automatic Shutdown:
[0027] 1. The spa controller may be programmed to shut down some or all equipment when the RFID tag is removed from the spa area. Some equipment may not be shut down when the RFID tag is removed; for example, in many applications, the circulation pump would not be disabled, or a low speed pump will continue to operate for a pre-determined filtration time. Examples of equipment that would be shut down include jets, lights, blowers mist sprayers, televisions, audio systems and other ancillary devices,
[0028] 2. Some items such as the yard lighting may have a separate timer so that the yard lighting will turn off after the user has had an opportunity to return to the house.
[0029] Inventory Control:
[0030] Manufacturers of spas can use the RFID tags to manage inventory while the spa is in production. An RFID Tag may be attached to an inventory item and information about that item stored in the tag (order number, part number, serial number, date code, etc.) This allows a speedy inventory count to be made by walking an RFID scanner down a row of items with RFID Tags attached. RFID tags may also facilitate the tracking of high-value items through a supply chain or delivery system.
[0031] In another exemplary embodiment, the personalized mobile information bearing device may be a card encoded with information. The spa system may include a card reader 230 , including a receptacle into which a card (a mobile information bearing device) with a bar code or magnetic code strip may be inserted for reading. FIG. 3 depicts an exemplary bar code card 232 which may carry a code, e.g. a bar code, which is stored in memory of the spa control system 206 . The cards could alternatively utilize magnetic strips such as hotel room keys, or even a punch card with holes to create the codes. The card 232 may be carried by an authorized user of the spa system, and by recognizing the code carried by the card 232 , the spa control system may activate features of the spa system.
[0032] Alternatively or in addition to the card reader 230 , the spa system 200 may also include a biometric scanner 240 , e.g. a scanner such as a finger print scanner or a retinal scanner ( FIG. 4 ). In this embodiment, the user's body, e.g. the user's digit or eye in the case of a retinal scanner, serves as the mobile information bearing device. A user may enter his biometric information during a programming mode, and the scanner 240 may be used to activate features of the spa system. The card reader and fingerprint scanner may be alternatives to the RFID tags.
[0033] In the case of a card reader 216 , the card 232 may be left in the reader while the spa is being used. Removal of the card may be interpreted by the spa controller in the same manner as removal of an RFID tag from the spa area, e.g. to activate an automated shutdown of spa features. Each card 232 has a unique bar code that could be activated and programmed into the control system in the same fashion as an RFID tag. In other words, the RFID tag ID and the bar code would then be recognized by the spa control system; this code allows a certain behavior of the spa system.
[0034] The biometric scanner is somewhat different in that a finger or eye cannot be left in place by the spa user during spa use. In that case, a control system timer may be started (e.g., 2 hours, 4 hours, 6 hours, etc.) that would allow the spa to function during for that time after a successful biometric scan. The use of such a timer may also be employed with other types of personalized information bearing devices, including the RFID tag and the encoded card. Multiple unique fingerprint or retinal scans could be authorized to activate features of the spa system.
[0035] FIG. 5 illustrates an overall block diagram of an exemplary embodiment of a spa system 200 . The system includes a spa tub or receptacle 202 for bathing water, and a control system 212 to activate and manage the various parameters of the spa. Connected to the spa tub 202 through a series of plumbing lines 113 are pumps 104 and 105 for pumping water, a skimmer 112 for cleaning the surface of the spa, a filter 120 for removing particulate impurities in the water, an air blower 106 for delivering therapy bubbles to the spa through air pipe 119 , and an electric heater 103 for maintaining the temperature of the spa at a temperature set by the user or control system. The heater 103 in this embodiment is an electric heater, but a gas heater can be used for this purpose also. Generally, a light 107 is provided for internal illumination of the water.
[0036] Service voltage power is supplied to the spa control system at electrical service wiring 115 , which can be 120V or 240V single phase 60 cycles, 220V single phase 50 cycles, or any other generally accepted power service suitable for commercial or residential service. An earth ground 11 6 is connected to the control system and there through to all electrical components which carry service voltage power and all metal parts. Electrically connected to the control system through cable 109 is the control panel 212 . All components powered by the control system are connected by cables 114 suitable for carrying appropriate levels of voltage and current to properly operate the spa.
[0037] Water is drawn to the plumbing system generally through the skimmer 112 or suction fittings 11 7 , and discharged back into the spa through therapy jets 11 8 .
[0038] An RFID sensor or reader 220 is connected to the control system 212 to provide a sensor signal which indicates whether the RFID tag 222 is within a localized spa area. As discussed above, the sensor 220 may be replaced or supplemented with a card key scanner 230 or biometric scanner 240 .
[0039] The particular equipment for a spa installation will depend on the particular implementation, and not all devices illustrated in FIG. 5 may be installed for some implementations.
[0040] FIG. 6 illustrates an exemplary method 300 employing RFID control with a bathing installation such as a spa or hot tub. At 302 , one or more unique RFID tags are supplied to a user, e.g. with the spa. At 304 , the user brings the RFID tag in range of the RFID sensor or reader device installed in the spa control system, and the unique code of the RFID tag is read and provided to the spa controller. At 306 , the spa controller determines whether the spa has settings for the RFID tag. If not, the user sets the spa equipment to the desired states at 308 . For example, the settings for heat, air pumps, lights, and blower may be set by the user as desired. The user will then execute a button sequence at 31 0 to instruct the spa controller to synchronize the spa equipment settings with the RFID tag. These settings are stored in memory in association with the code or identification data of the RFID tag.
[0041] If at 306 , the spa controller has stored settings associated with the RFID tag, then at 312 , the controller will initiate various functions based on the specific RFID tag and its stored settings. At 314 , the spa tub cover lock is unlatched by the spa controller, and at 318 , the cover alarm (if the spa installation is equipped with a cover and alarm) is disarmed. At 320 , the spa control panel is unlocked for use. At 322 , the user can turn on the desired spa associated equipment, e.g., lights, pumps, blowers, misters etc.
[0042] Still referring to FIG. 6 , now consider that a different RFID tag with its own unique code is brought into range of the RFID sensor at 330 . If the controller determines at 332 that another RFID tag is already in range of the RFID sensor, the controller will ignore subsequent RFID tags that may come into range of the sensor. If at 332 , no other RFID tags are in range, operation proceeds to 306 .
[0043] At 336 ( FIG. 6 ), the original RFID tag is taken out of range of the RFID sensor. If the controller determines at 338 that another RFID tag is within range of the sensor, operation proceeds to 332 . If no other RFID tag is within range, then at 340 , the spa controller shuts down unnecessary equipment, e.g., spa lights, pumps, blowers and misters. At 342 , the spa tub cover lock is engaged, and at 344 the cover alarm is armed after a predetermined time period or after the cover is locked. At 346 the spa control panel is locked electronically to prevent use or changes in settings. At 348 , the yard lighting associated with the spa is shut down after a predetermined time period, e.g. a delay which allows the user to walk from the vicinity of the spa to the nearby residence, or to exit a gate associated with the spa.
[0044] FIG. 7 illustrates an exemplary method 400 employing bar code or other optical or magnetic code control with a bathing installation such as a spa or hot tub. At 402 , one or more unique code cards are supplied to a user, e.g. with the spa. At 404 , the user inserts the card into the card reader installed in the spa control system, and the unique code of the card is read and provided to the spa controller. At 406 , the spa controller determines whether the spa has settings for the inserted card. If not, the user sets the spa equipment to the desired states at 408 . For example, the settings for heat, air pumps, lights, and blower may be set by the user as desired. The user will then execute a button sequence at 410 to instruct the spa controller to synchronize the spa equipment settings with the inserted card and its code. These settings are stored in memory in association with the code or identification data of the inserted card.
[0045] If at 406 , the spa controller has stored settings associated with the inserted card, then at 412 , the controller will initiate various functions based on the specific inserted card and its stored settings. At 414 , the spa tub cover lock is unlatched by the spa controller, and at 416 , the cover alarm (if the spa installation is equipped with a cover and alarm) is disarmed. At 418 , the spa control panel is electronically enabled or unlocked for use. At 420 , the user can turn on the desired spa associated equipment, e.g., lights, pumps, blowers, misters etc., allowing the spa to be controlled manually if desired by the user.
[0046] Still referring to FIG. 7 , now consider the event that a different card with its own unique code is placed in the card reader at 422 . If the controller determines at 424 that the spa is already in use, and the controller has settings for the different card, the controller will change the spa settings to those programmed for the new card code. If at 424 , no other card is in use or the controller does not have settings for the different card, operation proceeds to 406 .
[0047] At 428 ( FIG. 7 ), the original card is removed from the card reader. If the controller determines at 430 that the card has been replaced with another card, operation proceeds to 424 . If the original card has not been replaced in the reader, then at 432 , the spa controller shuts down unnecessary equipment, e.g., spa lights, pumps, blowers and misters, after a predetermined time delay. At 434 , the spa tub cover lock is engaged, and at 436 the cover alarm is armed after a predetermined time period or after the cover is locked. At 438 the spa control panel is locked electronically to prevent use or changes in settings. At 440 , the yard lighting associated with the spa is shut down after a predetermined time period, e.g. a delay which allows the user to walk from the vicinity of the spa to the nearby residence, or to exit a gate associated with the spa.
[0048] FIG. 8 illustrates an exemplary method 500 employing a finger print or other biometric scanner with a bathing installation such as a spa or hot tub. At 502 , the end user's existing stored biometric information is used to startup the spa. The user places his or her fingertip or other unique biometric feature on or near a biometric scanner installed at the spa installation. At 506 , the spa controller determines whether the spa has settings for the scanned biometric information. If not, the user sets the spa equipment to the desired states at 508 . The user will then execute a button sequence on the spa control panel at 51 0 to instruct the spa controller to synchronize the spa equipment settings with the user's scanned biometric data. These settings are stored in memory in association with the user's biometric data scanned at 504 , for use the next time the user attempts to use the spa. In an exemplary embodiment, a security feature will be applied, to control the number or identity of persons allowed to store their biometric data in the spa controller. That feature may be set for a limited period of time, or disabled completely, by an authorized user. For example, an authorized user may enter a command, opening the spa to entry of new users, for a limited time, after which time, new users are blocked for entering biometric data as an authorized user.
[0049] If at 506 , the spa controller has stored settings associated with the scanned biometric data, then at 512 , the controller will initiate various functions based on the specific inserted card and its stored settings. At 514 , the spa tub cover lock is unlatched by the spa controller, and at 516 , the cover alarm (if the spa installation is equipped with a cover and alarm) is disarmed. At 518 , the spa control panel is electronically enabled or unlocked for use. At 520 , the spa associated equipment, e.g., lights, pumps, blowers, misters etc. that are associated with the stored biometric data are activated by the controller. The user can also set the spa to other settings if desired, since the control panel has been unlocked for use.
[0050] Still referring to FIG. 8 , now consider that a different user places his finger tip or other biometric feature on or near the biometric scanner at 530 . If the controller determines at 532 that the spa installation is already in use, the controller will change the spa settings to those programmed for the different user, at 534 . If at 532 , the spa is not in use, operation proceeds to 506 .
[0051] At 540 ( FIG. 8 ), one of the initial users initiates another biometric scan. At 542 , the controller queries the user (by interaction using the control panel, e.g. a display and control buttons, for example) to determine if the user wishes to shut down the spa. If the response is negative, the spa installation will continue to run for the duration of a time allotment, either one which is predetermined, or set by the user, and then shut down. If the user does want to shut down the spa operation, then at 546 , the spa controller shuts down unnecessary equipment, e.g., spa lights, pumps, blowers and misters, after a predetermined time delay. At 548 , the spa tub cover lock is engaged, and at 550 the cover alarm is armed after a predetermined time period or after the cover is locked. At 550 the spa control panel is locked electronically to prevent use or changes in settings. At 552 , the yard lighting associated with the spa is shut down after a predetermined time period, e.g. a delay which allows the user to walk from the vicinity of the spa to the nearby residence, or to exit a gate associated with the spa. If no biometric scans are performed within a time period, either preset or programmed by the user, then the controller will shut down non-essential operations of the spa.
[0052] FIG. 9 is a flow diagram illustrating a method 600 utilizing an RFID tag for facilitating tracking of a spa or hot tub during and following production. The RFID tag may be attached to the hot tub and information about that item stored in the tag (order number, part number, serial number, date code, etc.). The RFID tag may be the same RFID tag which will be used to control access to the spa once it is installed, or it may be a different tag. The RFID tag travels with the hot tub or spa during production ( 602 ). Features can be added to the hot tub or hot tub and programmed into the configuration ( 604 ). Once the hot tub is completed, it may be counted, and identified by its RFID tag ( 606 ). Shipping information can be generated by scanning the RFID tag ( 608 ).
[0053] Although the foregoing has been a description and illustration of specific embodiments of the subject matter, various modifications and changes thereto can be made by persons skilled in the art without departing from the scope and spirit of the invention as defined by the following claims.
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A bathing installation system includes a water receptacle, a plurality of electrically powered devices, and an electronic control system adapted to control operation of the devices. A sensor senses the presence of a personalized mobile information bearing device, the sensor having an output signal coupled to the electronic control system for indicating the sensed presence or absence of the mobile device. The electronic control system is responsive to the sensor output signal to be placed in a first state when the sensor signal indicates the sensed presence of the mobile device, and to be placed in a second state when the sensor signal indicates the absence of the mobile device.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuing application, under 35 U.S.C. § 120, of copending International Application No. PCT/EP2005/013248, filed Dec. 9, 2005, which designated the United States; this application also claims the priority, under 35 U.S.C. § 119, of German Patent Application 10 2004 061 438.5, filed Dec. 17, 2004; the prior applications are herewith incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a calibrating body, gage or measuring device, preferably a screw-thread measuring device, at least partially including a C-SiC body constructed of a porous, carbon-containing material with infiltrated liquid Si, with the Si converted at least partially to SiC by reaction with carbon. The invention also relates to a method of producing the calibrating body, gage or measuring device, preferably a screw-thread measuring device.
[0004] A calibrating body or a gage will be understood to mean, hereinafter, a solid gage for assessing, by comparison, whether or not a structure or a component complies with the solid gage or for calibrating a measuring device. Measuring devices are, conversely, devices that measure the actual dimensions of a structure or of a component or provide values from which they can be derived.
[0005] A calibrating body of that type and a method of that type are known from German Published, Non-Prosecuted Patent Application DE 100 03 176 A1, corresponding to U.S. Pat. No. 6,833,163 and U.S. Patent Application Publication No. US 2001/0022034. In order to produce the C/C-SiC material described therein, carbon fibers are used in the form of woven or knitted mats. In accordance with that reference, a fiber length shorter than 3 mm causes an increased reaction of the fibers with the liquid silicon while forming SiC. U.S. Patent Application Publication No. US 2004/0097360 A1 also discloses a C/C-SiC-material for calibrating bodies for which carbon fiber bundles are used as a starting basis. Those carbon fibers, which have not taken part in the reaction with Si, are embedded in the matrix of the C/C-SiC material and help to increase the ductility of the material. Moreover, the total proportion of Si and SiC is at most 60 vol. %. That results in a material which, due to its relatively low local hardness and ductility caused by the fibers, is unable to meet higher requirements for wear resistance, which play an important role for calibrating bodies and measuring devices that come into repeated sliding and rubbing contact with the structure that is to be inspected or measured.
SUMMARY OF THE INVENTION
[0006] It is accordingly an object of the invention to provide a calibrating body, a gage or measuring device, preferably a screw-thread measuring device and a method of production thereof, which overcome the hereinafore-mentioned disadvantages of the heretofore-known devices and methods of this general type and with which higher wear resistance is obtained.
[0007] With the foregoing and other objects in view there is provided, in accordance with the invention, a method of producing a calibrating body, gage or measuring device, preferably a screw-thread measuring device at least partially comprising a C-SiC material constructed of a porous, carbon-containing material with infiltrated liquid Si and converting the Si at least partially to SiC by reaction with carbon. The C-SiC material is produced from a C-C material based on carbon felt material produced by pressing monofibers or fiber fragments irregularly entwined with each other.
[0008] With the objects of the invention in view, there is also provided a calibrating body, gage or measuring device, preferably a screw-thread measuring device at least partially comprising C-SiC material constructed of a porous, carbon-containing material with infiltrated liquid Si, the Si being converted at least partially to SiC by reaction with carbon. The C-SiC material is substantially free of carbon fibers and has a proportion of Si and SiC between 70 wt. % and 90 wt. % and a proportion of carbon between 10 wt. % and 30 wt. %.
[0009] A felt is to be understood in the following as a material produced by compression of randomly intertwined individual fibers or fiber fragments. Compared with the carbon mats used in the state of the art, with densely packed bundles of fibers (Rorings or Roring segments) of parallel fibers or filaments, such a carbon felt has a lower density and consequently more room between the fibers for the infiltrated silicon, so that due to the larger reaction area available, substantially all of the carbon of the felt reacts during Si liquid infiltration to form SiC (silicon carbide). The result is a body with a matrix formed from the three components C, Si, and SiC, whereas because of the almost complete reaction of the carbon felt in the matrix, preferably no or almost no carbon constituents are still present, which could have an adverse effect on wear resistance, since they increase the ductility of the material. This matrix-dominant material is very suitable, due to its good wear resistance, for use in calibrating bodies, gages or measuring devices, which, or components of which, come repeatedly into sliding and rubbing contact with the structure being inspected.
[0010] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0011] Although the invention is illustrated and described herein as embodied in a calibrating body, a gage or measuring device, preferably a screw-thread measuring device and a method of production thereof, 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.
[0012] 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.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0013] FIG. 1 is a diagrammatic, side-elevational view of an electrode with a tapering internal thread and a nipple with a tapering external thread; and
[0014] FIG. 2 is an enlarged, fragmentary, cross-sectional view of a screw-thread measuring device for measuring a tapering internal thread of the electrode, which contains SiC bodies, that were produced according to a preferred embodiment of the method according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Referring now to the figures of the drawings in detail and first, particularly, to FIG. 1 thereof, there is seen a segment of a graphite electrode labeled generally with reference numeral 1 , which is used for conducting current during melting of electric steel in an electric arc furnace. Since the graphite electrode is also consumed over time under the action of the electric arc, graphite electrode segments 1 must be supplied continually on the side facing away from the arc, which is achieved by screwing a new graphite electrode segment 1 onto the segment currently in use, using a screw-thread connection 2 . The screw-thread connection 2 includes a preferably separate, double-conical nipple 4 with an external thread 5 , one half of which, in FIG. 1 , is screwed into an internal thread of a tapering blind hole 6 in the graphite electrode segment 1 , which is otherwise identical to, but is a mirror image of, another tapering blind hole 8 with an internal thread 10 , shown in an exploded view in FIG. 1 . It can easily be seen that a graphite electrode segment 1 is then continually screwed onto the segment currently in use in an almost endless series, thus ensuring feed of electrode material that is required for a continuous melting process.
[0016] Since the graphite electrode segments I have a relatively large size and are positioned and screwed together manually or by robots, the construction of the internal thread 10 as a tapering thread is advantageous due to the then centering effect and quick accomplishment of the screwing operation. In order to ensure a safe, rigid connection and alignment of the central axes without any large shaft angle deviations of the graphite electrode segments 1 that are screwed together, it is necessary for the screw-thread connection 2 to meet certain manufacturing tolerances with respect to defined values characterizing this connection, such as, for example, the taper angle and the maximum diameter of the tapering blind hole 8 .
[0017] Tolerance is checked by using a screw-thread measuring device 12 shown in FIG. 2 , which includes two circular disks 14 , 16 with different diameters, the radially outer peripheral surfaces of which are constructed to be tapering and complementary, for example to the blind hole 8 that is to be inspected, and are each provided with an external thread 20 , 22 , so that first the smaller, lower disk 16 in FIG. 2 and then the larger, upper disk 20 in FIG. 2 , can be screwed into the blind hole 8 . Moreover, the diameter of the larger disk 14 is preferably dimensioned in such a way that in the fully screwed-in state its outer surface 26 pointing away from the bottom 24 of the blind hole 8 is approximately coplanar with a level end face 28 of the graphite electrode segment 1 , at least in the region of the rim of the blind hole 8 . The larger disk 14 carries on its outer surface 26 a first dial gage 30 , with which the depth to which it is screwed in, relative to a reference surface, which is preferably formed by the end face 28 of the graphite electrode segment 1 , can be determined as a first characteristic dimension.
[0018] Furthermore, the two disks 14 , 16 are joined together by a pin 32 , which is positioned centrally and perpendicularly on the smaller disk 16 and fits into a central through-opening 34 in the larger disk 14 with a small clearance. When the smaller disk 16 is likewise screwed in fully, an end face 36 of the pin 32 points away from the bottom 24 of the blind hole 8 , not quite reaching the plane of the outer surface 26 of the larger disk 14 . Therefore, a second characteristic dimension is present, that depends on the relative position of the two disks 14 , 16 or on the screwed-in depth of the smaller disk 16 , and which can be detected by a second dial gage 38 carried by the larger disk 14 . It is then possible, for example, to calculate the taper angle and the maximum diameter of the tapering blind hole 8 and/or of the internal thread 10 as a function of the two characteristic dimensions.
[0019] In order to manipulate the screw-thread measuring device 12 , hand-grips 44 , 46 of the two disks 14 , 16 , preferably made of aluminum, are fitted to the respective surfaces 26 , 42 of the blind hole 8 pointing away from the bottom 24 . Since the graphite electrode segments 1 and in particular their screw-thread connections 2 are regularly checked with respect to their dimensional stability, it is necessary to screw the screw-thread measuring device 12 into blind holes 8 once again for measurement, whereby the external threads 20 , 22 of the two disks 14 , 16 come into sliding and rubbing contact with the internal threads 10 . Excessive wear on the radially outer peripheral surfaces of the two disks 14 , 16 would then result in a larger screwed-in depth and thus give an incorrect measurement result. Accordingly, high wear resistance of the two disks 14 , 16 is desirable.
[0020] For this reason, preferably at least the threaded zones of the two disks 14 , 16 of the screw-thread measuring device 12 are made from a particularly wear-resistant material, the production of which is described below.
[0021] The two disks 14 , 16 , at least in the threaded zone, both include SiC bodies, constructed of a porous, carbon-containing material with infiltrated liquid Si, with the Si converted at least partially to SiC by reaction with carbon. The SiC bodies 14 , 16 are produced from a C-C material based on carbon felt material and/or fine-pore and open-pore carbon structures and/or based on pyrolyzed wood.
[0022] The carbon felt material can, for example, be a rayon felt, a polyacrylonitrile (PAN) felt or a viscose felt or a combination of these materials. The carbon felt material can have a layered structure, i.e. the felt can be built up in several parallel layers to form boards of a defined thickness. However, the felt material can also be formed randomly.
[0023] According to a particularly preferred embodiment of the production process, carbon felt material is used and is impregnated with a polymer, preferably phenolic resin, and cured, producing boards of plastic with interspersed carbon fibers (CFP). Then these CFP intermediate products are carbonized or pyrolyzed. The carbonization or pyrolysis temperature is preferably in a range of from 900° C. to 1000° C. This process step can be repeated several times. Based on the number of so-called redensifications including re-impregnation and carbonization, it is possible to adjust the porosity of the CFP boards, as the pore size decreases through re-impregnation with phenolic resin and subsequent carbonization. A consequence of using layered felt material as a starting product is that the CFP boards manufactured therefrom may display anisotropic material properties due to the horizontal parting planes between the felt layers. However, this is not of decisive importance for the intended use as disk material in screw-thread measuring devices.
[0024] Alternatively, to minimize or completely exclude anisotropy of the material, the felt can be ground, so that the layered structure of the material is broken down. The resultant felt particles can be mixed with resin and compressed to form CFP boards. In order to eliminate any other volatile constituents from the pyrolyzed boards, the boards are preferably graphitized, with the graphitization temperature being at a maximum of 3000° C.
[0025] Because the C-C material is relatively soft as compared with the C-SiC material obtained after the last production step, the C-C boards are machined close to the final contour, which means in the present case that the two disks 14 , 16 with diameters substantially close to the final shape are produced from the boards.
[0026] Next, the C-C disks 14 , 16 are converted to disks 14 , 16 of C-SiC material by infiltration of liquid Si. The carbon is then converted to SiC at least partially, and ideally completely by reaction with Si, resulting in a ceramic body formed from the three components SiC, Si and C, and due to the almost complete reaction of the carbon with the infiltrated Si, no or almost no carbon is still present. The material structure is very fine, and the density of the C-SiC bodies 14 , 16 is, for example, 2.7 g/cm 3 .
[0027] The C-SIC disks 14 , 16 , which are substantially free from carbon fibers, have a proportion of Si and SiC between 70 wt. % and 90 wt. % and a proportion of carbon between 10 wt. % and 30 wt. %. Preferably, the proportion of Si can be between 30 wt. % and 35 wt. %, the proportion of SiC between 50 wt. % and 60 wt. % and the proportion of carbon between 10 wt. % and 15 wt. %.
[0028] Tables 1.1 and 1.2 show selected mechanical and thermal properties of the C-SiC material of the disks 14 , 16 , when carbon felt with a layered structure is used as the starting material.
TABLE 1.1 Mechanical properties Parameter Temperature Unit Typical value Density g/cm 3 2.7 Tensile strength 20° C. MPa 80 1200° C. MPa 80 Tensile modulus 20° C. GPa 230 1200° C. GPa 230 Elongation at rupture % 0.04 Bending strength 20° C. MPa 150 (3-point) 1200° C. MPa 130 Bending modulus 20° C. GPa 150 (3-point) 1200° C. GPa 110 Compressive 20° C. MPa 1300 strength 1200° C. MPa 1300 Tear strength K 1C 5 Weibull modulus m 25
[0029]
TABLE 1.2
Thermal properties
Parameter
Temperature
Unit
Typical value
Maximum
° C.
1350
service
temperature
Thermal shock
K/s
2100
resistance
Thermal
0° C. . . . 300° C.
10 −6 /K
3.5
expansion
300° C. . . . 1200° C.
10 −6 /K
4.5
Thermal
20° C.
W/m · K
125
conductivity
1200° C.
W/m · K
80
Specific heat
20° C.
J/g · K
0.8
capacity
1200° C.
J/g · K
1.2
[0030] Tables 2.1 and 2.2 show the mechanical and thermal properties of the C-SiC material of the disks 14 , 16 , when CFP boards are compressed from ground carbon felt.
[0031] In the last process step, the two disks 14 , 16 are machined to the final diameter by grinding and the external thread 20 , 22 is ground-in.
[0032] Any fine-pore and open-pore carbon structures and/or pyrolyzed wood can be used as the starting material instead of carbon felt. The invention therefore proposes, for the first time, the use of C-SiC material based on carbon felt and/or fine-pore and open-pore carbon structures and/or based on pyrolyzed wood for calibrating bodies, gages and measuring devices or for their components, in order to increase wear resistance, and is not limited to application in screw-thread measuring devices.
TABLE 2.1 Mechanical properties Parameter Temperature Unit Typical value Density g/cm 3 2.60-2.70 Elongation at rupture 20° C. % 0.06 Bending strength σ B 20° C. MPa 135 (4-point) Bending modulus of 20° C. GPa 205 elasticity (4-point) Weibull modulus m 19
[0033]
TABLE 2.2
Thermal properties
Parameter
Temperature
Unit
Typical value
Thermal expansion
(measured)
in plane
20 K to RT
10 −6 /K
0.75
orthogonal
20 K to RT
10 −6 /K
0.70
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A method of producing a calibrating body, gage or measuring device, preferably a screw-thread measuring device, at least partially including a C-SiC material constructed of a porous, carbon-containing material with infiltrated liquid Si, includes converting the Si at least partially to SiC by reaction with carbon. The C-SiC material is produced from a C-C material based on carbon felt material produced by pressing monofibers or fiber fragments irregularly entwined with each other. A calibrating body, gage or measuring device, preferably a screw-thread measuring device, is also provided.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to a co-pending U.S. application Ser. No. 11/562,958, filed on Nov. 22, 2006, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a method for fabricating nanoparticles containing fenofibrate.
[0004] 2. Description of the Related Art
[0005] Nanotechnology is widely used in various fields such as biochemistry, medicine and chemical engineering. Regarding to medicine transfer in the biomedical field, for example, nanonization of medicines can effectively increase the total particle surface area of medicines, thus accelerating absorption rate of medicines and bioavailability. The key point of therapy using medicines is whether the medicines can be essentially (or completely) absorbed, thus particle dimensions and uniformity may directly influence the therapeutic effect.
[0006] Present nanonization of medicines may comprise physical and chemical methods. Physical methods include, for example, electrospray, ultrasound, spray drying, superior fluid, and cryogenic technology. For example, U.S. Pat. No. 6,368,620 discloses a process for preparing a nanocrystal or nanoparticle fibrate composition. U.S. Pat. No. 6,682,761 disclose a process for the preparation of small particles containing a poorly water soluble drug. U.S. Pat. No. 6,696,084 discloses a process for the preparation of small particles or microparticles containing fenofibrate and a phospholipid surface stabilizing substance. Most technologies have a common issue i.e. uneven distribution of particle diameters, which can be solved by subsequent filtering, however, manufacturing process complexity, and cost also increases. Accordingly, processes suitable for large-scale production capable of obtaining nanoparticles (such as nanoparticles containing fenofibrate) with uniform diameter are desirable.
BRIEF SUMMARY OF THE INVENTION
[0007] One embodiment of the invention discloses a method for fabricating nanoparticles containing fenofibrate, comprising: (a) mixing a hydrophobic substance, an organic solvent and a solubility enhancing additive to form a saturated solution; and (b) spray-drying the saturated solution to form the nanoparticles containing the hydrophobic substance, wherein the solubility enhancing additive comprises a surfactant or an excipient.
[0008] Another embodiment of the invention discloses a method for fabricating nanoparticles containing fenofibrate and that the hydrophobic substance comprises fenofibrate.
[0009] Another embodiment of the invention discloses a method for fabricating nanoparticles containing fenofibrate and that the solvent comprises an organic solvent.
[0010] Another embodiment of the invention discloses a method for fabricating nanoparticles containing fenofibrate and that the organic solvent comprises alcohol.
[0011] Another embodiment of the invention discloses a method for fabricating nanoparticles containing fenofibrate and that the additive comprises a surfactant or excipient.
[0012] The solubility and of active ingredients (for example, fenofibrate) in solution can be increased by means of utilizing the solubility enhancing additive.
[0013] A detailed description is given in the following embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The present invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
[0015] FIG. 1 shows one embodiment of a nanoparticle fabrication method.
[0016] FIG. 2 shows one embodiment of a system for fabricating nanoparticles.
[0017] FIG. 3 shows one embodiment of the particle size distribution.
[0018] FIG. 4 shows one embodiment of the particle size distribution.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims.
[0020] Embodiments of the invention provide methods for fabricating nanoparticles from a supersaturated liquid solution with a substance to be transformed into nanoscale. The liquid solution is preferably composed of a solvent, a solubility enhancing additive, and the substance to be transformed into nanoscale dissolved therein. The solvent, for example, can be alcohol (also ethanol). However, other solvents, or mixtures of solvents, which can dissolve the substance and are miscible with the anti-solvent selected in the nanoparticle formation device are also suitable. An example of a solubility enhancing additive is a surfactant (i.e. Brij 76 (purchased from Sigma-Aldrich, St. Louis, Mo.)); nonetheless, other additives that are able to increase the intrinsic solubility of the substance in the solvent are also included. In addition, substances suitable to be transformed into nanoscale include bioactive material, polymer material, biomaterial, chemical material or mixtures thereof. Note that the substances are active agents in the solvent. Furthermore, the additive is a stabilizer or an excipient.
[0021] Nanoparticle fabrication, the process of which a substance to be transformed into nanoparticle, is done via fabrication apparatus and process described later.
[0022] FIG. 1 shows an embodiment of a nanoparticle fabrication method. As shown in FIG. 1 , the system 100 includes a micro droplet sprayer 110 , a drying chamber 115 , a liquid supplier and a pressure controller 120 of the micro droplet sprayer 110 , a device (e.g. a controller or a control system) 130 of the micro droplet sprayer 110 , a nitrogen supplier 140 of the system 100 , an inner loop 150 of the system 100 , a particle collector 160 and a particle filter 170 .
[0023] The micro droplet sprayer 110 , for example, can be an inkjet sprayer including a liquid tank (not shown), a channel (not shown), an actuator (not shown), and orifices (not shown). The actuator drives several orifices to spray the solution, thus micro droplets 112 are generated. The actuator can be a thermal bubble actuator or a piezoelectric actuator. In embodiments of the invention, the solution such as a medicine solution employing alcohol as a solvent is poured into the micro droplet sprayer 110 . The drying chamber 115 is used to collect and dry the droplets 112 , and it can be a thermal dryer or a hot air generator. The liquid supplier and pressure controller 120 are capable of supplying liquid steadily and controlling the pressure required by micro droplet sprayer 110 , thus avoiding the pressure change rendered by the volume change of solution during operation. Driving forces of the pressure controller 120 comprise mechanical forces, atmosphere difference or potential difference. The device (e.g. a controller or a control system) 130 can provide the micro droplet sprayer 110 with various energy pulses or other parameters for spraying liquid. The nitrogen suppliers 140 are provided for keeping oxygen concentration to less than a specific value by steadily providing the system with nitrogen because the system 100 utilizes an organic solvent as solvent of the medicinal solution to be sprayed and is operated under high temperature that may cause an explosion. The inner loop 150 can recycle the nitrogen (the heated nitrogen can be used as hot air) and condense organic solvent for collection. The particle collector 160 and particle filter 170 can prevent particles from escaping into the air.
[0024] The liquid supplier and pressure controller 120 inject the medicine solution into the micro droplet sprayer 110 . In addition, The micro droplet sprayer 110 is driven by the device (e.g. a controller or a control system) 130 to spray the medicine solution, thus micro droplets 112 are formed in the drying chamber 115 . The nitrogen supplier 140 simultaneously injects nitrogen into the drying chamber 115 , generating hot air 125 and drying the micro droplets 112 released from the micro droplet sprayer 110 . As a result, nanoparticles (i.e. the dried micro droplets 112 ) are obtained. The nanoparticles then settle to the bottom 117 of drying chamber 115 for collection by the particle collector 160 following the direction of arrow 119 . The nanoparticles, remaining in the nitrogen, however, are trapped by the particle filter 170 . The used nitrogen is then recycled by means of the inner loop 150 and enters the drying chamber 115 again. In embodiments of the invention, an auxiliary element (not shown) for controlling spray directions of the droplets 112 is provided, thus avoiding turbulence or collision therebetween during operation of micro droplet sprayer 110 . In addition, the auxiliary element is arranged in a front end of the micro droplet sprayer and the shape of the auxiliary element is cylindrical or conical.
[0025] As shown in FIG. 1 , the processes and parameters for the system 100 are described as the following. First, the drying chamber 115 is filled with nitrogen and heated to a desired temperature e.g., 100° C. When the system reaches a steady state, the micro droplet sprayer 110 is driven to steadily spray the medicinal solution, forming the droplets 112 . In addition, the medicinal solution includes alcohol as solvent and the spray frequency is 0.3 kHz. Subsequently, nanoparticles are rapidly obtained due to the small size of the droplets 112 are tiny and sprayed into a high temperature ambient. Specifically, the described nanoparticles have uniform diameters due to recipes of the solutions. Finally, nanoparticles are collected by the particle collector 160 .
[0026] In the following five embodiments, a medicine solution containing fenofibrate is employed in the system 100 shown in FIG. 1 , fabricating nanoparticles containing fenofibrate. The same or similar apparatus and processes are omitted in each embodiment.
First Embodiment
[0027] The solubility of fenofibrate (substance) in ethanol was increased from value of 2.5% (w/v) with an excipient such as poly vinyl pyrrolidone (PVP) at substance to excipient ratio of 1:1 to 10% (w/v) with an excipient such as Brij 76 (purchased from Sigma-Aldrich, St. Louis, Mo.) at substance to excipient ratio of 1:1. Precipitation of substance was observed overnight suggesting supersaturation phenomenon.
Second Embodiment
[0028] The solubility of fenofibrate (substance) in ethanol was increased from value of 2.5% (w/v) with an excipient such as poly vinyl pyrrolidone (PVP) at substance to excipient ratio of 1:1 to 10% (w/v) with an excipient such as Brij 76 (purchased from Sigma-Aldrich, St. Louis, Mo.) at substance to excipient ratio of 1:2. As shown in FIG. 3 , the particle size of the substance (fenofibrate) produced by the nanonization apparatus (inkjet spray-dryer) is 287.3 nm+/−102.9 μm. The distribution range of the particles is in the nanoscale range of 251.2 nm (95.0%)−316.2 nm (4.6%); thus, illustrates that the particles produced are uniformly distributed. The percentage indicated in the parentheses is intensity percentage of the particle measured using dynamic light scattering (DLS) technique.
Third Embodiment
[0029] The solubility of fenofibrate (substance) in ethanol was increased from value of 2.5% (w/v) with an excipient such as poly vinyl pyrrolidone (PVP) at substance to excipient ratio of 1:1 to 10% (w/v) with an excipient such as D-alpha-tocopheryl polyethylene glycol 1000 succinate (vitamin E TPGS), purchased from Eastman Chemical Company, Kingsport, Tenn.) at substance to excipient ratio of 1:1. Precipitation of substance was observed overnight suggesting supersaturation phenomenon.
Fourth Embodiment
[0030] The solubility of fenofibrate (substance) in ethanol was increased from value of 2.5% (w/v) with an excipient such as poly vinyl pyrrolidone (PVP) at substance to excipient ratio of 1:1 to 10% (w/v) with an excipient such as D-alpha-tocopheryl polyethylene glycol 1000 succinate (vitamin E TPGS), purchased from Eastman Chemical Company, Kingsport, Tenn. at substance to excipient ratio of 1:2. Precipitation of substance was observed overnight suggesting supersaturation phenomenon. As shown in FIG. 4 , the particle size of the substance (fenofibrate) produced by the nanonization apparatus (inkjet spray-dryer) is 192.8 nm+/−47.2 nm. The distribution range of the particles is in the nanoscale range of 158.5 nm (55.8%)−199.5 nm (44.2%); thus, illustrates that the particles produced are uniformly distributed. The percentage indicated in the parentheses is intensity percentage of the particle measured using dynamic light scattering (DLS) technique.
Fifth Embodiment
[0031] The solubility of fenofibrate (substance) in ethanol was increased from value of 2.5% (w/v) with an excipient such as poly vinyl pyrrolidone (PVP) at substance to excipient ratio of 1:1 to 10% (w/v) with an excipient such as Solutol HS15 mainly including poly-oxyethylene esters of 12-hydroxystearic acid (manufactured by BASF, Florham Park, N.J.) at substance to excipient ratio of 1:1.
[0032] The solubility of fenofibrate (substance) in ethanol was increased from value of 2.5% (w/v) with an excipient such as poly vinyl pyrrolidone (PVP) at substance to excipient ratio of 1:1 to 10% (w/v) with an excipient such as Arlacel 83 mainly including sorbitan sesquioleate (manufactured by Stobec, Quebec, Canada) at substance to excipient ratio of 1:1.
[0033] FIG. 2 shows one embodiment of a system for fabricating nanoparticles. As shown in FIG. 2 , the system 200 e.g. a hot air drying system dries the droplets using hot air, thus, nanoparticles are formed. The system 200 includes a drying chamber 210 , micro droplet sprayer 220 , orifices 230 of micro droplet sprayer, pipes 240 , nitrogen entrance 250 , water (from circulation chamber) entrance 260 , hot air entrance 270 , hot air exit 280 , and the bottom 290 of drying chamber 210 . First to fifth embodiments are also suitable to the system 200 .
[0034] As described, the invention fabricates nanoparticles with uniform diameters by integrating injection printing techniques into subsequent drying and formation processes. In addition, the system is further equipped with the auxiliary element for controlling spray directions of the droplets and particle collector for collecting dried nanoparticles. Compared to the related art, the invention has advantages such as low cost, fine droplets, uniform droplet diameters, and simple apparatus and processes. Specifically, the nanoparticles fabricated by the invention have uniform particle diameters, thus, they can be used to manufacture medicines enhancing absorption and solubility in the blood. The invention aids in improving the therapeutic effect of medicines.
[0035] While the invention has been described by way of example and in terms of the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
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A method employs the addition of additive to increase the solubility of active ingredients in solution. Furthermore, a nanoparticle apparatus that uses inkjet dispenser is utilized to fabricate nanoparticles. The method comprises: (a) mixing a fenofibrate substance, an organic solvent and a solubility enhancing additive to form a saturated solution; and (b) spray-drying the saturated solution to form the nanoparticles containing fenofibrate, wherein the solubility enhancing additive comprises a surfactant or an excipient.
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This application is a continuation of U.S. application Ser. No. 12/762,051, filed on Apr. 16, 2010, now published, which is a continuation of U.S. application Ser. No. 11/416,460, filed on May 1, 2006, now abandoned, which is a continuation of U.S. application Ser. No. 10/026,925, filed on Dec. 18, 2001, now abandoned, which claims the benefit under 35 USC §120 of U.S. provisional application 60/256,380, filed Dec. 18, 2000 the entire content of each of which is herein incorporated by reference. The provisional application and the Tables attached to it are specifically incorporated by reference herein.
The present invention relates to focused libraries of genetic packages that each display, display and express, or comprise a member of a diverse family of peptides, polypeptides or proteins and collectively display, display and express, or comprise at least a portion of the focused diversity of the family. The focused diversity of the libraries of this invention comprises both sequence diversity and length diversity. In a preferred embodiment, the focused diversity of the libraries of this invention is biased toward the natural diversity of the selected family. In more preferred embodiment, the libraries are biased toward the natural diversity of human antibodies and are characterized by variegation in their heavy chain and light chain complementarity determining regions (“CDRs”).
The present invention further relates to vectors and genetic packages (e.g., cells, spores or viruses) for displaying, or displaying and expressing a focused diverse family of peptides, polypeptides or proteins. In a preferred embodiment the genetic packages are filamentous phage or phagemids or yeast. Again, the focused diversity of the family comprises diversity in sequence and diversity in length.
The present invention further relates to methods of screening the focused libraries of the invention and to the peptides, polypeptides and proteins identified by such screening.
BACKGROUND OF THE INVENTION
It is now common practice in the art to prepare libraries of genetic packages that individually display, display and express, or comprise a member of a diverse family of peptides, polypeptides or proteins and collectively display, display and express, or comprise at least a portion of the amino acid diversity of the family. In many common libraries, the peptides, polypeptides or proteins are related to antibodies (e.g., single chain Fv (scFv), Fv, Fab, whole antibodies or minibodies (i.e., dimers that consist of V H linked to V L )). Often, they comprise one or more of the CDRs and framework regions of the heavy and light chains of human antibodies.
Peptide, polypeptide or protein libraries have been produced in several ways in the prior art. See e.g., Knappik et al., J. Mol. Biol., 296, pp. 57-86 (20004, which is incorporated herein by references. One method is to capture the diversity of native donors, either naive or immunized. Another way is to generate libraries having synthetic diversity. A third method is combination of the first two. Typically, the diversity produced by these methods is limited to sequence diversity, i.e., each member of the library differs from the other members of the family by having different amino acids or variegation at a given position in the peptide, polypeptide or protein chain. Naturally diverse peptides, polypeptides or proteins, however, are not limited to diversity only in their amino acid sequences. For example, human antibodies are not limited to sequence diversity in their amino acids, they are also diverse in the lengths of their amino acid chains.
For antibodies, diversity in length occurs, for example, during variable region rearrangements. See e.g., Corbett et al., J. Mol. Biol., 270, pp. 587-97 (1997). The joining of V genes to J genes, for example, results in the inclusion of a recognizable D segment in CDR3 in about half of the heavy chain antibody sequences, thus creating regions encoding varying lengths of amino-acids. The following also may occur during joining of antibody gene segments: (i) the end of the V gene may have zero to several base deleted or changed; (ii) the end of the D segment may have zero to many bases removed or changed; (iii) a number of random bases may be inserted between V and D or between D and J; and (iv) the 5′ end of J may be edited to remove or to change several bases. These rearrangements result in antibodies that are diverse both in amino acid sequence and in length.
Libraries that contain only amino acid sequence diversity are, thus disadvantaged in that they do not reflect the natural diversity of the peptide, polypeptide or protein that the library is intended to mimic. Further, diversity in length may be important to the ultimate functioning of the protein, peptide or polypeptide. For example, with regard to a library comprising antibody regions, many of the peptides, polypeptides, proteins displayed, displayed and expressed, or comprised by the genetic packages of the library may not fold properly or their binding to an antigen may be disadvantaged, if diversity both in sequence and length are not represented in the library.
An additional disadvantage of prior art libraries of genetic packages that display, display and express, or comprise peptides, polypeptides and proteins is that they are not focused on those members that are based on natural occurring diversity and thus on members that are most likely to be functional. Rather, the prior art libraries, typically, attempt to include as much diversity or variegation at every amino acid residue as possible. This makes library construction time-consuming and less efficient than possible. The large number of members that are produced by trying to capture complete diversity also makes screening more cumbersome than it needs to be This is particularly true given that many members of the library will not be functional.
SUMMARY OF THE INVENTION
One objective of this invention is focused libraries of vectors or genetic packages that encode members of a diverse family of peptides, polypeptides or proteins wherein the libraries encode populations that are diverse in both length and sequence. The diverse length comprising components contain motifs that are likely to fold and function in the context of the parental peptide, polypeptide or protein.
Another object of this invention is focused libraries of genetic packages that display, display and express, or comprise a member of a diverse family of peptides, polypeptides and proteins and collectively display, display and express, or comprise at least a portion of the focused diversity of the family. These libraries are diverse not only in their amino acid sequences, but also in their lengths. And, their diversity is focused so as to more closely mimic or take into account the naturally-occurring diversity of the specific family that the library represents.
Another object of this invention is diverse, but focused, populations of DNA sequences encoding peptides, polypeptides or proteins suitable for display or display and expression using genetic packages (such as phage or phagemids) or other regimens that allow selection of specific binding components of a library.
A further object of this invention is focused libraries comprising the CDRs of human antibodies that are diverse in both their amino acid sequence and in their length (examples of such libraries include libraries of single chain Fv(scFv), Fv, Fab, whole antibodies or minibodies (i.e., dimers that consist of V H linked to V L ). Such regions may be from the heavy or light chains or both and may include one or, more of the CDRs of those chains. More preferably, they diversity or variegation occurs in all of the heavy chain and light chain CDRs.
It is another object of this invention to provide methods of making and screening the above libraries and the peptides, polypeptides and proteins obtained in such screening.
Among the preferred embodiments of this invention are the following:
1. A focused library of vectors or genetic packages that display, display and express, or comprise a member of a diverse family of human antibody related peptides, polypeptides and proteins and collectively display, display and express, or comprise at least a portion of the diversity of the antibody family, the vectors or genetic packages being characterized by variegated DNA sequences that encode a heavy chain CDR1 selected from the group consisting of:
(1) <1> 1 Y 2 <1> 3 M 4 <1> 5 (SEQ ID NO:100), wherein <1> is an equimolar mixture of each of amino acid residues A, D, E, F, G, H, I, K, L, M, N, P, Q, R, S, T, V, W, and Y; (2) (S/T) 1 (S/G/X) 2 (S/G/X) 3 Y 4 Y 5 W 6 (S/G/X) 7 (SEQ ID NO:101) wherein (S/T) is a 1:1 mixture of S and T residues, (S/G/X) is a mixture of 0.2025 S, 0.2025 G and 0.035 of each of amino acid residues A, D, E, F, H, I, K, L, H, N, P, Q, R, T, V, W, and Y; (3) V 1 S 2 G 3 G 4 S 5 I 6 S 7 <1> 8 <1> 9 <1> 10 Y 11 Y 12 W 13 <1> 14 (SEQ ID NO:1), wherein <1> is an equimolar mixture of each of amino acid residues A, D, E, F, G, H, I, K, L, M, N, P, Q, R, S, T, V, W, and Y; and (4) mixtures of vectors or genetic packages characterized by any of the above DNA sequences, preferably in the ratio: HC CDR1s (1):(2):(3)::0.80:0.17:0.02.
2. A focused library of vectors or genetic packages that display, display and express, or comprise a member of a diverse family of human antibody related peptides, polypeptides and proteins and collectively display, display and express or comprise at least a portion of the diversity of the antibody facility, the vectors or genetic packages being characterized by variegated DNA sequences that encode a heavy chain CDR2 selected from the group consisting of:
(1) <2>I<2><3>SGG<1>T<1>YADSVKG (SEQ ID NO:2), wherein <1> is an equimolar mixture of each of amino acid residues 2 1 1, 0, E, F, G, H, I, K, L, M, N, P, 0, P, S, T, V, W, and Y; <2> is an equimolar mixture of each of amino acid residues Y, R, W, V, G, and S; and <3> is an equimolar mixture of each of amino acid residues P, S, and G or an equimolar mixture of P and S; (2) <1>I<4><1><1><G><5><1><1><1>YADSVKG (SEQ ID NO:3), wherein <1> is an equimolar mixture of each of amino acid residues A, D, E, F, G, H, I, K, L, M, N, P, Q, R, S, T, V, W, and Y; <4> is an equimolar mixture of residues D, I, N, S, W, Y; and <5> is an equimolar mixture of residues S, G, D and N; (3) <1>I<4><1><1>G<5><1><1> YNPSLKG (SEQ ID NO:4), wherein <1> is an equimolar mixture of each of amino acid residues A, D, E, F, G, H, I, K, L, M, N; P, Q, R, S, T, V, W and Y, and <4> and <5> are as defined above; (4) <1>I<8>S<1><1><1>GGYY<1>YAASVKG (SEQ ID NO:5), wherein <1> is an equimolar mixture of each amino acid residues A, D, E, F, Gill, I, K, L, M, N, P, Q, R, S, T, V, and Y; <8> is 0.27 R and 0.027 of each of ADEFGHIKLMNPQSTVWY; and (5) mixtures of vectors or genetic packages characterized by any of the above DNA sequences, preferably in the ratio: HC CDR2s:(1)/(2) (equimolar):(3):(4)::0.54:0.43:0.03.
3. A focused library of vectors or genetic packages that display, display and express, or comprise a member of a diverse family of human antibody related peptides, polypeptides and proteins and collectively display, display and express, or comprise at least a portion of the diversity of the antibody family, the vectors or genetic packages being characterized by variegated DNA sequences that encode a heavy chain CDR3 was selected from the group consisting of:
(1) YYCA21111YFDYWG (SEQ ID NO:6), Wherein 1 is an equimolar mixture of each amino acid residues A, D, E, F, G, H, I, K, L, M, N, P, Q, R, S, T, V, W and Y; and 2 is an equimolar mixture of K and R; (2) YYCA2111111YFDYWG (SEQ ID NO:7), wherein 1 is an equimolar mixture of each amino acid residues A, D, E, F, G, H, K, L, M, N, P, Q, R, S, T, V, W and Y; and 2 is an equimolar mixture of K and R; (3) YYCA211111111YFDAYTG (SEQ ID NO:8), wherein 1 is an equimolar mixture of each amino acid residues A, D, E, F, G, H, 1, K, L, M, N, P, Q, R, S, T, V, W and Y; and 2 is an equimolar mixture of K and R; (4) YYCAR111S2S3111YFDYWG (SEQ ID NO:9), wherein 1 is an equimolar mixture of each amino acid residues A, D, E, G, H, I, K, L, M, N, P, Q, R, S, T, V, W and Y; and 2 is an equimolar mixture of S and G; and 3 is an equimolar mixture of Y and W; (5) YYCA2111CSG11CY1YFDYWG (SEQ ID NO:10), wherein 1 is an equimolar mixture of each amino acid residues A, D, E, F, G, H, I, K, L, M, N, P, Q, R, S, T, V, W and Y; and 2 is an equimolar mixture of K and R; (6) YYCA211S1TIFG11111YFDYWG (SEQ ID NO:11), wherein 1 is an equimolar mixture of each amino acid residues A, D, E, F, G, H, I, K, L, M, N, P, Q, R, S, T, V, W and Y; and 2 is an equimolar mixture of K and R. (7) YYCAR111YY2S3344111YFDYWG (SEQ ID NO:12), wherein 1 is an equimolar mixture of each amino acid residues A, D, E, F, G, H, I, K, L, M, N, P, Q, R, S, T, V, W and Y; 2 is an equimolar mixture of D and S; and 3 is an equimolar mixture of S and G; (8) YYCAR1111YC2231CY111YFDYWG (SEQ ID NO:13), wherein 1 is an equimolar mixture of each amino acid residues A, D, E, F, G, H, I, K, L, M, N, P, Q, R, S, T, V, W and Y; 2 is an equimolar mixture of S and G; and 3 is an equimolar mixture of T, D and G; and (9) mixtures of vectors or genetic packages characterized by any of the above DNA sequences, preferably the HC CDR3s (1) through (8) are in the following proportions in the mixture: (1) 0.10 (2) 0.14 (3) 0.25 (4) 0.13 (5) 0.13 (6) 0.11 (7) 0.04 and (8) 0.10; and more preferably the HC CDR3s (1) through (8) are in the following proportions in the mixture: (1) 0.02 (2) 0.14 (3) 0.25 (4) 0.14 (5) 0.14 (6) 0.12 (7) 0.08 and (8) 0.11.
Preferably, 1 in one or all of HC CDR3s (1) through (8) is 0.095 of each of G and Y and 0.048 of each of A, D, E, F H, 1, K, L, M, N, P, Q, R, S, T, V, and W.
4. A focused library of vectors or genetic packages that display, display and express, or comprise a member of a diverse family of human antibody related peptides, polypeptides and proteins and collectively display, display and express, or comprise at least a portion of the diversity of the antibody family, the vectors or genetic packages being characterized by variegated DNA sequences that encodes a kappa light chain CDR1 selected from the group consisting of:
(1) RASQ<1>V<2><2><3>LA (SEQ ID NO:14)
(2) RASQ<1>V<2><2><2><3>LA (SEQ ID NO:15); wherein <1> is an equimolar mixture of amino acid residues ADEFGHIKLMNPQRSTVWY; <2> is 0.2 S and 0.044 of each of ADEFGHIKLMNPQRTVWY; and <3> is 0.2Y and 0.044 each of ADEFGHIKLMNPQRTVW and S; and
(3) mixtures of vectors or genetic packages characterized by any of the above DNA sequences, preferably in the ratio CDR1s (1):(2)::0.68:0.32.
5. A focused library of vectors or genetic packages that display, display and express, or comprise a member of a diverse family of human antibody related peptides, polypeptides and proteins and collectively display, display and express, or comprise at least a portion of the diversity of the-antibody family the vectors or genetic packages being characterized by variegated DNA sequences that encode a kappa light-chain CDR2 having the sequence:
<1>AS<2>R<4><1> (SEQ ID NO:102),
wherein <1> is an equimolar mixture of amino acid residues ADEFGHIKLMNPQRSTVWY; <2> is 0.2 S and 0.044 of each of ADEFGHIKLMNPQRTVWY; and <4> is 0.2.A and 0.044 each of DEFGHIKLMNPQRSTVWY.
6. A focused library of vectors or genetic packages that display, display and express, or comprise a member of a diverse family of human antibody related peptides, polypeptides and proteins and collectively display, display and express, or comprise at least a portion of the diversity of the antibody family, the vectors or genetic packages being characterized by variegated DNA sequences that encode a kappa light chain CDR3 selected from the groups consisting of:
(1) QQ<3><1><1><1>P<1>T (SEQ ID NO:16), wherein <1> is an equimolar mixture of amino acid residues ADEFGHIKLMNPQRSTVWY; <3> is 0.2 Y and 0.044 each of ADEFGHIKIMNPQRTVW; (2) QQ33111P (SEQ ID NO:103), wherein 1 and 3 are as defined in (1) above; (3) QQ3211PP1T (SEQ ID NO:17), wherein 1 and 3 are as defined in (1) above and 2 is 0.2 S and 0.044 each of ADEFGHIKLMNPQRTVWY; and (4) mixtures of vectors or genetic packages characterized by any of the above DNA sequences, preferably in the ratio CDA3s (1):(2):(3)::0.65:0.1:0.25.
7. A focused library of vectors or genetic packages that display, display and express, or comprise a member of a diverse family of human antibody related peptides, polypeptides and proteins and collectively display, display and express, or comprise at least a portion of the diversity of the antibody family, the vectors or genetic packages being characterized by variegated DNA sequences that encode a lambda light chain CDR1 selected from the group consisting of:
(1) TG<1>SS<2>VG<1><3><2><3>VS (SEQ ID NO:18), wherein <1> is 0.27 T, 0.27 G and 0.027 each of ADEFRIKLMNPQRSVWY: <2> is 0.27 D, 0.27 N and 0.027 each of AEFGHIKLMPQRSTVWY, and <3> is 0.36 Y and 0.036 each of ADEFGHIKLMNPQRSTVW; (2) G<2><4>L<4><4><4><3><4><4> (SEQ ID NO:104), wherein <2> is as defined in (1) above and <4> is an equimolar mixture of amino acid residues ADEFGHIKIMNPQRSTVWY; and (3) mixtures of vectors or genetic packages characterized by any of the above DNA sequences, preferably in the ratio CDR1 (1):(2)::0.67:0.33;
8. A focused library of vectors or genetic packages that display, display and express, or comprise a member of a diverse family of human antibody related peptides, polypeptides and proteins and collectively display, display and express, or comprise at least a portion of the diversity of the antibody family, the vectors or genetic packages being characterized by variegated DNA sequences that encode a lambda light chain CDR2 has the sequence:
<4><4><4><2>RPS (SEQ ID NO:105)
wherein <2> is 0.27 D, 0.27 N, and 0.027 each of AEFGHIKIMPQRSTVWY and <4> is an equimolar mixture of amino acid residues ADEFGHIKLONPQRSTVW.
9. A focused library of vectors or genetic packages that display, display and express, or comprise a member of a diverse family of human antibody related peptides, polypeptides and proteins and collectively display, display and express, or comprise at least a portion of the diversity of the antibody family, the vectors or genetic packages being characterized by variegated DNA sequences that encode a lambda light chain CDR3 selected from the group consisting of:
(1) <4><5><4><2><4>S<4><4><4><4>V (SEQ ID NO:106), wherein <2> is 0.27 D, 0.27 N, and 0.027 each of AEFGHIKIMPQRSTVWY; <4> is an equimolar mixture of amino acid residues ADEFGHIKLMVPQRSTVW; and <5> is 0.36 S and 0.6355 each of ADEFGHIKLMNPQRTVWY; (2) <5>SY<1><5>S<5><1><4>V (SEQ ID NO:19), wherein <1> is an equimolar mixture of ADEFGHIKLMNPQRSTVWY; and <4> and 5 <5> are as defined in (1) above; and (3) mixtures of vectors or genetic packages characterized by any of the above DNA sequences, preferably in the ratio CDR3s
10. A focused library comprising variegated-DNA sequences that encode a heavy chain CDR selected from the group consisting of:
(1) one or more of the heavy chain CDR's of paragraph 1 above; (2) one or more of the heavy chin CDR2s of paragraph 2 above; (3) one or more of the heavy chain CDR3s of paragraph 3 above; and (4) mixtures of vectors or genetic-packages characterized by (1), (2) and (3).
11. The focused library comprising one or more of the variegated DNA sequences that encodes a heavy chain CDR of paragraphs 1, 2 and 3 and further comprising variegated DNA sequences that encodes a light chain CDR selected from the group consisting of (1) one or more the kappa light chain CDR1s of paragraph 4;
(2) the kappa light chain. CDR2 of paragraph 5; (3) one or more of the kappa light chain CDR3s of paragraph 6; (4) one or more of the kappa light chain CDR1s of paragraph 7; (5) the lambda light chain ‘CDR2’ of paragraph 8 (6) one or more of the lambda light chain CDR3s of paragraph. 9; and (7) mixtures of vectors and genetic packages characterized by one or more of (1) through (6).
12. A population of variegated DNA sequences as. described in paragraphs 1-11 above.
13. A population of vectors comprising the variegated DNA sequences as described in paragraphs 1-11 above.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Antibodies (“Ab”) concentrate their diversity into those regions that are involved in determining affinity and specificity of the Ab for particular targets. These regions may be diverse in sequence or in length. Generally, they are diverse In both ways. However, within families of human antibodies the diversities, both in sequence and in length, are not truly random. Rather, some amino acid residues are preferred at certain positions of the CDRs and some CDR lengths are preferred. These preferred diversities account for the natural diversity of the antibody family.
According to this invention, and as more fully described below, libraries of vectors and genetic packages that more closely mirror the natural diversity, both in sequence and in length, of antibody families, or portions thereof are prepared and used.
Human Antibody Heavy Chain Sequence and Length Diversity
(a) Framework
The heavy chain (“HC”) Germ-Line Gene (GLG) 3-23 (also known as 1/1)-47) accounts for about 12% of all human Abs and is preferred as the framework in the preferred embodiment of the invention. It should, however, be understood that other well-known frameworks, such as 4-34, 3-30, 3-30.3 and 4-30.1, may also be used without departing from the principles of the focused diversities of this invention.
In addition, JH4(YFDYWGQGTLVTVSS; SEQ ID NO:20) occurs more often than JH3 in native antibodies. Hence, it is preferred for the focused libraries of this invention. However, JH3 (AFDIWGQGTMVTVSS; SEQ ID NO:21) could as well be used.
(b) Focused Length Diversity: CDR1, 2 and 3
(i) CDR1
For CDR1, GLGs provide CDR1s only Of the lengths 5, 6, and 7. Mutations during the maturation of the v-domain gene, however, can lead to CDR1s having lengths as short as 2 and as long as 16. Nevertheless, length 5, predominates. Accordingly, in the preferred embodiment of this invention the preferred HC CDR1 is 5 amino acids, with less preferred CDR1s having lengths of 7 and 14. In the most preferred libraries of this invention, all three lengths are used in proportions similar to those found in natural antibodies.
(ii) CDR2
GLGs provide CDR2s only of the lengths 15:19, but mutations during maturation may result in CDR2s of lengths from 16 to 28 amino acids. The lengths 16 and 17 predominate in mature Ab genes. Accordingly, length 17 is the preferred length for HC CDR2 of the present invention. Less preferred HC CDR2s of this invention have lengths 16 and 19. In the most preferred focused libraries of this invention, all three lengths are included in proportions similar to those found in natural antibody families.
(iii) CDR3
HC CDR3s vary in length. About half of human HCs consist of the components: V::nz::D::ny::JHn where V is a V gene, nz is a series of bases (mean 12) that are essentially random, D is a D segment, often with heavy editing at both ends, ny is a series of bases (mean 6) that are essentially random, and JH is one of the six JH segments, often with heavy editing at the 5′ end. The D segments appear to provide spacer segments that allow folding of the IgG. The greatest diversity is at the junctions of y with D and of D with JH.
In the preferred-libraries of this invention both types of HC CDR3s are used. In HC CDR3s that have no identifiable D segment, the structure is V::nz::JHn where JH is usually edited at the 5′ end. In HC CDR3s that have an identifiable D segment, the structure is V::nz::D::ny::JHn.
(c) Focused Sequence Diversity: CDR1, 2 and 3
(i) CDR1
In 5 amino acid length CDR1, examination of a 3D model of a humanized Ab showed that the side groups of residues 1, 3, and 5 were directed toward the combining pocket. Consequently, in the focused libraries of this invention, each of these positions may be selected from any of the native amino acid residues, except cysteine (“C”). Cysteine can form disulfide bonds, which are an important component of the canonical Ig fold. Having free thiol groups Could, thus, interfere with proper folding of the HC and could lead to problems in production or manipulation of selected Abs. Thus, in the focused libraries of this invention cysteine is excluded from positions 1; 3 and 5 of the preferred 5 amino acid CDR1s. The other 19 natural amino acids residues may be used at positions 1, 3 and 5. Preferably, each is present in equimolar ratios in the variegated libraries of this invention.
3D modeling also suggests that the side groups of residue 2 in a 5 amino acid CDR1 are directed away from the combining pocket. Although this position shows substantial diversity, both in GLG and mature genes, in the focused libraries of this invention this residue is preferably Tyr (Y) because it occurs in 681/820 mature antibody genes. However, any of the other native amino acid residues, except Cys (C), could also be used at this position.
For position 4, there is also some diversity in GLG and mature antibody genes. However, almost all mature genes have uncharged hydrophobic amino acid residues: A, G, L, P, F, M, W, I, V, at this position. Inspection of a 3D model also shows that the side group of residue 4 is packed into the innards of the HC. Thus, in the preferred embodiment of this invention which uses framework 3-23, residue 4 is preferably Met because it Is likely to fit very well into the framework of 3-23. With other frameworks, a similar fit consideration is used to assign residue 4.
Thus, the most preferred HC CDR1 of this invention consists of the amino acid sequence <1>Y<I>M<1> where <1> can be any one of amino acid residues: A, D, E, G, H, I, K, L, M, N, R, Q, S, T, V, W, Y (not C), preferably present at each position in an equimolar amount. This diversity is shown in the context of a framework 3-23:JH4 in Table 1. It has a diversity of 6859-fold.
The two less preferred HC CDR1s of this invention have length 7 and length 14. For length 7, a preferred variegation is (S/T) (S/G/<1>) 2 (S/G/<1>) 3 Y 4 Y 5 W 6 (S/G/<1>) 7 (SEQ ID NO:107); where (S/T) indicates an equimolar mixture of Ser and Thr codons; (S/G/<1>) indicates a mixture Of 0.2025 S, 0.2025 G, and 0.035 for each of A, D, E, F, H, I, K, L, M, N, P, Q, R, T, V, W, Y. This design gives a predominance of Ser and Gly at positions 2, 3, and 7, as occurs in mature HC genes. For length 14, a preferred variegation is VSGGSIS<1><1><1>YYW<1> (SEQ ID NO:108), where <1> is an equimolar mixture of the 19 native amino acid residues, except Cys (C).
The DNA that encodes these preferred HC CDR1s is preferably synthesized using trinucleotide building blocks so that each amino acid residue ii present in essentially equimolar or other described amounts. The preferred codons for the <1> amino acid residues are gct, gat, gag, ttt, ggt, cat, att, aag, ctt, atg, aat, cct, cag, cgt, tct, act, gtt, tgg, and tat. Of course, other codons for the chosen amino acid residue could also be used.
The diversity oligonucleotide (ON) is preferably synthesized from BspEI to BstXI (as shown in Table 1) and can, therefore, be incorporated either by PCR synthesis using overlapping ONs or introduced by ligation of BspEI/BstXI-cut fragments. Table 2 shows the oligonucleotides that embody the specified variegations of the preferred length 5 HC CDR1s of this invention. PCR using ON-R1V1vg, ON-R1top, and ON-R1bot gives a dsDNA product of 73 base-pairs, cleavage with 14spEI and BstXI trims 11 and 13 bases from the ends and provides cohesive ends that can be ligated to similarly cut vector having the 3-23 domain shown in Table 1. Replacement of ON-R1V1vg with either ONR1V2vg or ONR1V3vg (see Table 2) allows synthesis of the two alternative diversity patterns—the 7 residue length and the 14 residue length HC CDR1.
The more preferred libraries of this invention comprise the 3 preferred HC CDR1 length diversities. Most preferably, the 3 lengths should be incorporated in approximately the ratios in which they are observed in antibodies selected without reference to the length of the CDRs. For example, one sample of 1095 HC genes have the three lengths present in the ratio: L=5:L=7:L=14::820:175:23::0.80:0.17:0.02. This is the preferred ratio in accordance with this invention.
(ii) CDR2
Diversity in HC CDR2 was designed with the same considerations as for HC CORI: GLG sequences, mature sequences and 3D structure. A preferred length for CDR2 is 17, as shown in Table 1. For this preferred 17 length CDR2, the preferred variegation in accordance with the invention is: <2>I<2><3>SGG<1>T<1>YADSVKG (SEQ ID NO:2), where <2> indicates any amino acid residue selected from the group of Y, R, W, V, G and S (equimolar mixture), <3> is P, S and G or P and S only (equimolar mixture), and <1> is any native amino acid residue except C (equimolar mixture).
ON-R2V1vg shown in Table 3 embodies this diversity pattern. It is preferably synthesized so that fragments of dsDNA containing the BstXI and XbaI site can be generated by PCR. PCR with ON-R2V1vg, ON-R2top, and ONR2bot gives a dsDNA product of 122 base pairs. Cleavage with BstXI and XbaI removes about 10 bases from each end and produces cohesive ends that can be ligated to similarly cut vector that contains the 3-23 gene-shown in Table 1.
In an alternative embodiment for a 17 length HC CDR2, the following variegation may be used; <1>I<4><1><1>G<5><1><1><1>YADSVKG (SEQ ID NO:3), where <1> is as described above for the more preferred alternative of HC CDR2; <4> indicates an equimolar mixture of DINSWY, and <5> indicates an equimolar mixture of SGDN. This diversity pattern is embodied in ON-R2V2vg shown in Table 3. Preferably, the two embodiments are used in equimolar mixtures in the libraries of this invention.
Other preferred HC CDR2s have lengths 16 and 19. Length 16: <1>I<4><1><1>G<5<1><1>YNPSLKG (SEQ ID NO:4); Length:19: <1>I<8>S<1><1><1>GGYY<1>YAASVKG (SEQ ID NO:5), wherein <1> is an equimolar mixture of all native amino acid residues except C; <4> is a equimolar mixture of DINSWY; <5> is an equimolar mixture of SGDN; and <8> is 0.27 R and 0:0 7 of each of residues ADEFGHIKLMNPQSTVWY. Table 3 shows ON-R2V3vg which embodies a preferred aDR2 variegation of length 16 and ON7R2V4vg which embodies a preferred CDR2 variegation of length 19. To prepare these variegations ON-R2V3vg may be PCR amplified with ON-A2top and ON-R2bo3 and ON-R2V4vg may be PCR amplified with ON-R2top and ON-R2-bo4. See Table 3. In the most preferred embodiment of this invention, all three HC CDR2 lengths are used. Preferably, they are present in a ratio 17:16:19::579:464:31::0.54:0.43:0.03.
(iii) CDR3
The preferred libraries of this invention comprise several BC CDR3 components. Some of these will have only sequence diversity. Others will have sequence diversity with embedded D segments to extend the length, while also incorporating sequences known to allow Igs to fold. The HC CDR3 components of the preferred libraries of this invention and their diversities are depicted in Table 4: Components 1-8.
This set of components was chosen after studying the sequences of 1383 human BC sequences. The proposed components are meant to fulfill the following goals:
1) approximately the same distribution of lengths as seen in native Ab genes;
2) high level of sequence diversity at places having high diversity in native Ab genes; and
3) incorporation of constant sequences often seen in native Ab genes.
Component 1 represents all the genes having lengths 0 to 8 (counting from the YYCAR motif at the end of FR3 to the WG dipeptide motif near the start of the J region, i.e., FR4). Component 2 corresponds the all the genes having lengths 9 or 10. Component 3. corresponds to the genes having lengths 11 or 12 plus half the genes having length 13. Component 4 corresponds to those having length 14 plus half those having length 13. Component 5 corresponds to the genes having length 15 and half of those having length 16. Component. 6 corresponds to genes of length 17 plus half of those with length 16. Component 7 corresponds to those with length 18. Component 8 corresponds to those having length 19 and greater. See Table 4.
For each HC CDR3 residue having the diversity <1>, equimolar ratios are preferably not used. Rather, the following ratios are used 0.095 [G and Y] and 0.048 [A, D, E, F, H, I, K, L, M, N, P, Q, R, S, T, V, and W]. Thus, there is a double dose of G and Y with the other residues being in equimolar ratios. For the other diversities, e.g., KR or SG, the residues are present in equimolar mixtures.
In the preferred libraries of this invention the eight components are present in the following fractions: 1 (0.10), 2 (0.14), 3 (0.25), 4 (0.13), 5 (0.13), 6 (0.11), 7 (0.04) and 8 (0.10). See Table 4.
In the more preferred embodiment of this invention, the amounts of the eight components is adjusted because the first component is not complex enough to justify including it as 10% of the library. For example, if the final library were to have 1×10 9 members, then 1×10 8 sequences would come from component 1, but it has only 2.6×10 5 CDR3 sequences so that each one would occur in ˜385 CDR1/2 contexts. Therefore, the more preferred amounts of the eight components are 1(0.02), 2(0.14), 3(0.25), 4(0.14), 510.14), 6(0.12), 7(0.68), 8(0.11). In accordance with the more preferred embodiment component 1 occurs in ˜77 CDR1/2 contexts and the other, longer CDR3s occur more often.
Table 5 shows vgDNA that embodies each of the eight HC CDR3 components shown in Table 4. In Table 5, the oligonucleotides (ON) Ctop25, CtprmA, C8prmB, and CBot25 allow PCR amplification of each of the variegated ONs (vgDNA): C1t08, C2t10, C3t12, C4t14, C5t15, C6t17, C7t18, and C8t19. After amplification, the dsDNA can be cleaved with AfiII and BstEII (or KpnI) and ligated to similarly cleaved vector that contains the remainder of the 3-23 domain. Preferably, this vector already contains diversity in one, or both, of CDR1 and CDR2 as disclosed herein. Most preferably, it contains diversity in both the CDR1 and CDR2 regions. It is, of course, to be understood that the various diversities can be incorporated into the vector in any order.
Preferably, the recipient vector originally contains a stuffer in place of CDR1, CDR2 and CDR3 so that there will be no parental sequence that would then occur in the resulting library. Table 6 shows a version of the V3-23 gene segment with each CDR replaced by a short segment that contains both stop codons and restriction sites that will allow specific cleavage of any vector that does not have the stuffer removed. The stuffer can either be short and contain a restriction enzyme site that will not occur in the finished library, allowing removal of vectors that are not cleaved by both AfiII and BstEII (or AionI) and religated. Alternatively, the stuffer could be 200-400 bases long so that uncleaned or once-cleaved vector can be readily separated from doubly cleaved vector.
Human Antibody Light Chain: Sequence and Length Diversity
(i) Kappa Chain
(a) Framework
In the preferred embodiment of this invention, the kappa light chain is built in an A27 framework with a JK1 region. These are the most common V and J regions in the native genes. Other frameworks, such as 012, L2, and All, and other J regions, such as JK4, however, may be used without departing from the scope of this invention.
(b) CDR1
In native human kappa chains, CDR1s with lengths of 11, 12, 13, 16, and 17 were observed with length 11 being predominant and length 12 being well represented. Thus, in the preferred embodiments of this invention LC CDR1s of length 11 and 12 are used in an and mixture similar to that observed in native antibodies), length 11 being most preferred. Length 11 has the following sequence: RASQ<1>V<2><2><3>LA (SEQ ID NO:14) and Length 12 hag the following sequence: RASQ<1>V<25<2><2><3>LA (SEQ ID NO:15), wherein <1> is an equimolar mixture of ill of the native-amino acid residues, except C, <2> is 0.2 S and 0.044 of each of ADEFGHIKLMNPQRTVWY, and <3> is 0.2.Y and 0.044 each of A, D, E, F, G, H, 1, K, L, M, N, Q, R, T, V, W and S. In the most preferred embodiment of this invention, both CDR1. lengths are used. Preferably, they are present in a ratio of 11:12::154:73:0.68:0.32.
(c) CDR2
In native kappa, CDR2 exhibits only length 7. This length is used in the preferred embodiments of-this invention. It has the sequence <1>AS<2>R<4><1>, wherein <1> is an-equimolar mixture of amino acid residues ADEFGHIKLMNPQRSTVWY; <2> is 0.2 S and 0.004 of each of ADEFGHIKLMNPQRTVWY; and <4> is 0.2 A and 0.044 of each of DEFGHIKLMNPQRSTUWY.
(d) CDR3
In native kappa, CDR3 exhibits lengths of 4, 6, 7; 8, 9, 10, 11, 12, 13, 0.0 . . . and 19. While any of these lengths and mixtures of them can be employed in this invention, we prefer lengths 8, 9 and 10, length 9 being more preferred. For the preferred Length 9, the sequence is, QQ<3><1><1><1>P<1>T, wherein <1> is an equimolar mixture of amino acid residues ADEFGHIKLMNPQRSTVWY and <3> is 0.2? and 0.044 each of ADEFGHIKLWQRSVW. Length 8 is preferably QQ33111P and Length 10 is Preferably QQ3211PP1T, wherein 1 and 3 are as defined for Length 9 and 2 is S (0.2) and 0.044 each of ADEFGHIKLMNPQRTVWY. A mixture of all 3 lengths being most preferred (ratios as in native antibodies), i.e., 8:9:10i28:166:63::0.1:0.65:0.25.
Table 7 shows a kappa chain gene of this invention, including a PlacZ promoter a ribosome-binding site, and signal sequence (MI3 III signal). The DNA sequence encodes the GLG amino acid sequence but does not comprise the GLG DNA sequence. Restriction sites are designed to fall within each framework region so that diversity can be cloned into the CDRs. XmaI and Espl are in FR1, SexAI is in FR2, RsrII is in FR3, and KpnI (or Acc65I), are in FR4. Additional sites are provided in the constant kappa chain to facilitate construction of the gene.
Table 7 also shows a suitable scheme of variegation for kappa. In CDR1, the most preferred length 11 is depicted. However, most preferably both lengths 11 and 12 are used. Length 12 in CDR1 can be construed by introducing codon 51 as <2> (i.e. a Ser-biased mixture). CDR2 of kappa is always 7 codons. Table 7 shows a preferred variegation scheme for CDR2. Table 7 Shows a variegation scheme for the most preferred CDR3 (length 9). Similar variegations can be lied for CDRs of length 8 and 10. In the preferred embodiment of this invention, those three lengths (8, 9 and 10) are included in the libraries of this invention in the native ratios, as described above.
Table 9 shows series of diversity oligonucleotides and primers that may be used to construct the kappa chain diversities depicted in Table 7.
(ii) Lambda Chain
(a) Framework
The lambda chain is preferably built in a 2a2 framework with an L2J region. These are the most common V and J regions in the native genes. Other frameworks, such as 31, 4b, la and 6a, and other J regions, such as L1J, L3J and L7J, however, may be used without departing from the scope of this invention.
(b) CDR1
In native human lambda chains, CDR1s with length 14 predominate, lengths 11, 12 and 13 also occur. While any of these can be used in this invention, lengths 11 and 14 are preferred. For length 11 the sequence is: TG<2><4>L<4><4><4><3><4><4> (SEQ ID NO:22) and for Length 14 the sequence is: TG<1>SS<2>VG<1><3><2><3>VS (SEQ ID NO:18), wherein <1> is 0.27 T, 0.21 G and 0.027 each of ADEFHIKLMNPQRSVWY; <2> is 0.27 D, 0.27 N and 0.027 each of AEFGHIKLMPQRSTVWY; <3> is 0.36 Y and 0.0355 each of ADEFGHIKLMNPQRSTVW; and <4> is an equimolar mixture of amino acid residues ADEFGHIKLMNPQRSTVWY. Most preferably, Mixtures (similar to those occurring in native antibodies) preferably, the ratio is 11:14::23:46::0.33:0.67 of the three lengths are used.
(c) CDR2
In native human lambda chains 4 .CDR2s with length 7 are by far the most common. This length is preferred in this invention. The sequence of this Length 7 CDR2 is <4><4><4><2>RPS, wherein <2> is 0.27 D, 0.27 N, and 0.027 each of AEFGHIKLMPQRTVWY and <4> is an equimolar mixture of amino acid residues ADEFGHIKLMNPQRSTVW.
(d) CDR3
In native human lambda chains, CDR3s of length 10 and 11 predominate, while length 9 is also common. Any of these three lengths can be used in the invention. Length 11 is preferred and mixtures of 10 and 11 more preferred. The sequence of Length 11 is <4><5><4><2><4>S<4><4><4><4>V, where <2> and <4> are as defined for the lambda CORI and <5> is 0.36 S and 0.0355 each of ADFFGHIKLMNFORTVWY. The sequence of Length 10 is <5>SY<1><5>S<5><1><4>V (SEQ ID NO:19), wherein <1> is an equimolar mixture of ADEFGHIKLMNPQRSTVWY; and <4> and <5> are as defined for Length 11. The preferred mixtures of this invention comprise an equimolar mixture of Length 10 and Length 11. Table 8 shows a preferred focused lambda light chain diversity in accordance with this invention.
Table 9 shows a series of diversity oligonucleotides and primers that may be used to construct 10 the lambda chain diversities depicted in Table 7.
Method of Construction of the Genetic Package
The diversities of heavy chain and the kappa and lambda light chains are best constructed in separate vector's. First a synthetic gene is designed to embody each of the synthetic variable domains. The light chains are bounded by restriction sites for ApaLI (positioned at the very end of the signal sequence) and AscI (positioned after the stop codon). The heavy chain is bounded by SfiI (positioned within the PelB signal sequence) and NotI (positioned in the linker between CH1 and the anchor protein). Signal sequences other than PelB may also need, e.g., a M13 pIII signal sequence.
The initial genes are made with “stuffer” sequences in place of the desired CDRs. A “stuffer” is a sequence that is to be cut away and replaced by diverse DNA but which does not allow expression ‘of a functional antibody gene. For example, the stuffer may contain several stop codons and restriction sites that will not occur in the correct finished library vector. For example, in Table 10, the stuffer for CDR1 of kappa A27 contains a StuI site. The vgDNA for CDR1 is introduced as a cassette from EspI, XmaI, or Af1II to dither SexAI or KasI. After the ligation, the DNA is cleaved with Still; there should be no StuI sites in the desired vectors.
The sequences of the heavy chain gene with stuffers is depicted in Table 6. The sequences of the kappa light chain gene with stuffers is depicted in Table 10. The sequence of the lambda light chain gene with stuffers is depicted in Table 11.
In another embodiment of the present invention the diversities of heavy chain and the kappa or lambda light chains are constructed in a single vector or genetic packages (e.g., for display or display and expression) having appropriate restriction sites that allow cloning of these chains. The processes to construct such vectors are well known and widely used in the art. Preferably, a heavy chain and Kappa light Chain library and a heavy chain and lambda light chain library would be prepared separately. The two libraries, most preferably, will then be mixed in equimolar amounts to attain maximum diversity.
Most preferably, the display is had on the surface of a derivative of M13 phage. The most preferred vector contains all the genes of M13, an antibiotic resistance-gene, and the display cassette. The preferred vector is provided with restriction sites that allow introduction and excision of members of the diverse family of genes, as cassettes. The preferred vector is stable against rearrangement under the growth conditions used to amplify phage.
In another embodiment of this invention, the diversity captured by the methods of the present invention may be displayed and/or expressed in a phagemid vector (e.g., pCES1) that displays and/or expresses the peptide, polypeptide or protein. Such vectors may also be used to store the diversity for subsequent display and/or expression using other vectors or phage.
In another embodiment of this invention, the diversity captured by the methods of the present invention may be displayed and/or expressed in a yeast vector.
TABLE 1
3-23:JH4 CDR1/2 diversity = 1.78 × 10 8
FR1(VP47/V3-23)---------------
20 21 22 23 24 25 26 27 28 29 30
A M A E V Q L L E S G (SEQ ID NO: 99)
ctgtctgaac cc atg gcc gaa|gtt|caa|ttg|tta|gag|tct|ggt|
Scab...... NcoI.... MfeI
--------------FR1--------------------------------------------
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
G G L V Q P G G S L R L S C A
|ggc|ggt|ctt|gtt|cag|cct|ggt|ggt|tct|tta|cgt|ctt|tct|tgc|gct|
Sites of variegation <1> <1> <1> <1> 6859-fold diversity
----FR1-------------------->|.....CDR1....................|---FR2------
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
A S G F T F S - Y - M - W V R
|gct|tcc|gga|ttc|act|ttc|tct| - |tac| - |atg| - |tgg|gtt|cgc|
BspEI BsiWI BstXI.
Sites of variegation-><2> <2> <3>
-------FR2-------------------------------->|...CDR2.........
61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
Q A P G K G L E W V S - I - -
|caa|gct|cct|ggt|aaa|ggt|ttg|gag|tgg|gtt|tct| - |atc| - | - |
...BstXI
<1> <1> 25992-fold diversity in CDR2
.....CDR2 ....................................... |---FR3---
76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
S G G - T - Y A D S V K G R F
|tct|ggt|ggc| - |act| - |tat|gct|gac|tcc|gtt|aaa|ggt|cgc|ttc|
-- - - FR3--------------------------------------------------
91 92 93 94 95 96 97 98 99 100 101 102 103 104 105
T I S R D N S K N T L Y L Q M
|act|atc|tct|aga|gac|aac|tct|aag|aat|act|ctc|tac|ttg|cag|atg|
XbaI
---FR3------------------------------------------------------
106 107 108 109 110 111 112 113 114 115 116 117 118 119 120
N S L R A E D T A V Y Y C A K
|aac|agc|tta|agg|gct|gag|gac|acc|gct|gtc|tac|tac|tgc|gcc|aaa|
AflII
......CDR3.................| Replaced by the various components!
121 122 123 124 125 126 127
D Y E G T G Y (SEQ ID NO: 24)
|gac|tat|gaa|ggt|act|ggt|tat| (SEQ ID NO: 23)
|---------- FR4 ---(JH4)--------------------------------------------------
Y F D Y W G Q G T L V T V S S (SEQ ID NO: 26)
|tat|ttc|gat|tat|tgg|ggt|caa|ggt|acc|ctg|gtc|acc|gtc|tct|agt|. (SEQ ID NO: 25)
KpnI BstEII
<1> = Codons for ADEFGHIKLMNPQRSTVWY (equimolar mixture)
<2> = Codons for YRWVGS (equimolar mixture)
<3> = Codons for PS or PS and G (equimolar mixture)
TABLE 2
Oligonucleotides used to variegate CDR1 of human HC
CDR1 - 5 residues
(ON-R1V1vg):
5′-ct|tcc|gga|ttc|act|ttc|tct|<1>|tac|<1>|atg|<1>|tgg|gtt|cgc|caa|
gct|cct|gg-3′ (SEQ ID NO: 27)
<1> = Codons of ADEFGHIKLMNPQRSTVWY 1:1
(ON-R1top):
5′-cctactgtct|tcc|gga|ttc|act|ttc|tct-3′ (SEQ ID NO: 28)
(ON-R1bot) [RC]:
5′-tgg|gtt|cgc|caa|gct|cct|ggttgctcactc-3′ (SEQ ID NO: 29)
CDR1 - 7 residues
(ON-R1V2vg):
5′-ct|tcc|gga|ttc|act|ttc|tct|<6>|<7>|<7>|tac|tac|tgg|<7>|tgg|
gtt|cgc|caa|gct|cct|gg-3′ (SEQ ID NO: 30)
<6> = Codons for ST, 1:1
<7> = 0.2025(Codons for SG) + 0.035(Codons for ADEFHIKLMNPQRTVWY)
CDR1 - 14 residues
(ON-R1V3vg):
5′-ct|tcc|gga|ttc|act|ttc|tct|atc|agc|ggt|ggt|tct|atc|tcc|<1>|<1>|<1>|-
tac|tac|tgg|<1>|tgg|gtt|cgc|caa|gct|cct|gg-3′ (SEQ ID NO: 31)
<1> = Codons for ADEFGHIKLMNPQRSTVWY 1:1
TABLE 3
Oligonucleotides used to variegate CDR2 of human HC
CDR2 - 17 residues
(ON-R2V1vg):
5′-ggt|ttg|gag|tgg|gtt|tct|<2>|atc|<2>|<3>|tct|ggt|ggc|<1>|act|<1>|tat|gct|-
gac|tcc|gtt|aaa|gg-3′ (SEQ ID NO: 32)
(ON-R2top):
5′-ct|tgg|gtt|cgc|caa|gct|cct|ggt|aaa|ggt|ttg|gag|tgg|gtt|tct-3′ (SEQ ID NO: 33)
(ON-R2bot) [RC]:
5′-tat|gct|gac|tcc|gtt|aaa|ggt|cgc|ttc|act|atc|tct|aga|ttcctgtcac-3′ (SEQ ID NO: 34)
<1> = Codons for A, D, E, F, G, H, I, K, L, M, N, P, Q, R, S, T, V, W and Y
(equimolar mixture)
<2> = Codons for Y, R, W, V, G and S (equimolar mixture)
<3> = Codons for P and S (equimolar mixture) or P, S and G (equimolar mixture)
(ON-R2V2vg):
5′-ggt|ttg|gag|tgg|gtt|tct|<1>|atc|<4>|<1>|<1>|ggt|<5>|<1>|<1>|<1>|tat|gct|-
gac|tcc|gtt|aaa|gg-3′ (SEQ ID NO: 35)
<4> = Codons for DINSWY (equimolar mixture)
<5> = Codons for SGDN, (equimolar mixture)
CDR2 - 16 residues
(ON-R2V3vg):
5′-ggt|ttg|gag|tgg|gtt|tct|<1>|atc|<4>|<1>|<1>|ggt|
<5>|<1>|<1>|tat|aac|cct|tcc|ctt|aag|gg-3′ (SEQ ID NO: 36)
(ON-R2bo3) [RC]:
5′-tat|aac|cct|tcc|ctt|aag|ggt|cgc|ttc|act|atc|tct|aga|ttcctgtcac-3′ (SEQ ID NO: 37)
CDR2 - 19 residues
(ON-R2V4vg):
5′-ggt|ttg|gag|tgg|gtt|tct|<1>|atc|<8>|agt|<1>|<1>|
<1>|ggt|ggt|act|act|<1>|tat|gcc|gct|tcc|gtt|aag|gg-3′ (SEQ ID NO: 38)
(ON-R2bo4) [RC]:
5′-tat|gcc|gct|tcc|gtt|aag|ggt|cgc|ttc|act|atc|tct|aga|ttcctgtcac-3′ (SEQ ID NO: 39)
<1>, <2>, <3>, <4> and <5> are as defined above
<8> is 0.27 R and 0.027 each of ADEFGHIKLMNPQSTVWY
TABLE 4
Preferred Components of HC CDR3
Preferred
Fraction
Adjusted
Component
Length
Complexity
of Library
Fraction
1
YYCA21111YFDYWG.
8
2.6 × 10 5
.10
.02
(SEQ ID NO: 6)
(1 = any amino acid residue, except C; 2 = K and R)
2
YYCA2111111YFDYWG.
10
9.4 × 10 7
.14
.14
(SEQ ID NO: 7)
(1 = any amino acid residue, except C; 2 = K and R)
3
YYCA211111111YFDYTG.
12
3.4 × 10 10
.25
.25
(SEQ ID NO: 8)
(1 = any amino acid residue, except C; 2 = K and R)
4
YYCAR111S2S3111YFDYWG.
14
1.9 × 10 8
.13
.14
(SEQ ID NO: 9)
(1 = any amino acid residue, except C; 2 = S and G 3 =
Y and W)
5
YYCA2111CSG11CY1YFDYWG.
15
9.4 × 10 7
.13
.14
(SEQ ID NO: 10)
(1 = any amino acid residue, except C; 2 = K and R)
6
YYCA211S1TIFG11111YFDYWG.
17
1.7 × 10 10
.11
.12
(SEQ ID NO: 11)
(1 = any amino acid residue, except C; 2 = K and R)
7
YYCAR111YY2S33YY111YFDYWG.
18
3.8 × 10 8
.04
.08
(SEQ ID NO: 12)
(1 = any amino acid residue, except C; 2 = D or G;
3 = S and G)
8
YYCAR1111YC2231CY111YFDYWG.
19
2.0 × 10 11
.10
.11
(SEQ ID NO: 13)
(1 = any amino acid residue, except C; 2 = S and
G; 3 = T, D and G)
TABLE 5
Oligonucleotides used to variegate the eight components of HC CDR3
(Ctop25):
5′-gctctggtcaac|tta|agg|gct|gag|g-3′ (SEQ ID NO: 40)
(CtprmA):
5′-gctctggtcaac|tta|agg|gct|gag|gac|acc|gct|gtc|tac|tac|tgc|gcc-3′ (SEQ ID NO: 41)
AflII...
(CBprmB) [RC]:
5′-|tac|ttc|gat|tac|tgg|ggc|caa|ggt|acc|ctg|gtc|acc|tcgctccacc-3′ (SEQ ID NO: 42)
BstEII...
(CBot25) [RC]:
5′-|ggt|acc|ctg|gtc|acc|tcgctccacc-3′ (SEQ ID NO: 43)
The 20 bases at 3′ end of CtprmA are identical to the most 5′ 20 bases
of each of the vgDNA molecules.
Ctop25 is identical to the most 5′ 25 bases of CtprmA.
The 23 most 3′ bases of CBprmB are the reverse complement of the
most 3′ 23 bases of each of the vgDNA molecules.
CBot25 is identical to the 25 bases at the 5′ end of CBprmB.
Component 1
(C1t08):
5′-cc|gct|gtc|tac|tac|tgc|gcc|<2>|<1>|<1>|<1>|<1>|tac|ttc|gat|tac|tgg|ggc|caa|gg-3′
(SEQ ID NO: 44)
<1> = 0.095 Y + 0.095 G + 0.048 each of the residues ADEFHIKLMNPQRSTVW, no C; <2> = K and R
(equimolar mixture)
Component 2
(C2t10):
5′-cc|gct|gtc|tac|tac|tgc|gcc|<2>|<1>|<1>|<1>|<1>|<1>|<1>|tac|ttc|gat|tac|tgg|
ggc|caa|gg-3′ (SEQ ID NO: 45)
<1> = 0.095 Y + 0.095 G + 0.048 each of ADEFHIKLMNPQRSTVW, no C; <2> = K and R (equimolar
mixture)
Component 3
(C3t12):
5′-cc|gct|gtc|tac|tac|tgc|gcc|<2>|<1>|<1>|<1>|<1>|<1>|<1>|<1>|<1>|tac|ttc|gat|tac|-
tgg|ggc|caa|gg-3′ (SEQ ID NO: 46)
<1> = 0.095 Y + 0.095 G + 0.048 each of ADEFHIKLMNPQRSTVW, no C; <2> = K and R (equimolar
mixture)
Component 4
(C4t140):
5′-cc|gct|gtc|tac|tac|tgc|gcc|cgt|<1>|<1>|<1>|tct|<2>|tct|<3>|<1>|<1>|<1>|tac|ttc|gat|-
tac|tgg|ggc|caa|gg-3′ (SEQ ID NO: 47)
<1> = 0.095 Y + 0.095 G + 0.048 each of ADEFHIKLMNPQRSTVW, no C; <2> = S and G (equimolar
mixture); <3> = Y and W (equimolar mixture)
Component 5
(C5t15):
5′-cc|gct|gtc|tac|tac|tgc|gcc|<2>|<1>|<1>|<1>|tgc|tct|ggt|<1>|<1>|tgc|tat|<1>|tac|-
ttc|gat|tac|tgg|ggc|caa|gg-3′ (SEQ ID NO: 48)
<1> = 0.095 Y + 0.095 G + 0.048 each of ADEFHIKLMNPQRSTVW, no C; <2> = K and R (equimolar
mixture)
Component 6
(C6t17):
5′-cc|gct|gtc|tac|tac|tgc|gcc|<2>|<1>|<1>|tct|<1>|act|atc|ttc|ggt|<1>|<1>|<1>|<1>|-
<1>|tac|ttc|gat|tac|tgg|ggc|caa|gg-3′ (SEQ ID NO: 49)
<1> = 0.095 Y + 0.095 G + 0.048 each of ADEFHIKLMNPQRSTVW, no C; <2> = K and R (equimolar
mixture)
Component 7
(C7t18):
5′-cc|gct|gtc|tac|tac|tgc|gcc|cgt|<1>|<1>|<1>|tat|tac|<2>|tct|<3>|<3>|tac|tat|-
<1>|<1>|<1>|tac|ttc|gat|tac|tgg|ggc|caa|gg-3′ (SEQ ID NO: 50)
<1> = 0.095 Y + 0.095 G + 0.048 each of ADEFHIKLMNPQRSTVW, no C; <2> = D and G (equimolar
mixture); <3> = S and G (equimolar mixture)
Component 8
(c8t19):
5′-cc|gct|gtc|tac|tac|tgc|gcc|cgt|<1>|<1>|<1>|<1>|tat|tgc|<2>|<2>|<3>|<1>|tgc|tat|-
<1>|<1>|<1>|tac|ttc|gat|tac|tgg|ggc|caa|gg-3′ (SEQ ID NO: 51)
<1> = 0.095 Y + 0.095 G + 0.048 each of ADEFHIKLMNPQRSTVW, no C; <2> = S and G (equimolar
mixture); <3> = TDG (equimolar mixture);
TABLE 6
3-23::JH4 Stuffers in place of CDRs
FR1(DP47/V3-23)---------------
20 21 22 23 24 25 26 27 28 29 30
A M A E V Q L L E S G
ctgtctgaac cc atg gcc gaa|gtt|caa|ttg|tta|gag|tct|ggt|
(SEQ ID NO: 99)
Scab...... NcoI.... MfeI
--------------FR1--------------------------------------------
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
G G L V Q P G G S L R L S C A
|ggc|ggt|ctt|gtt|cag|cct|ggt|ggt|tct|tta|cgt|ctt|tct|tgc|gct|
----FR1-------------------->|...CDR1 stuffer....|---FR2------
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
A S G F T F S S Y A | | W V R
|gct|tcc|gga|ttc|act|ttc|tct|tcg|tac|gct|tag|taa|tgg|gtt|cgc|
BspEI BsiWI BstXI.
-------FR2-------------------------------->|...CDR2 stuffer.
61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
Q A P G K G L E W V S | p r |
|caa|gct|cct|ggt|aaa|ggt|ttg|gag|tgg|gtt|tct|taa|cct|agg|tag|
...BstXI AvrII..
.....CDR2 stuffer....................................|---FR3---
91 92 93 94 95 96 97 98 99 100 101 102 103 104 105
T I S R D N S K N T L Y L Q M
|act|atc|tct|aga|gac|aac|tct|aag|aat|act|ctc|tac|ttg|cag|atg|
XbaI
---FR3-----------..> CDR3 Stuffer------------->|
106 107 108 109 110
N S L R A (SEQ ID NO: 53)
|aac|agc|tta|agg|gct|tag taa agg cct taa (SEQ ID NO: 52)
AflII StuI...
|----- FR4 ---(JH4)-----------------------------------------
Y F D Y W G Q G T L V T V S S (SEQ ID NO: 26)
|tat|ttc|gat|tat|tgg|ggt|caa|ggt|acc|ctg|gtc|acc|gtc|tct|agt|... (SEQ ID NO: 25)
KpnI BstEII
TABLE 7
A27:JH1 Human Kappa light chain gene
gaggacc attgggcccc ctccgagact ctcgagcgca
Scab...... EcoO109I XhoI..
ApaI.
acgcaattaa tgtgagttag ctcactcatt aggcacccca ggctttacac tttatgcttc
..-35.. Plac ..-10.
cggctcgtat gttgtgtgga attgtgagcg gataacaatt tcacacagga
aacagctatg accatgatta
cgccaagctt tggagccttt tttttggaga ttttcaac (SEQ ID NO: 54)
pflMI.......
Hind III
M13 III signal sequence (AA seq)--------------------------->
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
M K K L L F A I P L V V P F Y
gtg aag aag ctc cta ttt gct atc ccg ctt gtc gtt ccg ttt tac
--Signal-->FR1------------------------------------------->
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
S H S A Q S V L T Q S P G T L
|agc|cat|agt|gca|caa|tcc|gtc|ctt|act|caa|tct|cct|ggc|act|ctt|
ApaLI...
----- FR1 ------------------------------------->| CDR1------>
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
S L S P G E R A T L S C R A S (SEQ ID NO: 55)
|tcg|cta|agc|ccg|ggt|gaa|cgt|gct|acc|tta|agt|tgc|cgt|gct|tcc| (SEQ ID NO: 54; Cont'd)
EspI..... AflII...
XmaI....
For CDR1:
<1> ADEFGHIKLMNPQRSTVWY 1:1
<2> S(0.2) ADEFGHIKLMNPQRTVWY (0.044 each)
<3> Y(0.2) ADEFGHIKLMNPQRSTVW (0.044 each)
(CDR1 installed as AflII-(SexAI or KasI) cassette.) For the most preferred 11 length codon 51
(XXX) is omitted; for the preferred 12 length this codon is <2>
------- CDR1 --------------------->|--- FR2 --------------->
<1> <2> <2> xxx <3>
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Q - V - - - - L A W Y Q Q K P (SEQ ID NO: 55; Cont'd)
|cag| - |gtt| - | - | - | - |ctt|gct|tgg|tat|caa|cag|aaa|cct| (SEQ ID NO: 54; Cont'd)
SexAI...
For CDR2:
<1> ADEFGHIKLMNPQRSTVWY 1:1
<2> S(0.2) ADEFGHIKLMNPQRTVWY (0.044 each)
<4> A(0.2) DEFGHIKLMNPQRSTVWY (0.044 each)
CDR2 installed as (SexAI or KasI) to (BamHI or RsrII) cassette.)
----- FR2 ------------------------->|------- CDR2 ---------->
<1> <2> <4>
61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
G Q A P R L L I Y - A S - R - (SEQ ID NO: 55; Cont'd)
|ggt|cag|gcg|ccg|cgt|tta|ctt|att|tat| - |gct|tct| - |cgc| - | (SEQ ID NO: 54; Cont'd)
SexAI.... KasI....
CDR2-->|--- FR3 ----------------------------------------------->
<1>
76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
- G I P D R F S G S G S G T D
| - |ggg|atc|ccg|gac|cgt|ttc|tct|ggc|tct|ggt|tca|ggt|act|gac|
BamHI...
RsrII.....
------ FR3 ------------------------------------------------->
91 92 93 94 95 96 97 98 99 100 101 102 103 104 105
F T L T I S R L E P E D F A V (SEQ ID NO: 55' Cont'd)
|ttt|acc|ctt|act|att|tct|aga|ttg|gaa|cct|gaa|gac|ttc|gct|gtt| (SEQ ID NO: 54; Cont'd)
XbaI...
For CDR3 (Length 9):
<1> ADEFGHIKLMNPQRSTVWY 1:1
<3> Y(0.2) ADEFGHIKLMNPQRTVW (0.044 each)
For CDR3 (Length 8): QQ33111P
1 and 3 as defined for Length 9
For CDR3 (Length 10): QQ3211PP1T
1 and 3 as defined for Length 9
2 S(0.2) and 0.044 each of ADEFGHIKLMNPQRTVWY
CDR3 installed as XbaI to (StyI or BsiWI) cassette.
----------->|----CDR3-------------------------->|-----FR4--->
<3> <1> <1> <1> <1>
106 107 108 109 110 111 112 113 114 115 116 117 118 119 120
Y Y C Q Q - - - - P - T F G Q (SEQ ID NO: 55; Cont'd)
|tat|tat|tgc|caa|cag| - | - | - | - |cct| - |act|ttc|ggt|caa| (SEQ ID NO: 54; Cont'd)
BstXI...........
-----FR4------------------->| <------- Ckappa ------------
121 122 123 124 125 126 127 128 129 130 131 132 133 134
G T K V E I K R T V A A P S
|ggt|acc|aag|gtt|gaa|atc|aag| |cgt|acg|gtt|gcc|gct|cct|agt|
StyI.... BsiWI..
135 136 137 138 139 140 141 142 143 144 145 146 147 148 149
V F I F P P S D E Q L K S G T
|gtg|ttt|atc|ttt|cct|cct|tct|gac|gaa|caa|ttg|aag|tca|ggt|act|
MfeI...
150 151 152 153 154 155 156 157 158 159 160 161 162 163 164
A S V V C L L N N F Y P R E A (SEQ ID NO: 55; Cont'd)
|gct|tct|gtc|gta|tgt|ttg|ctc|aac|aat|ttc|tac|cct|cgt|gaa|gct| (SEQ ID NO: 54; Cont'd)
BssSI...
165 166 167 168 169 170 171 172 173 174 175 176 177 178 179
K V Q W K V D N A L Q S G N S
|aaa|gtt|cag|tgg|aaa|gtc|gat|aac|gcg|ttg|cag|tcg|ggt|aac|agt|
MluI....
180 181 182 183 184 185 186 187 188 189 190 191 192 193 194
Q E S V T E Q D S K D S T Y S
|caa|gaa|tcc|gtc|act|gaa|cag|gat|agt|aag|gac|tct|acc|tac|tct|
195 196 197 198 199 200 201 202 203 204 205 206 207 208 209
L S S T L T L S K A D Y E K H
|ttg|tcc|tct|act|ctt|act|tta|tca|aag|gct|gat|tat|gag|aag|cat|
210 211 212 213 214 215 216 217 218 219 220 221 222 223 224
K V Y A C E V T H Q G L S S P (SEQ ID NO: 55; Cont'd)
|aag|gtc|tat|GCt|TGC|gaa|gtt|acc|cac|cag|ggt|ctg|agc|tcc|cct| (SEQ ID NO: 54; Cont'd)
SacI....
225 226 227 228 229 230 231 232 233 234
V T K S F N R G E C (SEQ ID NO: 55; Cont'd)
|gtt|acc|aaa|agt|ttc|aac|cgt|ggt|gaa|tgc|taa|tag ggcgcgcc
DsaI.... AscI....
BssHII
acgcatctctaa gcggccgc aacaggaggag (SEQ ID NO: 54; Cont'd)
NotI....
TABLE 8
2a2:JH2 Human lambda-chain gene
gaggaccatt gggcccc ttactccgtgac
Scab...... EcoO109I
ApaI..
-----------FR1-------------------------------------------->
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
S A Q S A L T Q P A S V S G S P G (SEQ ID NO: 57)
agt|gca|caa|tcc|gct|ctc|act|cag|cct|gct|agc|gtt|tcc|ggg|tca|cct|ggt| (SEQ ID NO: 56)
ApaLI... NheI... BstEII...
SexAI....
For CDR1 (length 14):
<1> = 0.27 T, 0.27 G, 0.027 each of ADEFHIKLMNPQRSVWY, no C
<2> = 0.27 D, 0.27 N, 0.027 each of AEFGHIKLMPQRSTVWY, no C
<3> = 0.36 Y, 0.0355 each of ADEFGHIKLMNPQRSTVW, no C
T G <1> S S <2> V G
------FR1------------------> |-----CDR1---------------------
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Q S I T I S C T G - S S - V G
|caa|agt|atc|act|att|tct|tgt|aca|ggt| - |tct|tct| - |gtt|ggc|
BsrGI..
<1> <3> <2> <3> V S = vg Scheme #1, length = 14
-----CDR1------------->|--------FR2-------------------------
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
- - - - V S W Y Q Q H P G K A (SEQ ID NO: 57; Cont'd)
| - | - | - | - |gtt|tct|tgg|tat|caa|caa|cac|ccg|ggc|aag|gcg| (SEQ ID NO: 56; Cont'd)
XmaI.... KasI.....
AvaI....
A second Vg scheme for CDR1 gives segments of length 11:
T 22 G<2><4>L<4><4><4><3><4><4> where
<4> = equimolar mixture of each of ADEFGHIKLMNPQRSTVWY, no C
<3> = as defined above for the alternative CDR1
For CDR2:
<2> and <4> are the same variegation as for CDR1
<4> <4> <4> <2> R P S
--FR2-----------------> |------CDR2--------------->|-----FR3-
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
P K L M I Y - - - - R P S G V
|ccg|aag|ttg|atg|atc|tac| - | - | - | - |cgt|cct|tct|ggt|gtt|
KasI....
-------FR3----------------------------------------------------
61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
S N R F S G S K S G N T A S L (SEQ ID NO: 57; Cont'd)
|agc|aat|cgt|ttc|tcc|gga|tct|aaa|tcc|ggt|aat|acc|gca|agc|tta| (SEQ ID NO: 56; Cont'd)
BspEI.. HindIII.
BsaBI........(blunt)
-------FR3-------------------------------------------------->|
76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
T I S G L Q A E D E A D Y Y C (SEQ ID NO: 57; Cont'd)
|act|atc|tct|ggt|ctg|cag|gct|gaa|gac|gag|gct|gac|tac|tat|tgt| (SEQ ID NO: 56; Cont'd)
PstI...
CDR3 (Length 11):
<2> and <4> are the same variegation as for CDR1
<5> = 0.36 S, 0.0355 each of ADEFGHIKLMNPQRTVWY no C
CDR3 (Length 10): <5> SY <1> <5> S <5> <1> <4> V
<1> is an equimolar mixture of ADEFGHIKLMNPQRSTVWY, no C
<4> and <5> are as defined for Length 11
<4> <5> <4> <2> <4> S <4> <4> <4> <4> V
-----CDR3---------------------------------->|---FR4---------
91 92 93 94 95 96 97 98 99 100 101 102 103 104 105
- - - - - S - - - - V F G G G
| - | - | - | - | - |tct| - | - | - | - |gtc|ttc|ggc|ggt|ggt|
KpnI...
-------FR4-------------->
106 107 108 109 110 111 112 113 114 115 116 117 118 119 120
T K L T V L G Q P K A A P S V
|acc|aaa|ctt|act|gtc|ctc|ggt|caa|cct|aag|gct|gct|cct|tcc|gtt|
KpnI... HincII..
Bsu36I...
121 122 123 124 125 126 127 128 129 130 131 132 133 134 135
T L F P P S S E E L Q A N K A (SEQ ID NO: 57; Cont'd)
|act|ctc|ttc|cct|cct|agt|tct|gaa|gag|ctt|caa|gct|aac|aag|gct| (SEQ ID NO: 56; Cont'd)
SapI.....
136 137 138 139 140 141 142 143 144 145 146 147 148 149 150
T L V C L I S D F Y P G A V T
|act|ctt|gtt|tgc|ttg|atc|agt|gac|ttt|tat|cct|ggt|gct|gtt|act|
BclI....
151 152 153 154 155 156 157 158 159 160 161 162 163 164 165
V A W K A D S S P V K A G V E
|gtc|gct|tgg|aaa|gcc|gat|tct|tct|cct|gtt|aaa|gct|ggt|gtt|gag|
BsmBI...
166 167 168 169 170 171 172 173 174 175 176 177 178 179 180
T T T P S K Q S N N K Y A A S
|acg|acc|act|cct|tct|aaa|caa|tct|aac|aat|aag|tac|gct|gcg|agc|
BsmBI.... SacI....
181 182 183 184 185 186 187 188 189 190 191 192 193 194 195
S Y L S L T P E Q W K S H K S (SEQ ID NO: 57; Cont'd)
|tct|tat|ctt|tct|ctc|acc|cct|gaa|caa|tgg|aag|tct|cat|aaa|tcc| (SEQ ID NO: 56; Cont'd)
SacI...
196 197 198 199 200 201 202 203 204 205 206 207 208 209 210
Y S C Q V T H E G S T V E K T
|tat|tcc|tgt|caa|gtt|act|cat|gaa|ggt|tct|acc|gtt|gaa|aag|act|
BspHI...
211 212 213 214 215 216 217 218 219
V A P T E C S . .
|gtt|gcc|cct|act|gag|tgt|tct|tag|tga|ggcgcgcc
AscI....
BssHII
aacgatgttc aag gcggccgc aacaggaggag (SEQ ID NO: 56; Cont'd)
NotI.... Scab.......
TABLE 9
Oligonucleotides For Kappa and Lambda Light Chain Variegation
(Ctop25):
5′-gctctggtcaac|tta|agg|gct|gag|g-3′ (SEQ ID NO: 58)
(CtprmA):
5′-gctctggtcaac|tta|agg|gct|gag|gac|acc|gct|gtc|tac|tac|tgc|gcc-3′ (SEQ ID NO: 59)
AflII...
(CBprmB) [RC]:
5′-|tac|ttc|gat|tac|ttg|ggc|caa|ggt|acc|ctg|gtc|acc|tcgctccacc-3′ (SEQ ID NO: 60)
BstEII...
(CBot25) [RC]:
5′-|ggt|acc|ctg|gtc|acc|tcgctccacc-3′ (SEQ ID NO: 61)
Kappa chains:
CDR1 (“1”), CDR2 (“2”), CDR3 (“3”)
CDR1
(Ka1Top610):
5′-ggtctcagttg|cta|agc|ccg|ggt|gaa|cgt|gct|acc|tta|agt|tgc|
cgt|gct|tcc|cag-3′ (SEQ ID NO: 62)
(Ka1STp615):
5′-ggtctcagttg|cta|agc|ccg|ggt|g-3′ (SEQ ID NO: 63)
(Ka1Bot620) [RC]:
5′-ctt|gct|tgg|tat|caa|cag|aaa|cct|ggt|cag|gcg|ccaagtcgtgtc-3′ (SEQ ID NO: 64)
(Ka1SB625) [RC]:
5′-cct|ggt|cag|gcg|ccaagtcgtgtc-3′ (SEQ ID NO: 65)
(Ka1vg600):
5′-gct|acc|tta|agt|tgc|cgt|gct|tcc|cag-
|<1>|gtt|<2>|<2>|<3>|ctt|gct|tgg|tat|caa|cag|aaa|cc-3′ (SEQ ID NO: 66)
(Ka1vg600-12):
5′-gct|acc|tta|agt|tgc|cgt|gct|tcc|cag-
|<1>|gtt|<2>|<2>|<2>|<3>|ctt|gct|tgg|tat|caa|cag|aaa|cc-3′ (SEQ ID NO: 67)
CDR2
(Ka2Tshort657):
5′-cacgagtccta|cct|ggt|cag|gc-3′ (SEQ ID NO: 68)
(Ka2Tlong655):
5′-cacgagtccta|cct|ggt|cag|gcg|ccg|cgt|tta|ctt|att|tat-3′ (SEQ ID NO: 69)
(Ka2Bshort660): [RC]:
5′-|gac|cgt|ttc|tct|ggt|tctcacc-3′ (SEQ ID NO: 70)
(Ka2vg650):
5′-cag|gcg|ccg|cgt|tta|ctt|att|tat|<1>|gct|tct|<2>|-
|cgc|<4>|<1>|ggg|atc|ccg|gac|cgt|ttc|tct|ggt|tctcacc-3′ (SEQ ID NO: 71)
CDR3
(Ka3Tlon672):
5′-gacgagtccttct|aga|ttg|gaa|cct|gaa|gac|ttc|gct|gtt|tat|tat|tgc|caa|c-3′
(SEQ ID NO: 72)
(Ka3BotL682) [RC]:
5′-act|ttc|ggt|caa|ggt|acc|aag|gtt|gaa|atc|aag|cgt|acg|tcacaggtgag-3′
(SEQ ID NO: 73)
(Ka3Bsho694) [RC]:
5′-gaa|atc|aag|cgt|acg|tcacaggtgag-3′ (SEQ ID NO: 74)
(Ka3vg670):
5′-gac|ttc|gct|gtt|-
|tat|tat|tgc|caa|cag|<3>|<1>|<1>|<1>|cct|<1>|act|ttc|ggt|caa|-
|ggt|acc|aag|gtt|g-3′ (SEQ ID NO: 75)
(Ka3vg670-8):
5′-gac|ttc|gct|gtt|-
|tat|tat|tgc|caa|cag|<3>|<3>|<1>|<1>|<1>|cct|ttc|ggt|caa|-
|ggt|acc|aag|gtt|g-3′ (SEQ ID NO: 76)
(Ka3vg670-10):
5′-gac|ttc|gct|gtt|tat|-
|tat|tgc|caa|cag|<3>|<2>|<1>|<1>|cct|cct|<1>|act|ttc|ggt|caa|-
|ggt|acc|aag|gtt|g-3′ (SEQ ID NO: 77)
Lambda Chains:
CDR1 (“1”), CDR2 (“2”), CDR3 (“3”)
CDR1
(Lm1TPri75):
5′-gacgagtcctgg|tca|cct|ggt|-3′ (SEQ ID NO: 78)
(Lm1tlo715):
5′-gacgagtcctgg|tca|cct|ggt|caa|agt|atc|act|att|tct|tgt|aca|ggt-3′ (SEQ ID NO: 79)
(Lm1blo724) [rc]:
5′-gtt|tct|tgg|tat|caa|caa|cac|ccg|ggc|aag|gcg|agatcttcacaggtgag-3′ (SEQ ID NO: 80)
(Lm1bsh737) [rc]:
5′-gc|aag|gcg|agatcttcacaggtgag-3′ (SEQ ID NO: 81)
(Lm1vg710b):
5′-gt|atc|act|att|tct|tgt|aca|ggt|<2>|<4>|ctc|<4>|<4>|<4>|-
|<3>|<4>|<4>|tgg|tat|caa|caa|cac|cc-3′ (SEQ ID NO: 82)
(Lm1vg710):
5′-gt|atc|act|att|tct|tgt|aca|ggt|<1>|tct|tct|<2>|gtt|ggc|-
|<1>|<3>|<2>|<3>|gtt|tct|tgg|tat|caa|caa|cac|cc-3′ (SEQ ID NO: 83)
CDR2
(Lm2TSh757):
5′-gagcagaggac|ccg|ggc|aag|gc-3′ (SEQ ID NO: 84)
(Lm2TLo753):
5′-gagcagaggac|ccg|ggc|aag|gcg|ccg|aag|ttg|atg|atc|tac|-3′ (SEQ ID NO: 85)
(Lm2BLo762) [RC]:
5′-cgt|cct|tct|ggt|gtc|agc|aat|cgt|ttc|tcc|gga|tcacaggtgag-3′ (SEQ ID NO: 86)
(Lm2BSh765) [RC]:
5′-cgt|ttc|tcc|gga|tcacaggtgag-3′ (SEQ ID NO: 87)
(Lm2vg750):
5′-g|ccg|aag|ttg|atg|atc|tac|-
<4>|<4>|<4>|<2>|cgt|cct|tct|ggt|gtc|agc|aat|c-3′ (SEQ ID NO: 88)
CDR3
(Lm3TSh822):
5′-ctg|cag|gct|gaa|gac|gag|gct|gac-3′ (SEQ ID NO: 89)
(Lm3TLo819):
5′-ctg|cag|gct|gaa|gac|gag|gct|gac|tac|tat|tgt|-3′ (SEQ ID NO: 90)
(Lm3BLo825) [RC]:
5′-gtc|ttc|ggc|ggt|ggt|acc|aaa|ctt|act|gtc|ctc|ggt|caa|cct|aag|g-
acacaggtgag-3′ (SEQ ID NO: 91)
(Lm3BSh832) [RC]:
5′-c|ggt|caa|cct|aag|gacacaggtgag-3′ (SEQ ID NO: 92)
(Lm3vg817):
5′-gac|gag|gct|gac|tac|tat|tgt|-
|<4>|<5>|<4>|<2>|<4>|tct|<4>|<4>|<4>|<4>|-
Gtc|ttc|ggc|ggt|ggt|acc|aaa|ctt|ac-3′ (SEQ ID NO: 93)
(Lm3vg817-10):
5′-gac|gag|gct|gac|tac|tat|tgt|-
|<5>|agc|tat|<1>|<5>|tct|<5>|<1>|<4>|gtc|ttc|ggc|ggt|ggt|-
|acc|aaa|ctt|ac-3′ (SEQ ID NO: 94)
TABLE 10
A27:JH1 Kappa light chain gene with stuffers in place of CDRs
Each stuffer contains at least one stop codon and a
restriction site that will be unique within the diversity vector.
gaggacc attgggcccc ctccgagact ctcgagcgca
Scab.....EcoO109I
ApaI.
XhoI..
acgcaattaa tgtgagttag ctcactcatt aggcacccca ggctttacac tttatgcttc
..-35.. Plac ..-10.
cggctcgtat gttgtgtgga attgtgagcg gataacaatt tcacacagga aacagctatgac
catgatta cgccaagctt tggagccttt tttttggaga ttttcaac (SEQ ID NO: 95)
PflMI.......
Hind3.
M13 III signal sequence (AA seq)--------------------------->
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
M K K L L F A I P L V V P F Y
gtg aag aag ctc cta ttt gct atc ccg ctt gtc gtt ccg ttt tac
--Signal--> FR1------------------------------------------->
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
S H S A Q S V L T Q S P G T L
|agc|cat|agt|gca|caa|tcc|gtc|ctt|act|caa|tct|cct|ggc|act|ctt|
ApaLI...
----- FR1 --------------------------------->|-------Stuffer->
31 32 33 34 35 36 37 38 39 40 41 42 43
S L S P G E R A T L S | | (SEQ ID NO: 96)
|tcg|cta|agc|ccg|ggt|gaa|cgt|gct|acc|tta|agt|tag|taa|gct|ccc| (SEQ ID NO: 95; Cont'd)
EspI..... AflII...
XmaI....
- Stuffer for CDR1--> FR2 ------- FR2 ------>|-----------Stuffer for CDR2
59 60 61 62 63 64 65 66
K P G Q A P R
|agg|cct|ctt|tga|tct|g|aaa|cct|ggt|cag|gcg|ccg|cgt|taa|tga|aagcgctaatggccaacagtg
StuI... SexAI... KasI.... AfeI.. MscI..
Stuffer-->|--- FR3 ----------------------------------------------->
76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
T G I P D R F S G S G S G T D (SEQ ID NO: 96; Cont'd)
|act|ggg|atc|ccg|gac|cgt|ttc|tct|ggc|tct|ggt|tca|ggt|act|gac| (SEQ ID NO: 95; Cont'd)
BamHI...
RsrII.....
------ FR3 ----->----------------STUFFER for CDR3------------------>
91 92 93 94 95 96 97
F T L T I S R | |
|ttt|acc|ctt|act|att|tct|aga|taa|tga| gttaac tag acc tacgta acc tag
XbaI... HpaI.. SnaBI.
-----------------CDR3 stuffer------------------>|-----FR4--->
118 119 120
F G Q
|ttc|ggt|caa|
-----FR4------------------->| <------- Ckappa ------------
121 122 123 124 125 126 127 128 129 130 131 132 133 134
G T K V E I K R T V A A P S (SEQ ID NO: 96; Cont'd)
|ggt|acc|aag|gtt|gaa|atc|aag| |cgt|acg|gtt|gcc|gct|cct|agt|
StyI.... BsiWI.. (SEQ ID NO: 95; Cont'd)
135 136 137 138 139 140 141 142 143 144 145 146 147 148 149
V F I F P P S D E Q L K S G T (SEQ ID NO: 95; Cont'd)
|gtg|ttt|atc|ttt|cct|cct|tct|gac|gaa|caa|ttg|aag|tca|ggt|act|
MfeI...
acgcatctctaa gcggccgc aacaggaggag
NotI....
EagI..
TABLE 11
2a2:JH2 Human lambda-chain gene with stuffers in place of CDRs
gaggaccatt gggcccc ttactccgtgac
Scab...... EcoO109I
ApaI..
-----------FR1-------------------------------------------->
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
S A Q S A L T Q P A S V S G S P G
agt|gca|caa|tcc|gct|ctc|act|cag|cct|gct|agc|gtt|tcc|ggg|tca|cct|ggt|
ApaLI... NheI... BstEII...
SexAI....
------FR1------------------> |-----stuffer for CDR1---------
16 17 18 19 20 21 22 23
Q S I T I S C T (SEQ ID NO: 98)
|caa|agt|atc|act|att|tct|tgt|aca|tct tag tga ctc (SEQ ID NO: 97)
BsrGI..
-----Stuffer--------------------------->-------FR2---------->
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
R S | | P | H P G K A
aga tct taa tga ccg tag cac|ccg|ggc|aag|gcg|
BglII XmaI.... KasI.....
AvaI....
--|-------------Stuffer for CDR2 ------------------------------------->
P
|ccg|taa|tga|atc tcg tac g ct|ggt|gtt|
KasI.... BsiWI...
-------FR3----------------------------------------------------
61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
S N R F S G S K S G N T A S L (SEQ ID NO: 98; Cont'd)
|agc|aat|cgt|ttc|tcc|gga|tct|aaa|tcc|ggt|aat|acc|gca|agc|tta| (SEQ ID NO: 97; Cont'd)
BspEI.. HindIII.
BsaBI........(blunt)
-------FR3------------->|--Stuffer for CDR3----------------->|
76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
T I S G L Q
|act|atc|tct|ggt|ctg|cag|gtt ctg tag ttc caattg ctt tag tga ccc
PstI... MfeI..
-----Stuffer------------------------------->|---FR4---------
103 104 105
G G G
|ggc|ggt|ggt|
KpnI...
-------FR4-------------->
106 107 108 109 110 111 112 113 114 115 116 117 118 119 120
T K L T V L G Q P K A A P S V (SEQ ID NO: 98; Cont'd)
|acc|aaa|ctt|act|gtc|ctc|ggt|caa|cct|aag|gct|gct|cct|tcc|gtt| (SEQ ID NO: 97; Cont'd)
KpnI... HincII..
Bsu36I...
121 122 123 124 125 126 127 128 129 130 131 132 133 134 135
T L F P P S S E E L Q A N K A
|act|ctc|ttc|cct|cct|agt|tct|gaa|gag|ctt|caa|gct|aac|aag|gct|
SapI.....
136 137 138 139 140 141 142 143 144 145 146 147 148 149 150
T L V C L I S D F Y P G A V T (SEQ ID NO: 98; Cont'd)
|act|ctt|gtt|tgc|ttg|atc|agt|gac|ttt|tat|cct|ggt|gct|gtt|act| (SEQ ID NO: 97; Cont'd)
BclI....
The invention relates to generation of useful diversity in synthetic antibody (Ab) gene, especially to Ab genes having frameworks derived from human Abs.
BACKGROUND OF THE INVENTION
Antibodies are highly useful molecules because of their ability to bind almost any substance with high specificity and affinity and their ability to remain in circulation in blood for prolonged periods as therapeutic or diagnostic agents. For treatment of humans, Abs derived from human Abs are much preferred to avoid immune response to the Ab. For example, murine Abs very often cause Human Anti Mouse Antibodies (HAMA) which at a minimum prevent the therapeutic effects of the murine Ab. For many medical applications, monoclonal Abs are preferred. Nowadays the preferred method of obtaining a human Ab having a particular binding specificity is to select the Ab from a library of human-derived Abs displayed on a genetic package, such as filamentous phage.
Libraries of phage-displayed Fabs and scFvs have been produced in several ways. One method is to capture the diversity of donors, either naive or immunized. Another way is to generate libraries having synthetic diversity. The present invention relates to methods of generating useful diversity in human Ab scaffolds.
As is well known, typical Abs consist of two heavy chains (HC) and two light chains (LC). There are several types of HCs: gamma, mu, epsilon, delta, etc. Each type has an N-terminal V domain followed by three or more constant domains. The LCs comprise an N-terminal V domain followed by a constant domain. LCs come in two types: kappa and lambda.
Within each V domain (LC or HC) there are seven canonical regions, named FR1, CDR1, FR2, CDR2, FR3, CDR3, and FR4, where “FR” stands for “Framework Region” and “CDR” stands for “Complementarity Determining Region”. For LC and HC, the FR and CDR GLGs have been selected over time to be secretable, stable, non-antigenic and these properties should be preserved as much as possible. Actual Ab genes contain mutations in the FR regions and some of these mutations contribute to binding, but such useful FR mutations are rare and are not necessary to obtain high-affinity binding. Thus, the present invention will concentrate diversity in the CDR regions.
In LC, FR1 up to FR3 and part of CDR3 comes from a genomic collection of genes called “V-genes”. The remainder of CDR3 and FR4 comes from a genomic collection of genes called “J-genes”. The joining may involve a certain degree of mutation, allowing diversity in CDR3 that is not present in the genomic sequences. After the LC gene is formed, somatic mutations can give rise to mature, rearranged LC genes that have higher affinity for an antigen (Ag) than does any LC encoded by genomic sequences. A large fraction of somatic mutations occur in CDRs.
The HC V region is more complicated. A V gene is joined to a J gene with the possible inclusion of a D segment. About half of HC Abs sequences contain a recognizable D segment in CDR3. The joining is achieved with an amazing degree of molecular sloppiness. Roughly, the end of the V gene may have zero to several bases deleted or changed, the D segment may have zero to many bases removed or changed at either end, a number of random bases may be inserted between V and D or between D and J, and the 5′ end of J may be edited to remove or change several bases. Withal, it is amazing that human heavy chains work, but they do. The upshot is that the CDR3 is highly diverse both in encoded amino-acid sequences and in length. In designing synthetic libraries, there is the temptation to just throw in a high degree of synthetic diversity and let the phage sort it out. Nevertheless, D regions serve a function. They cause the Ab repertoire to be rich in sequences that a) allow Abs to fold correctly, and b) are conducive to binding to biological molecules, i.e. antigens.
One purpose of the present invention is to show how a manageable collection of diversified sequences can confer these advantages on synthetic Ab libraries. Another purpose of the present invention is to disclose analysis of known mature Ab sequences that lead to improved designs for diversity in the CDR1 and CDR2 of HC and the three CDRs of lambda and kappa chains.
BRIEF STATEMENT OF THE INVENTION
The invention is directed to methods of preparing synthetically diverse populations of Ab genes suitable for display on genetic packages (such as phage or phagemids) or for other regimens that allow selection of specific binding. Said populations concentrate the diversity into regions of the Ab that are likely to be involved in determining affinity and specificity of the Ab for particular targets. In particular, a collection of actual Ab genes has been analyzed and the sites of actual diversity have been identified. In addition, structural considerations were used to determine whether the diversity is likely to greatly influence the binding activity of the Ab. Schemes of variegation are presented that encode populations in which the majority of members will fold correctly and in which there is likely to be a plurality of members that will bind to any given Ag. Specifically, a plan of variegation is presented for each CDR of the human heavy chain, kappa light chain, and lambda light chain. The variegated CDRs are presented in synthetic HC and LC frameworks.
In one embodiment, the invention involves variegation of human HC variable domains based on a synthetic 3-23 domain joined to a JH4 segment in which the variability in CDR1 and CDR2 comprises sequence variation of segments of fixed length while in CDR3 there are several components such that the population has lengths roughly corresponding to lengths seen in human Abs and having embedded D segments in a portion of the longer segments. In the light chains, the kappa chain is built in an A27 framework and a JK1 while lambda is built in a 2a2 framework with an L2 J region.
EXAMPLES
Choice of a Heavy-Chain V Domain
The HC Germ-Line Gene (GLG) 3-23 (also known as VP-47) accounts for about 12% of all human Abs and it suitable for the framework of the library. Certain types of Ags elicit Abs having particular types of VH genes; in some cases, the types elicited are otherwise rarely found. This apparent Ag/Ab type specificity has been ascribed to possible structural differences between the various families of V genes. It is also possible that the selection has to do with the availability of particular AA types in the GLG CDRs. Suppose, for example, that the sequence YR at positions 4 and 5 of CDR2 is particularly effective in binding a particular type of Ag. Only the V gene 6-1 provides this combination. Most Abs specific for the Ag will come from GLG 6-1. If Y4-R5 were provided in other frameworks, then other frameworks are likely to be as effective in binding the Ag.
Analysis of HC CDR1 and CDR2:
In CDR1 and CDR2 of HCs, the GLGs provide limited length diversity as shown in Table 15P. Note that GLGs provide CDR1s only of the lengths 5, 6, and 7. Mutations during the maturation of the V-domain gene leads to CDR1s having lengths as short as 2 and as long as 16. Nevertheless, length 5 predominates. The preferred length for the present invention is 5 AAs in CDR1 with a possible supplemental components having lengths of 7 and 14.
GLGs provide CDR2s only of the lengths 15-19, but mutations during maturation result in CDR2s of length from 16 to 28 AAs. The lengths 16 and 17 predominate in mature Ab genes and length 17 is the most preferred length for the present invention. Possible supplementary components of length 16 and 19 may also be incorporated.
Table 20P shows the AA sequences of human GLG CDR1s and CDR2. Table 21P shows the frequency of each amino-acid type at each position in the GLGs. The GLGs as shown in Table 20P have been aligned by inserting gaps near the middle of the segment so that the ends align.
The 1398 mature V-domain genes used in studying D segments (vide infra) were scanned for examples in which CDR1 and CDR2 could be readily identified. Of this sample 1095 had identifiable CDR1, 2, and 3. The CDRs were identified by finding subsequences of the GLGs in an open reading frame. There are 51 human HC V genes. At the end of FR1, there are 20 different 9-mers. At the start of FR2, there are 11 different 9-mers. At the end of FR2 there are 14 different 9-mers. At the start of FR3, there are 14 different 9-mers. At the end of FR3, there are 13 different 9-mers. At the start of JH, there are three different 9-mers. These motifs were compared to the reported gene in frame and a match, at the site of maximum similarity, of seven out of nine was deemed acceptable. Only when all three CDRs were identified were any of the CDRs included in the analysis. In addition, the type of the gene was determined by comparing the framework regions to the GLG frameworks; the results are shown in Table 22P.
Design of HC CDR1 and CDR2 Diversity.
Diversity in CDR1 and CDR2 was designed from: a) the diversity of the GLGs, b) observed diversity in mature HC genes, and c) structural considerations. In CDR1, examination of a 3D model of a humanized Ab showed that the side groups of residues 1, 3, and 5 were directed toward the combining pocket. Consequently, we allow each of these positions to be any amino-acid type except cysteine. Cysteine can form disulfide bonds. Disulfide bonds are an important component of the canonical Ig fold. Having free thiol groups could interfere with proper folding of the HC and could lead to problems in production or manipulation of selected Abs. Thus, I exclude cysteine from the menu. The side groups of residue 2 is directed away from the combining pocket. Although this position shows substantial diversity, both in GLG and mature genes, I fixed this residue as Tyr because it occurs in 681/820 mature genes (Table 21P). Position 4 is fixed as Met. There is some diversity here, but almost all mature genes have uncharged hydrophobic AA types: M, W, I, V, etc. (Table 21P). Inspection of a 3D model shows that the side group of residue 4 is packed into the innards of the HC. Since we are using a single framework (3-23), we retain the Met that 3-23 has because it is likely to fit very well into the framework of 3-23. Thus, the most preferred CDR1 library consists of XYXMX (SEQ ID NO:109) where X can be any one of [A,D,E,F,G,H,I,K,L,M,N,P,Q,R,S,T,V,W,Y] (no C). The DNA that encodes this is preferably synthesized using trinucleotide building blocks so that each AA type is present in essentially equimolar amounts. Specifically, the X codons are synthesized using a mixture of the codons [gct, gat, gag, ttt, ggt, cat, att, aag, atg, aat, cct, cag, cgt, tct, act, gtt, tgg, tat]. This diversity is shown in the context of a synthetic 3-23 gene in Table 18P. The diversity oligonucleotide (ON) is synthesized from BspEI to BstXI and can be incorporated either by PCR synthesis using overlapping ONs or introduced by ligation of BspEI/BstXI-cut fragments. Table 22P shows ONs that embody the specified variegation. PCR using ON-R1V1vg, ON-R1top, and ON-R1bot gives a dsDNA product of 73 base pairs, cleavage with BspEI and BstXI trims 11 and 13 bases from the ends and provides cohesive ends that can be ligated to similarly cut vector having the synthetic 3-23 domain shown in Table 18P. Replacement of ON-R1V1vg with either ONR1V2vg or ONR1V3vg allows synthesis of the two alternative diversity patterns given below.
Alternatively, one can include CDR1s of length 7 and/or 14. For length 7, a preferred diversity is (S/T) 1 (S/G/x) 2 (S/G/x) 3 Y 4 Y 5 W 6 (S/G/x) 7 (SEQ ID NO:107); where (S/T) indicates an equimolar mixture of Ser and Thr codons; (S/G/x) indicates a mixture of 0.2025 S, 0.2025 G, and 0.035 for each of A, D, E, F, H, I, K, L, M, N, P, Q, R, T, V, W, Y. Other proportions could be used. The design gives a predominance of Ser and Gly at positions 2, 3, and 7, as occurs in mature HC genes. For length 14, a preferred pattern of diversity is VSGGSISXXXYYWX (SEQ ID NO:1) where X can be any AA type except Cys. This pattern appears to arise by insertions into the GLG sequences (SGGYYWS; SEQ ID NO:110, (4-30.1 and 4-31) and similar sequences. There is a preference for a hydrophobic residue at position 1 (V or C) with a second insertion of SISXXX (SEQ ID NO:111) between GG and YY. Diversity ONs having CDR1s of length 7 or 14 are synthesized from BspEI to BstXI and introduced into the library in appropriate proportions to the CDR1 of length 5. The components should be incorporated in approximately the ratios in which they are observed in antibodies selected without reference to the length of the CDRs. For example, the sample of 1095 HC genes examined here have them in the ratios (L=5:L=7:L=14::820:175:23::0.80:0.17:0.02).
CDR2
Diversity at CDR2 was designed with the same considerations: GLG sequences, mature sequences and 3D structure. A preferred length for CDR2 is 17, as shown in Table 18P. Examination of a 3D model suggests that the residues shown as varied in Table 18P are the most likely to interact directly with Ag. Thus a preferred pattern of variegation is: <2>I<2><3>SGG<1>T<1>YADSVKG (SEQ ID NO:2), where <2> indicates a mixture of YRWVGS, <3> is a mixture of P and S, and <1> is a mixture of ADEFGHIKLMNPQRSTVWY (no C). ON-R2V1vg shown in Table 22P embodies this diversity pattern. PCR with ON-R2V1vg, ON-R2top, and ONR2bot gives a dsDNA product of 122 base pairs. Cleavage with BstXI and XbaI removes about 10 bases from each end and produces cohesive ends that can be ligated to similarly cut vector that contains the 3-23 gene shown in Table 18P.
An alternative pattern would include the variability seen in mature CDR2s as shown in Table 21P: <1>I<4><1><1>G<5><1><1><1>YADSVKG (SEQ ID NO:3), where <4> indicates a mixture of DINSWY, and <5> indicates a mixture of SGDN. This diversity pattern is embodied in ON-R2V2vg shown in Table 22P. For either case, the variegated ONs would be synthesized so that fragments of dsDNA containing the BstXI and XbaI site can be generated by PCR. ON-R2V2vg embodies this diversity pattern.
Alternatively, one can allow shorter or longer CDR2s. Table 22P shows ON-R2V3vg which embodies a CDR2 of length 16 and ON-R2V4vg which embodies a CDR2 of length 19. Table 22P shows ON-R2V3vg is PCR amplified with ON-R2top and ON-R2bo3 while ON-R2V4vg is amplified with ON-R2top and ONR2-bo4.
Analysis of HC CDR3:
CDR3s of HC vary in length and in sequence. About half of human HCs consist of the components: V::nz::D::ny::JHn where V is a V gene, nz is a series of bases (mean 12) that are essentially random, D is a D segment, often with heavy editing at both ends, ny is a series of bases (mean 6) that are essentially random, and JH is one of the six JH segments, often with heavy editing at the 5′ end. In HCs that have no identifiable D segment, the structure is V::nz::JHn where JH is usually edited at the 5′ end. Our goal is to mimic the diversity of CDR3, but not to duplicate it (which would be impossible). The D segments appear to provide spacer segments that allow folding of the IgG. The greatest diversity is at the junctions of V with D and of D with JH. The planned CDR3 library will consist of several components. Some of these will have only sequence diversity. Others will have sequence diversity with embedded D segments to extend the length while incorporating sequences known to allow Igs to fold.
There are many papers on D segments. Corbett et al. (1997) show which D segments are used in which reading frames. My analysis basically confirms their findings. They did not report, however, the level of editing of each D segment and this information is needed for design of an effective library.
The following diversified sequences would be incorporated in the indicated proportions: “1” stands for 0.095 [G, Y] and 0.048 [A, D, E, F, H, I, K, L, M, N, P, Q, R, S, T, V, W]; double dose of Gly and Tyr plus all other AAs except Cys at equal level.
The amount of each component is assigned from the tabulation of lengths of the collection of natural VH genes. Component 1 represents all the genes having length 0 to 8 (counting from the YYCAR (SEQ ID NO:112) motif to the WG dipeptide motif). Component 2 corresponds the all the chains having length 9 or 10. Component 3 corresponds to the genes having length 11 or 12 plus half the genes having length 13. Component 4 corresponds to those having length 14 plus half those having length 13. Component 5 corresponds to the genes having length 15 and half of those having length 16. Component 6 corresponds to genes of length 17 plus half of those with length 16. Component 7 corresponds to those with length 18. Component 8 corresponds to those having length 19 and greater.
The composition has been adjusted because the first component is not complex enough to justify including it as 10% of the library. If the final library were to be 1. E 9, then 1. E 8 sequences would come from component 1, but it has only 2.6 E 5 CDR3 sequences so that each one would occur in ˜385 CDR1/2 contexts. I think it better to have this short CDR3 diversity occur in ˜77 CDR1/2 contexts and have the other, longer CDR3s occur more often.
The ONs would be PCR amplified with the primers CtprmA and CBprmB, cut with AflII and BstEII, and ligated to similarly cut V3-23.
This set of components was designed after studying the sequences of 1383 human HC sequences as described below. The proposed components are meant to fulfill the goals:
1) approximately the same distribution of lengths as seen in real Ab genes,
2) high level of sequence diversity at places having high diversity in real Ab genes, and
3) incorporation of constant sequences often seen in real Ab genes.
Note that the design uses JH4 (YFDYWGQGTLVTVSS; SEQ ID NO:20), which is found more often, instead of JH3 (AFDIWGQGTMVTVSS; SEQ ID NO:21). This involves three changes in AA sequence, shown as double underscored bold. An alternative JH segment is shown.
How the Library Components were Designed:
The processing of sequence data was accomplished by a series of custom-written FORTRAN programs, each of which carries out a fairly simple transformation on the data and writes its results as one or more ASCII files. The next program then uses these files as input.
A set of 2049 human heavy-chain genes was selected from the version of GenBank that was available at Dyax on the Sun server on 26 Jun. 2000. A program named “Reformat” changed the format of the files to that of GenBank from the GCG format, creating one file per sequence. A second program named “IDENT_CDR3” processed each of these files as follows. Files were tested for duplication by previous entries, duplicates were discarded. Each reading frame was tested. Most entries had a single open reading frame (ORF), none had two, and some had none. Entries with multiple stops in every reading frame were discarded because this indicates poor quality of sequencing. The sequence was written in triplets in the ORF or in all three reading frames if no ORF was found. The sequence was examined for three motifs: a) AA sequence=“YYCxx”, b) DNA sequence=“tgg ggc (=WG)”, and DNA sequence=“g gtc acc (=BstEII)”. FR3 ends with a conserved motif YYCAR or a close approximation. When writing the DNA sequence, IDENT_CDR3 prints the DNA mostly in lower case. Cysteine codons (TGT or TGC) are printed in uppercase. When the motif “tay tay tgy” is found, IDENT_CDR3 starts a new line that contains “< > xxx xxx xxx xxx xxx” where the xxx's stand for the actual five codons that encode YYC and the next two codons (most often AR or AK). The following DNA is printed in triplets on new lines. A typical processed entry appears as in Table 1P.
Following the YYC motif, IDENT_CDR3 seeks the sequence “TGG GGC” (the “WG” motif) in the correct reading frame, 5/6 bases is counted as a hit. If found, the DNA is made uppercase. Following the WG motif (if found) or the YYC motif (if no WG found), IDENT_CDR3 seeks the sequence “G GTC ACC” (the BstEII site) in the correct reading frame, 6/7 bases is counted as a hit. If found, the bases are made upper case. If either the WG or BstEII motif are not found, a note is inserted saying that the feature was not identified. The output of IDENT_CDR3 was processed by hand. In many cases, the lacking YYC motif could be seen as a closely related sequence, such as YFC, FYC, or HYC. When this was supported by an appropriately positioned WG and/or BstEII site, the effective YYC site was marked and the sequence retained for further analysis. If the YYC motif could not be identified or if the WG or BstEII sites could not be found, the entry was discarded. For example, the entry in Table 2P had no YYC motif.
The double underscored sequence encodes YHCAS and is taken as the end of FR3. Note that there is a WG motif at bases 403-408 (bold upper case) and a BstEII site at bases 420-426 (bold upper case). Using WordPerfect, I first made all occurrences of TGC and TGT bold. I then searched for “YYC not found”. If I could see the “YYC”-related sequence quickly, I edited the entry so that a YYC was shown. The entry above would be converted to that shown in Table 3P. This processing reduced the list of entries to 1669.
A third program named “New_DJ” processed the output of IDENT_CDR3. The end of the YYC motif (including the two codon following TGy=Cys) was taken as the end of FR3. The WG motif was taken as the end of the region that might contain a D segment. If WG was not observed and BstEII was, the WG site was assumed to be 17 bases upstream of BstEII. Using the WG motif for alignment, the sequence was compared to each human GLG JH segment (1-6) and the best one identified (New_DJ always assigned a JH segment). Starting from the WG motif of JH and moving toward the 5′ end, the program looked for the first codon having more than one mismatch. The region from YYCxx (SEQ ID NO:113) to this codon was taken as the region that might contain a D segment.
The region that might contain a D segment was tested against all the germ-line genes (GLGs) of human D segments and the best D segment was identified. The scoring involved matching the observed sequence to the GLG sequence in all possible ways. Starting at each base, multiply by 4 for a match and divide by 4 for a mismatch. Record the maximum value obtained for this function. The match was deemed significant if 7/7, 8/9, 9/11, etc. or more bases matched. Of the 1383 sequences examined for D segments,
“Assign_D” processes the output of New_DJ. For each sequence that had a significant match with a GLG D segment, a file was written containing the putative D segment, the DJ segment, the identified GLG D segment, the identified JH segment, the phase of the match between observed and GLG gene. For example, “D1 — 1-01_Phz0_hsa239356.txt” is a file recording the match of entry hsa239356 with D1-01 in phase 0. The file contains the information shown in Table 4P. The final DV of the second sequence immediately precedes the WG in JH and is ascribed to JH3. Other files that begin D1 — 1-01_Phz0 match the same GLG D segment and these can be aligned by sliding amino-acid sequences across each other.
Table 5P shows how sequence hs6d4xb7 is first assigned to JH4 and then to D3-22. Note that the DNA sequence TGGGGG is aligned to the TGG GGC of the GLG and that the sequence is truncated on the left to fit. The program finds that JH4 has the best fit (5 misses and 18 correct out of 23). From the right, the program sees that DYWGQ (underscored) come from JH, but then the match drops off and the rest of the sequence on the left comes either from added bases or a D segment.
The lower part of Table 5P shows that the possible D segment matches D#13 (3-23) is a very good match.
Of 1383 files accepted by Assign_D, 757 had identifiable D segments. The tally of JHs in Table 6P shows that JH4 is by far the most common.
JH4 is most common, JH6 next, followed by JH3 and JH5. JH1 and JH2 are seldom used. Table 7P shows the length distributions of each JH class; they do not differ significantly class to class. These lengths count only amino-acids that are not accounted for by JH and so are shorter that the lengths given in Table 8P which cover from YYCAR (SEQ ID NO:112) to WG.
Table 8P contains the distribution of lengths for a) all the CDR3 segments, b) the CDR3 segments with identified D segments, and c) the CDR3 segments having no identifiable D segment. The CDR3s with identifiable D segments (13.9) are systematically longer than are those that lack D segments (11.2).
The identified CDR3 segments can be collated in two ways: aligned to the left (looking for a pattern following YYCAR; SEQ ID NO:112) or aligned to the right (looking for a pattern preceding WG). Table 9P shows the collation of left-aligned sequences while Table 10P shows the right-aligned sequences. For each position, I have tabulated the frequency of each AA type (A-M in the first block and N-Y in the second). The column headed “#” shows how many sequences have some AA at that position. The final column shows all of the AA types seen at that position with the most frequent first and the least frequent last. In the left-aligned sequences, we see that Gly is highly over-represented in the first seven positions while Tyr is over-represented at positions 8-16.
In Table 11P, I have tabulated the AA frequencies for the sequences having between 7 and 15 AAs between YYCAR (SEQ ID NO:112) and WG. The last four positions can be viewed as coming from JH and so would be given lower levels of diversity than would earlier positions. From these tabulations, I conclude that most AA types are allowed at all the positions, but there is a fairly strong tendency to have Gly at the early positions and to end in Asp-Tyr (DY). We could use these tendencies in designing a pattern of variegation. I would not exclude any AA except Cys, but I might increase the frequency of Gly in the first several positions and Tyr in the last few.
There are 80 sequences (5.8%) having a pair of cysteines in CDR3. It is more surprising that 53 (3.8%) have a single Cys in CDR3.
MS-DOS was used to make a list of the files written by Assign_D. “Filter” converts the output of MS-DOS Dir into a form that can be read into WordPerfect and sorted to bring a files
belonging to the same D region together.
“Filter2” collects the sequences and produces a draft table of sequences, grouped by the D-segment used, and written so that the sequences can be aligned. The output of Filter2 were edited by hand. For each group, the translation of the GLG was inserted and the collection of observed sequences was aligned to the conserved part of the GLG. “Filter3” collated the aligned sequences. Table 12P shows an example of an alignment and the tabulation of AA types. The entries are as follows: “Entry” is the name used in the data base, “Seq1” is the sequence from the YYCAR (SEQ ID NO:112) motif to the first amino acid not assigned to JH and “L1” is the length of the segment. The segments are shown aligned to the identified D segment. Seq2 is the sequence from the YYCAR (SEQ ID NO:112) motif to the WG motif (i.e. including part of JH) and “L2” is the length of that sequence. JH is the identified JH segment for this sequence. “P” is the phase of the match. For positive values of P, P bases are found in the observed sequence that do not correspond to any from the GLG, i.e. the observed sequence has had that many bases inserted. For negative values of P, there are |P| bases in the GLG sequence for which there are no corresponding bases in the observed sequence. “Score” is approximately 1/(probability of accidental match). This is calculated by looking at all possible alignments. For each alignment, the score is first set to 1.0. Base by base, the score is multiplied by 4. if the bases match and divided by 4. if they do not. This is done for all starting points and ending points and the maximum value is recorded.
Table 13P is a summary of how often each D segment was identified and in which reading frame. I have not been consistent with Corbett et al. in assigning the phases of the GLG D segments. The MRC Web page that I took the GLGs from did not have D segments D1-14, D4-11, D5-18, or D6-25. None of these contribute to any great extent and this omission is unlikely to have any serious effect on the conclusions. The column headed “%” contains the percentage of the sequences examined here. The column headed “C %” contains the percentage reported by Corbett et al. I assume that the data used in Corbett et al. is mostly included in my collection. Nevertheless, the observed frequencies differ in detail. For example, my compilation shows that 10.7% of the collection contains a D segment encoding two cysteines while they have only 4.16% in this category. In D3 phase “0”, I see 19.4% of the collection while they report 11.8%.
The most common actual D segments were further analyzed. The GLGs are heavily edited at either end. The aligned sequences were aligned. For each D-segment having more than seven examples, Filter3 produced a table of the frequency of each amino-acid type at each position. From these tabulations, library components shown in Table 17P were designed. At each position where at least half the examples have an amino acid, I entered either the dominant AA type or “x”. An AA type was “dominant” if it occurred more than 50% of the time. L is the length and f is the number of sequences observed that have related sequences.
Table 14P shows possible library components for a library of CDR3's. “L” is the length of the insert and “f” is the frequency of the motif in the assayed collection. Table 17P shows vgDNA that embodies each of the components shown in Table 14P. In Table 17P, the oligonucleotides (ON) Ctop25, CtprmA, CBprmB, and CBot25 allow PCR amplification of each of the variegated ONs (vgDNA): C1t08, C2t10, C3t12, C4t14, C5t15, C6t17, C7t18, and c8t19. After amplification, the dsDNA can be cleaved with AflII and BstEII (or KpnI) and ligated to similarly cleaved vector that contains the remainder of the 3-23 synthetic domain. Preferably, this vector already contains diversity in CDR1 and CDR2 as disclosed herein. Preferably, the recipient vector contains a stuffer in place of CDR3 so that there will be no parental sequence that would then occur in the resulting library. Table 50P shows a version of the V3-23 gene segment with each CDR replaced by a short segment that contains both stop codons and restriction sites that will allow specific cleavage of any vector that does not have the stuffer removed. The stuffer can either be short and contain a restriction enzyme site that will not occur in the finish library, allowing removal of vectors that are not cleaved by both AflII and BstEII (or KpnI) and religated. Alternatively, the stuffer could be 200-400 bases long so that uncleaved or once cleaved vector can be readily separated from doubly cleaved vector.
In the vgDNA for HC CDR3, <1> means a mixture comprising 0.27 Y, 0.27 G, and 0.027 of each of the amino-acid codons {A, D, E, F, H, I, K, L, M, N, P, Q, R, S, T, V, W}; <2> means an equimolar mixture of K and R; and <3> means an equimolar mixture of S and G.
Analysis of Human Kappa Light Chains and Preferred Variegation Scheme:
A collection of 285 human kappa chains was assembled from the public data base. Table 27 shows the names of the entries used. The GLG sequences of nine bases at each end of the framework regions were used to find the FR/CDR junctions. Only in cases where all six junctions could be found was the sequences included. Table 25P shows the distribution of lengths in CDRs in human kappas. CDR1s with lengths of 11, 12, 13, 16, and 17 were observed with 11 being predominant and 12 well represented. CDR2 exhibits only length 7. CDR3 exhibits lengths of 1, 4, 6, 7, 8, 9, 10, 11, 12, 13, and 19. Essentially all examples are in the 8, 9, or 10 length groups.
Table 26P shows the distribution of V and J genes seen in the sample. A27 is the most common V and JK1 is the most common J. Thus, a suitable synthetic kappa gene comprises A27 joined to JK1. Table 30P shows a suitable synthetic kappa chain gene, including a PlacZ promoter, ribosome-binding site, and signal sequence (M13 III signal). The DNA sequence encodes the GLG amino-acid sequence, but does not comprise the GLG DNA sequence. Restriction sites are designed to fall within each framework region so that diversity can be cloned into the CDRs. XmaI and Espl are in FR1, SexAI is in FR2, RsrII is in FR3, and KpnI (or Acc65I) are in FR4. Additional sites are provided in the constant kappa chain to facilitate construction of the gene.
Table 30P also shows a suitable scheme of variegation for kappa. In CDR1, a preferred length is 11 codons. The A27 GLG has a CDR1 of 12 codons, but the sample of mature kappa chains has length 11 predominating. One could also introduce a component of kappas having length 12 in CDR1 by introducing codon 52 as <2> (i.e. a Ser-biased mixture). CDR2 of kappa is always 7 codons. Table 31P shows a tally of 285 CDR2s and a preferred variegation scheme for CDR2. The predominant length of CDR3 in kappa chains is 9 codons. Table 32P shows a tally of 166 CDR3s from human kappas and a preferred variegation scheme (which is also shown in Table 30P).
Analysis of Lambda Chains and Preferred Variegation Scheme:
A collection of 158 lambda sequences was obtained from the public data base. Of these 93 contained sequences in which the FR/CDR boundaries could be identified automatically. Table 33P shows the distribution of lengths of CDRs.
Method of Construction:
The diversity of HC, kappa, and lambda are best constructed in separate vectors. First a synthetic gene is designed to embody each of the synthetic variable domains. The light chains are bounded by restriction sites for ApaLI (positioned at the very end of the signal sequence) and AscI (positioned afer the stop codon). The heavy chain is bounded by SfiI (positioned within the PelB signal sequence) and NotI (positioned in the linker between CH1 and the anchor protein. The initial genes are made with “stuffer” sequences in place of the desired CDRs. A “Stuffer” is a sequence the is to be cut away and replaced by diverse DNA but which does not allow expression of a functional antibody gene. For example, the stuffer may contain several stop codons and restriction sites that will not occur in the correct finished library vector. In Table 40P, the stuffer for CDR1 of kappa A27 contains a StuI site. The vgDNA for CDR1 is introduced as a cassette from Espl, XmaI, or AflII to either SexAI or KasI. After the ligation, the DNA is cleaved with StuI; there should be no StuI sites in the desired vectors.
REFERENCES
Corbett, SJ, Tomlinson, I M, Sonnhammer, ELL, Buck, D, Winter, G. “Sequences of the Human Immunoglobulin Diversity (D) Segment Locus: A Systematic Analysis Provides No Evidence for the Use of DIR Segments, Inverted D Segments, ‘Minor’ D Segments or D-D Recombination”. J Molec Biol (1997) 270:587-597.
TABLE 1P
Typical entry in which YYC motif is found.
++++C:\tmp\haj10335.txt
LOCUS
HAJ10335 306 bp mRNA PRI 18-AUG-1998
DEFINITION
Homo sapiens mRNA for immunoglobulin heavy chain variable region,
clone ELD16/6.
ACCESSION
AJ010335
VERSION
AJ010335.1 GI: 3445266
Ngene =
306
Stop codons in reading frame 1
49 115 124 253 277
No stops in reading frame 2
Stop codons in reading frame 3
12 60 81 147 204 213
1 t ttg ggg tcc ctg aga ctc tcc TGT gca gcc tct gga ttc acc
44 gtc agt agc aac tac atg acc tgg gtc cgc cag gct cta ggg aag
89 ggg ctg gag tgg gtc tca gtt att tat agc ggt ggt agc aca tac
134 tac gca gac tcc gtg aag ggc gga ttc acc atc tcc aga gac aat
179 tcc aag aac aca ctg tat ctt caa atg aac agc ctg aga ccc gag
224 gac acg gct gtg
< > TAT TAC TGT gcg aca
251 ggt aat cgc ctg gaa atg gct gca att aac TGG GGC caa gga acc
263 ctG GTC ACC aa (SEQ ID NO: 113)
TABLE 2P
entry in which YYC motif was not automatically identified
++C:\tmp\hs202g3.txt
!!NA_SEQUENCE 1.0
LOCUS
HS202G3 522 bp mRNA PRI 03-AUG-1995
DEFINITION
H. sapiens mRNA for immunoglobulin variable region (clone 202-G3).
ACCESSION
Z47259
VERSION
Z47259.1 GI: 619470
Ngene =
522
No stops in reading frame 1
Stop codons in reading frame 2
89 110 305 314
Stop codons in reading frame 3
84 192 321 351 369
1 atg gac tgg acc tgg agg ttc ctc ttt gtg gtg gca gca gct aca
46 ggt gtc cag tcc cag gtg cag ctg gtg cag tct ggg gct gag gtg
91 aag aag cct ggg tcc tcg gtg aag gtc tcc TGC aag gct tct gga
136 ggc acc ttc agc agc tat gct atc agc tgg gtg cga cag gcc cct
181 gga caa ggg ctt gag tgg atg gga ggg atc atc cct atc ttt ggt
226 aca gca aac tac gca cag aag ttc cag ggc aga gtc acg att acc
271 gcg gac gaa tcc acg agc aca gcc tac atg gag ctg agc agc ctg
316 aga tct gag gac acg gcc gtg tat cac TGT gcg agt gag gga tgg
361 gag agt TGT agt ggt ggt ggc TGC tac gac ggt atg gac gtc TGG
406 GGC caa ggg acc ac G GTC ACC gtc tcc tca gct tcc acc aag ggc
451 cca tcg gtc ttc ccc ctg gcg ccc TGC tcc agg agc acc tct ggg
496 ggc aca gcg gcc ctg ggc TGC ctg
YYC not found !!!
TABLE 3P
Entry of Table 2P after editting.
++C:\tmp\hs202g3.txt
!!NA_SEQUENCE 1.0
LOCUS
HS202G3 522 bp mRNA PRI 03-AUG-1995
DEFINITION
H. sapiens mRNA for immunoglobulin variable region (clone 202-G3).
ACCESSION
Z47259
VERSION
Z47259.1 GI: 619470
Ngene = 522
No stops in reading frame 1
Stop codons in reading frame 2
89 110 305 314
Stop codons in reading frame 3
84 192 321 351 369
1
atg gac tgg acc tgg agg ttc ctc ttt gtg gtg gca gca gct aca
46
ggt gtc cag tcc cag gtg cag ctg gtg cag tct ggg gct gag gtg
91
aag aag cct ggg tcc tcg gtg aag gtc tcc TGC aag gct tct gga
136
ggc acc ttc agc agc tat gct atc agc tgg gtg cga cag gcc cct
181
gga caa ggg ctt gag tgg atg gga ggg atc atc cct atc ttt ggt
226
aca gca aac tac gca cag aag ttc cag ggc aga gtc acg att acc
271
gcg gac gaa tcc acg agc aca gcc tac atg gag ctg agc agc ctg
316
aga tct gag gac acg gcc gtg
<YHCAS>
tat cac TGT gcg agt
(SEQ ID NO: 115)
gag gga tgg
361
gag agt TGT agt ggt ggt ggc TGC tac gac ggt atg gac gtc TGG
406
GGC caa ggg acc ac G GTC ACC gtc tcc tca gct tcc acc aag ggc
451
cca tcg gtc ttc ccc ctg gcg ccc TGC tcc agg agc acc tct ggg
496
ggc aca gcg gcc ctg ggc TGC ctg (SEQ ID NO: 115)
YYC
not found !!!
TABLE 4P
contents of file D1_1-01_Phz0_hsa239356.txt
DRGGKYQLAPKGGM (SEQ ID NO: 117)
DRGGKYQLAPKGGMDV (SEQ ID NO: 118)
JH3 D# 1 Phase 15 Score 6.55D+04
TABLE 5P
alignment of a CDR3::JH segment to GLG JHs and D-segments.
+c:\tmp\hs6d4xb7.txt
1 1 2 2 3 3 3
1234567890 5 0 5 0 5 9
Observed
tatgatagtagtgggtcatactccgactacTGGGGGcag (SEQ ID NO: 119)
JH1
------------ g ctga atact t c c a gc act ggggccagggcaccctggtcaccgtctcctcag--(SEQ ID NO: 120)
Miss = 9 Nt = 27
JH2
-----------ctac t gg tact t cga tct c tggggccgtggcaccctggtcactgtctcctcag--(SEQ ID NO: 121)
Miss = 13 Nt = 28
JH3
--------------tgatgct t tt ga tat c tggggccaagggacaatggtcaccgtctcttcag--(SEQ ID NO: 122)
Miss = 14 Nt = 25
JH4
----------------ac tact tt gactac tggggccagggaaccctggtcaccgtctcctcag--(SEQ ID NO: 123)
Miss = 5 Nt = 23
JH5
-------------acaac t gg t t cgac cc c tggggccagggaaccctggtcaccgtctcctcag--(SEQ ID NO: 124)
Miss = 11 Nt = 26
JH6
- at t a ctactactac t acggtatg gac gt c tggggccaagggaccacggtcaccgtctcctcag--(SEQ ID NO: 125)
Miss = 23 Nt = 38
4
tat gat agt agt ggg tca TAC Tcc GAC TAC TGG GGg CAG (SEQ ID NO: 126)
Y D S S G S Y S D Y W G Q (SEQ ID NO: 127)
JH4
--- --- --- --- --- -ac tac ttt gac tac tgg ggc cag gga acc ctg gtc acc gtc tcc tca g--
(SEQ ID NO: 128)
- - - - - - Y F D Y W G Q G T L V T V S S -
(SEQ ID NO: 129)
Fract = 0.783 = 18/23
Matching the rest to D segments:
D#13
--------gtattactatgatagtagtggttattactac GLG (SEQ ID NO: 130)
gatcgccacaattactatgatagtagtgggtcatactcc Observed (SEQ ID NO: 131)
--------gt...................t.at....a. . = match
D#13
Phase = 9 Score = 4.3980E+12
TABLE 6P
Number of sequences identified as having JH derived from GLG JHn
JH
1
2
3
4
5
6
# sequences
17
40
198
707
160
261
TABLE 7P
Distribution of CDR3 fragments that might contain D segments.
For JH1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
0
0
1
1
3
1
1
2
0
3
1
1
1
2
Total = 17 Median = 8.0
For JH2
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
0
0
0
0
0
2
4
6
2
6
3
4
5
2
3
15
16
17
18
2
0
0
1
Total = 40 Median = 9.0
For JH3
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
0
0
2
6
16
12
17
17
15
22
20
20
18
13
4
15
16
17
18
19
8
3
2
1
2
Total = 198 Median = 8.6
For JH4
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
0
0
7
15
19
40
63
82
81
77
81
53
57
44
30
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
15
23
8
3
5
2
0
1
0
0
0
0
0
0
0
30
31
32
33
34
35
0
0
0
0
0
1
Total = 707 Median = 8.6
For JH5
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
0
0
0
3
4
6
13
19
12
14
22
18
10
18
10
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
5
1
1
0
0
1
1
0
0
0
0
0
0
0
0
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
45
46
0
1
Total = 160 Median = 9.4
For JH6
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
2
0
1
2
5
15
20
18
22
29
29
28
23
16
10
15
16
17
18
19
20
14
9
9
4
2
3
Total = 261 Median = 9.6
TABLE 8P
Lengths of CDR3 segments from YYCAR to WG.
Distribution of lengths from end of FR3 to WG motif all sequences.
L
0
1
2
3
4
5
6
7
8
9
N
6
0
0
4
2
9
13
38
61
88
Sum(N)
6
6
6
10
12
21
34
72
133
221
f
.004
.004
.004
.007
.009
.015
.025
.052
.096
.160
L
10
11
12
13
14
15
16
17
18
19
N
101
118
154
150
118
125
105
84
61
46
SN
322
440
594
744
862
987
1092
1176
1237
1283
f
.233
.318
.430
.538
.623
.714
.790
.850
.894
.928
L
20
21
22
23
24
25
26
27
28
29
N
42
16
17
7
9
2
1
0
2
1
SN
1325
1341
1358
1365
1374
1376
1377
1377
1379
1380
f
.958
.970
.982
.987
.993
.995
.996
.996
.997
.998
L
30
31
32
33
34
35
36
37
38
39
N
0
0
0
0
0
0
0
1
0
0
SN
1380
1380
1380
1380
1380
1380
1380
1381
1381
1381
f
.998
.998
.998
.998
.998
.998
.998
.999
.999
.999
L
40
41
42
43
44
45
46
N
0
0
1
0
0
0
1
SN
1381
1381
1382
1382
1382
1382
1383
f
.999
.999
.999
.999
.999
.999
1.0
Median = 12.65
Distribution of lengths from end of FR3 to WG motif with assigned D.
L
0
1
2
3
4
5
6
7
8
9
N
3
0
0
0
0
0
3
9
21
15
SN
3
3
3
3
3
3
6
15
36
51
f
.004
.004
.004
.004
.004
.004
.008
.019
.046
.065
L
10
11
12
13
14
15
16
17
18
19
N
39
64
77
97
72
77
75
63
45
35
SN
90
154
231
328
400
477
552
615
660
695
f
.115
.196
.294
.418
.510
.608
.703
.783
.841
.885
L
20
21
22
23
24
25
26
27
28
29
N
38
15
15
6
9
2
1
0
1
1
SN
733
748
763
769
778
780
781
781
782
783
f
.934
.953
.972
.980
.991
.994
.995
.995
.996
.997
L
30
31
32
33
34
35
36
37
38
39
N
0
0
0
0
0
0
0
1
0
0
SN
783
783
783
783
783
783
783
784
784
784
f
.997
.997
.997
.997
.997
.997
.997
.999
.999
.999
L
40
41
42
43
44
45
46
N
0
0
0
0
0
0
1
SN
784
784
784
784
784
784
785
f
.999
.999
.999
.999
.999
.999
1.0
Median = 13.90
Distribution of lengths from end of FR3 to WG motif with no assigned D.
L
0
1
2
3
4
5
6
7
8
9
N
3
0
0
4
2
9
10
29
40
73
SN
3
3
3
7
9
18
28
57
97
170
f
.005
.005
.005
.012
.015
.030
.047
.095
.162
.284
L
10
11
12
13
14
15
16
17
18
19
N
62
54
77
53
46
48
30
21
16
11
SN
232
286
363
416
462
510
540
561
577
588
f
.388
.478
.607
.696
.773
.853
.903
.938
.965
.983
L
20
21
22
23
24
25
26
27
28
29
N
4
1
2
1
0
0
0
0
1
0
SN
592
593
595
596
596
596
596
596
597
597
f
.990
.992
.995
.997
.997
.997
.997
.997
.998
.998
L
30
31
32
33
34
35
36
37
38
39
N
0
0
0
0
0
0
0
0
0
0
SN
597
597
597
597
597
597
597
597
597
597
f
.998
.998
.998
.998
.998
.998
.998
.998
.998
.998
L
40
41
42
N
0
0
1
SN
597
597
598
f
.998
.998
1.0
Median = 11.17
L is the length
N is the number of examples
Sum(N) = SN is the sum of the Ns
f is the cumulative fraction seen
TABLE 9P
Tally of left-aligned CDR3 sequences
A
C
D
E
F
G
H
I
K
L
M
#
1
74
6
278
109
11
319
50
18
11
60
8
1383
GDERVASLHTNQPIWYFKMCX
2
50
9
64
32
29
249
43
42
41
109
22
1377
GRPSLDVYTANHIQKEFMWCX
3
81
18
74
39
25
214
29
42
16
83
19
1377
GSYRTVLADPIWEQHNFMCK|
4
70
23
92
49
50
228
23
58
21
70
16
1373
GSYDRVALTIPFEWNCHQKMX
5
86
28
106
32
59
217
21
41
16
72
19
1371
GYSDAVTLRFIPWNECHMQK|X
6
88
17
104
28
94
171
17
48
12
50
17
1362
GYSDFATVRWPLINEQCHMK|
7
69
15
110
21
89
176
22
50
15
81
12
1349
GSYDFVLTAPRWINHEQCKM|X
8
53
19
141
17
90
150
18
47
17
68
11
1311
YSGDFLTVWAPIRNCHEKQM|
9
44
21
120
24
102
174
24
36
20
71
11
1250
YGSDFLNVRTAWPIEHCKQM|
10
39
31
129
23
124
116
23
42
9
58
32
1162
YDFGSLIARPTVWNMCEHQK
11
36
12
158
17
137
83
13
18
10
40
21
1061
YDFGSPLVANWMTRIEHCKQX
12
34
11
164
10
82
74
34
30
1
31
20
943
YDFGPSVAHLINMRTWCEQKX
13
32
2
121
6
84
56
10
26
7
43
32
789
YDFGLSPVAMIWRTHNKQEC
14
23
131
5
59
65
10
16
4
25
34
639
YDGFMVLAPISWNRHTQEKX
15
15
4
107
5
43
42
1
23
20
34
521
YDFGVMILWAPRSENCQTH|
16
4
2
80
3
33
26
4
5
1
10
29
396
YDVFMGPSLNTRIWAHECQ|K
17
3
1
63
19
19
9
13
12
21
291
DYVMFGILHPSTWAQRCNX
18
3
47
16
13
1
4
7
23
207
DYVMFGPSLTIAHN
19
5
1
39
1
4
13
3
3
1
14
146
DYVMGAFHINRSCELPQW
20
2
17
4
5
3
4
12
100
VYDMGFLIPSARWQ
21
17
3
8
1
1
4
58
DVGYMFHINTW
22
1
7
6
1
1
5
42
VDFMYSAGITW
23
9
1
1
1
1
25
DVYGILMPS
24
1
2
1
1
1
18
VYDAHLMPT
25
1
3
9
GVDPSY
26
2
2
7
GMSTV
27
2
1
1
6
DKMST
28
1
1
1
6
VADGS
29
1
4
DPSV
30
1
3
FST
31
1
1
3
KLV
32
1
1
3
FGP
33
1
3
PG
34
1
1
3
HLS
35
1
3
AVW
36
1
1
3
DFP
37
3
PSY
38
1
2
LS
39
1
1
2
AK
40
2
PS
41
2
ST
42
2
S
43
1
1
K
44
1
S
45
1
T
46
1
S
816
220
2186
421
1166
2428
358
568
205
920
421
N
P
Q
R
S
T
V
W
Y
|
X
#
1
35
23
31
108
63
50
94
16
13
6
1383
GDERVASLHTNQPIWYFKMCX
2
44
114
42
169
114
59
62
21
60
2
1377
GRPSLDVYTANHIQKEFMWCX
3
26
73
37
110
140
97
89
42
122
1
1377
GSYRTVLADPIWEQHNFMCK|
4
48
51
22
79
141
65
77
49
139
2
1373
GSYDRVALTIPFEWNCHQKMX
5
37
41
18
61
157
75
85
38
158
2
2
1371
GYSDAVTLRFIPWNECHMQK|X
6
32
54
23
67
152
80
78
64
165
1
1362
GYSDFATVRWPLINEQCHMK|
7
44
59
18
58
157
73
85
54
139
1
1
1349
GSYDFVLTAPRWINHEQCKM|X
8
38
48
14
41
167
68
59
59
185
1
1311
YSGDFLTVWAPIRNCHEKQM|
9
52
40
14
47
123
45
48
41
192
1
1250
YGSDFLNVRTAWPIEHCKQM|
10
33
37
12
39
73
36
36
35
235
1162
YDFGSLIARPTVWNMCEHQK
11
33
49
7
20
68
21
37
29
251
1
1061
YDFGSPLVANWMTRIEHCKQX
12
30
53
10
19
45
19
42
18
215
1
943
YDFGPSVAHLINMRTWCEQKX
13
10
34
7
22
40
15
33
25
184
789
YDFGLSPVAMIWRTHNKQEC
14
13
22
6
12
15
10
26
14
148
1
639
YDGFMVLAPISWNRHTQEKX
15
5
12
3
12
12
3
40
20
119
1
521
YDFGVMILWAPRSENCQTH|
16
10
24
2
6
12
7
49
5
82
2
396
YDVFMGPSLNTRIWAHECQ|K
17
1
8
2
2
8
5
42
4
58
1
291
DYVMFGILHPSTWAQRCNX
18
1
13
8
5
31
35
207
DYVMFGPSLTIAHN
19
2
1
1
2
2
24
1
29
146
DYVMGAFHINRSCELPQW
20
3
1
2
3
23
2
19
100
VYDMGFLIPSARWQ
21
1
1
14
1
7
58
DVGYMFHINTW
22
2
1
12
1
5
42
VDFMYSAGITW
23
1
1
5
5
25
DVYGILMPS
24
1
1
5
5
18
VYDAHLMPT
25
1
1
2
1
9
GVDPSY
26
1
1
1
7
GMSTV
27
1
1
6
DKMST
28
1
2
6
VADGS
29
1
1
1
4
DPSV
30
1
1
3
FST
31
1
3
KLV
32
1
3
FGP
33
2
3
PG
34
1
3
HLS
35
1
1
3
AVW
36
1
3
DFP
37
1
1
1
3
PSY
38
1
2
LS
39
2
AK
40
1
1
2
PS
41
1
1
2
ST
42
2
2
S
43
1
K
44
1
1
S
45
1
1
T
46
1
1
S
495
769
270
876
1518
741
1104
540
2572
10
17
18621
TABLE 10P
Tally of right-aligned sequences
A
C
D
E
F
G
H
I
K
L
M
#
5
1
1
G
6
1
S
7
1
1
G
8
1
1
G
9
2
RV
10
2
RV
11
1
1
2
GI
12
2
V
13
2
TY
14
1
1
3
DGN
15
1
3
ISY
16
1
3
DSY
17
1
3
APY
18
1
1
1
3
DFM
19
2
1
3
DG
20
1
1
3
ILV
21
3
WP
22
3
4
GS
23
2
1
6
GHQSV
24
1
3
1
6
GALR
25
1
2
1
7
DTAIS
26
1
1
1
1
1
1
1
9
ACDGKLMST
27
2
5
1
2
1
1
18
DAGVEILNQRS
28
2
2
3
1
2
25
TGQSDELPRIV
29
3
5
6
7
1
1
1
42
GEDVAPQRSKLMTY|
30
2
9
1
9
1
4
5
2
58
DGRLSIVPAMQTFHNY
31
4
2
19
9
2
18
1
2
1
3
100
DGSERVYALPTCFINHKW
32
10
5
18
5
3
16
3
3
2
14
1
146
DGLRVAPYSTCEQFHINWKM
33
20
18
10
7
34
7
8
2
6
1
207
GARDPSYTEVIFHLQWKM
34
13
4
31
18
9
37
8
16
4
14
4
291
GDRYPVEILASTFHQWCKMNX|
35
17
5
32
23
10
70
12
10
6
25
1
396
GRSDYLEVTPAHNFIWKCQM|
36
23
6
51
21
9
79
19
15
14
36
9
521
GDSYRLTVPAEHIKNFMWCQ|
37
35
12
56
23
15
110
14
17
5
24
4
639
GYDVRSTAPLEIFHNCWQKMX
38
28
19
68
27
29
133
26
31
12
43
7
789
GSYDVRLPTIFAEHCNWKQM
39
51
25
80
27
33
162
16
30
18
55
15
943
GSDRYVLATPFWIECKHMQNX
40
44
14
73
36
46
161
27
32
17
59
8
1061
GSRDYVTLPFAEIWHQNKCM
41
54
21
74
25
23
178
23
52
15
57
11
1162
GSYTDRVLPAIWNQEFHCKMX|
42
57
13
82
40
42
190
14
39
15
82
15
1250
GSYDLVRTANPFEIWQKMHC|
43
75
18
54
25
35
242
13
29
18
49
12
1311
GYSTARVPDLWNFIQECKHM|
44
63
17
79
15
43
197
20
38
14
76
8
1349
YGSTDLRAPVWNFIQHCEKM
45
59
16
69
35
55
165
26
23
23
75
9
1362
YGSLRTDNAFPVWEHIKCQM
46
41
19
125
26
27
208
31
14
16
38
8
1371
YGDSNRWATLPHFEVQCKIM
47
160
10
24
13
53
332
36
16
11
40
10
1373
GYAWPSFRLHTVNDIEKCMQX
48
21
4
8
5
680
27
4
44
5
145
288
1377
FMLISGVYPAWTDNQREKCHX
49
23
2
1181
29
1
30
15
4
2
8
1
1377
DGEAHNQSYVLPTIRCKW|FMX
50
7
7
15
42
3
41
135
3
59
4
1383
YVIPSLFHNDTACXMGKQRW|
816
220
2186
421
1166
2428
358
568
205
920
421
N
P
Q
R
S
T
V
W
Y
|
X
#
5
1
G
6
1
1
S
7
1
G
8
1
G
9
1
1
2
RV
10
1
1
2
RV
11
2
GI
12
2
2
V
13
1
1
2
TY
14
1
3
DGN
15
1
1
3
ISY
16
1
1
3
DSY
17
1
1
3
APY
18
3
DFM
19
3
DG
20
1
3
ILV
21
1
2
3
WP
22
1
4
GS
23
1
1
1
6
GHQSV
24
1
6
GALR
25
1
2
7
DTAIS
26
1
1
9
ACDGKLMST
27
1
1
1
1
2
18
DAGVEILNQRS
28
2
3
2
3
4
1
25
TGQSDELPRIV
29
3
3
2
2
1
5
1
1
42
GEDVAPQRSKLMTY|
30
1
3
2
7
5
2
4
1
58
DGRLSIVPAMQTFHNY
31
2
3
7
10
3
7
1
6
100
DGSERVYALPTCFINHKW
32
3
9
4
12
8
6
12
3
9
146
DGLRVAPYSTCEQFHINWKM
33
16
6
19
15
12
10
3
13
207
GARDPSYTEVIFHLQWKM
34
2
20
5
31
12
12
20
5
23
1
2
291
GDRYPVEILASTFHQWCKMNX|
35
12
18
5
39
35
19
23
7
26
1
396
GRSDYLEVTPAHNFIWKCQM|
36
11
24
6
42
47
29
28
7
44
1
521
GDSYRLTVPAEHIKNFMWCQ|
37
14
33
9
54
52
37
55
11
58
1
639
GYDVRSTAPLEIFHNCWQKMX
38
18
33
12
46
77
32
58
17
73
789
GSYDVRLPTIFAEHCNWKQM
39
11
38
12
70
94
42
61
33
68
2
943
GSDRYVLATPFWIECKHMQNX
40
24
52
27
74
140
61
66
29
71
1061
GSRDYVTLPFAEIWHQNKCM
41
31
55
29
70
156
76
61
51
97
1
2
1162
GSYTDRVLPAIWNQEFHCKMX|
42
48
47
24
68
171
68
70
39
125
1
1250
GSYDLVRTANPFEIWQKMHC|
43
38
58
28
73
164
76
66
43
194
1
1311
GYSTARVPDLWNFIQECKHM|
44
48
60
24
69
131
86
57
52
252
1349
YGSTDLRAPVWNFIQHCEKM
45
62
51
16
75
116
74
50
39
324
1362
YGSLRTDNAFPVWEHIKCQM
46
97
38
21
55
110
39
26
55
377
1371
YGDSNRWATLPHFEVQCKIM
47
25
54
9
44
54
34
32
122
292
2
1373
GYAWPSFRLHTVNDIEKCMQX
48
8
22
7
6
28
10
25
16
23
1
1377
FMLISGVYPAWTDNQREKCHX
49
15
6
13
4
13
5
9
2
11
2
1
1377
DGEAHNQSYVLPTIRCKW|FMX
50
23
122
3
3
67
9
350
3
480
1
6
1383
YVIPSLFHNDTACXMGKQRW|
50
495
769
270
876
1518
741
1104
540
2572
10
17
18621
TABLE 11P
Tallies of AA frequencies in all CDR3 by length
Tally of sequences of length 7 # = 38
A
C
D
E
F
G
H
I
K
L
M
#
1
1
8
1
1
14
1
1
5
38
GDLRWAEFHKS
2
1
1
2
6
3
2
1
1
38
RGNHVFKTYADLMW
3
1
4
1
5
1
2
2
38
GSDWYPVILTAFHN
4
3
1
1
12
1
1
1
38
GYSANRVDFHILPT
5
2
1
14
3
4
1
3
3
38
FIGLMARVYEKP
6
26
1
1
38
DVPTHISWY
7
1
2
2
3
1
38
YVINDHSALR
9
42
2
19
40
9
11
4
13
4
N
P
Q
R
S
T
V
W
Y
|
X
#
1
3
1
2
38
GDLRWAEFHKS
2
6
7
2
3
1
2
38
RGNHVFKTYADLMW
3
1
3
5
2
3
4
4
38
GSDWYPVILTAFHN
4
2
1
2
4
1
2
6
38
GYSANRVDFHILPT
5
1
2
2
2
38
FIGLMARVYEKP
6
2
1
2
3
1
1
38
DVPTHISWY
7
3
1
2
7
16
38
YVINDHSALR
12
7
15
13
7
20
8
31
266
Tally of sequences of length 8 # = 61
A
C
D
E
F
G
H
I
K
L
M
#
1
3
7
3
14
2
2
5
61
GDLTVRSAEHINWPQY
2
1
9
1
1
15
1
2
1
61
GDTNRSVKWYAEFILPQ
3
2
3
1
10
1
1
7
1
61
GLSTYVDPRAFHIMNQW
4
4
1
3
1
1
15
1
4
61
GYRALQDSWVCEFHNPT
5
10
2
1
9
5
1
5
1
61
AGYHLTPRVDSEKMW
6
5
1
24
2
7
5
2
61
FIALPSVYGMCQRW
7
5
37
2
4
1
2
61
DAHSELNVIP|
8
1
2
3
1
12
3
61
YISFLVDNAHPRT
31
2
63
8
30
65
14
24
3
32
4
N
P
Q
R
S
T
V
W
Y
|
X
#
1
2
1
1
4
4
5
5
2
1
61
GDLTVRSAEHINWPQY
2
6
1
1
4
3
8
3
2
2
61
GDTNRSVKWYAEFILPQ
3
1
3
1
3
7
7
5
1
7
61
GLSTYVDPRAFHIMNQW
4
1
1
4
5
3
1
2
3
11
61
GYRALQDSWVCEFHNPT
5
4
4
2
5
4
1
7
61
AGYHLTPRVDSEKMW
6
3
1
1
3
3
1
3
61
FIALPSVYGMCQRW
7
2
1
4
2
1
61
DAHSELNVIP|
8
2
1
1
7
1
3
24
61
YISFLVDNAHPRT
14
15
8
22
33
27
27
10
55
1
488
Tally of sequences of length 9 # = 88
A
C
D
E
F
G
H
I
K
L
M
#
1
9
12
4
21
1
1
2
5
88
GDARNVLEQTKWHIPSY
2
2
2
3
3
13
4
3
7
2
88
GPSRLNTHEFKYADMQW
3
4
2
3
3
3
15
1
1
88
GTPSQNRVWYADEFCLM
4
5
1
6
3
6
22
2
4
1
6
1
88
GSDFLARITYENPWHVCKM
5
7
1
4
3
4
14
2
7
2
88
GSYALNDFVERWHMQTCP
6
13
2
1
3
13
6
2
1
4
1
88
YAGHNLPSVFTWDIEKMQR
7
4
2
41
2
3
1
14
5
88
FLMAPWIDGSVKNQTY
8
1
1
73
2
2
1
2
88
DEGLSACHNQRV
9
1
1
4
1
3
8
2
88
YVISFHPLNTCDGR
45
6
105
19
64
103
19
18
8
48
12
N
P
Q
R
S
T
V
W
Y
|
X
#
1
7
1
3
8
1
3
7
2
1
88
GDARNVLEQTKWHIPSY
2
5
11
2
10
11
5
2
3
88
GPSRLNTHEFKYADMQW
3
5
7
6
5
7
11
5
5
5
88
GTPSQNRVWYADEFCLM
4
3
3
5
7
4
2
3
4
88
GSDFLARITYENPWHVCKM
5
6
1
2
3
12
2
4
3
11
88
GSYALNDFVERWHMQTCP
6
5
4
1
1
4
3
4
3
17
88
YAGHNLPSVFTWDIEKMQR
7
1
4
1
2
1
2
4
1
88
FLMAPWIDGSVKNQTY
8
1
1
1
2
1
88
DEGLSACHNQRV
9
2
3
1
8
2
9
43
88
YVISFHPLNTCDGR
35
34
16
34
54
31
34
22
85
792
Tally of sequences of length 10 # = 101
A
C
D
E
F
G
H
I
K
L
M
#
1
8
1
19
7
1
16
3
2
3
2
101
DGNAERTSQVHLWKMYCF
2
3
8
3
5
13
5
15
2
101
LGRDSPVFINTAEQYMW
3
6
9
1
26
1
3
1
4
1
101
GSYDAVTLNRIPWFHKMQ
4
7
6
1
25
1
5
4
1
101
GSYARDINPLTVWQFHM
5
6
5
9
4
16
1
3
4
101
GYTESANDPRFLVKQWH
6
6
1
6
5
4
23
2
4
3
3
1
101
GYRSWADEFINKLTHCMQV
7
13
3
1
5
9
3
1
4
1
101
YASGPRWFTVLDHNEIMQ
8
2
1
1
57
3
4
15
4
101
FLIMSGWANPVCEY
9
3
78
2
6
1
1
1
101
DGAQENIKLPRSW
10
3
4
4
13
1
101
YIPSVFHNDL
54
3
137
28
82
137
15
36
10
54
12
N
P
Q
R
S
T
V
W
Y
|
X
#
1
9
4
6
5
6
4
3
2
101
DGNAERTSQVHLWKMYCF
2
5
6
3
11
8
4
6
1
3
101
LGRDSPVFINTAEQYMW
3
4
3
1
4
14
5
6
2
10
101
GSYDAVTLNRIPWFHKMQ
4
5
5
3
7
11
4
4
4
8
101
GSYARDINPLTVWQFHM
5
6
5
2
5
8
10
4
2
11
101
GYTESANDPRFLVKQWH
6
4
1
8
7
3
1
7
12
101
GYRSWADEFINKLTHCMQV
7
2
7
1
7
11
5
5
6
17
101
YASGPRWFTVLDHNEIMQ
8
2
2
4
2
3
1
101
FLIMSGWANPVCEY
9
2
1
3
1
1
1
101
DGAQENIKLPRSW
10
4
8
7
5
52
101
YIPSVFHNDL
43
37
18
49
76
37
37
29
116
1010
Tally of sequences of length 11 # = 118
A
C
D
E
F
G
H
I
K
L
M
#
1
7
1
21
11
23
5
2
7
118
GDEVRALQHSPTINCWY
2
1
2
9
1
1
24
5
6
2
7
3
118
GSRDYLPIVHQTMNCKWAEFX
3
4
4
2
4
13
2
3
1
7
2
118
SGTVRLYWADFNQIEHMKP
4
10
3
3
2
25
1
2
4
3
118
SGARTWYLVDEMQFINPH
5
5
2
10
1
4
24
2
1
5
1
118
GSVYDTNALRFWCHQEKM
6
6
4
2
7
19
2
3
1
5
1
118
GSYWTFAVLRDINEHQKMP
7
4
1
8
5
2
20
4
1
2
1
118
GYSNRDWTEPAHFLQVCIM
8
13
2
6
1
8
12
4
2
7
118
YAGWFLDPRSTHCKVE
9
2
2
68
2
5
14
7
118
FLMYVITADGP
10
2
1
100
5
3
2
1
1
118
DEGAHCLMNPQ
11
2
6
1
7
1
6
1
118
YPVISFLNDHKM
54
9
169
31
102
165
28
29
8
65
20
N
P
Q
R
S
T
V
W
Y
|
X
#
1
2
4
7
8
5
3
10
1
1
118
GDEVRALQHSPTINCWY
2
3
7
4
10
11
4
6
2
9
1
118
GSRDYLPIVHQTMNCKWAEFX
3
4
1
4
8
25
12
9
6
7
118
SGTVRLYWADFNQIEHMKP
4
2
2
3
9
26
8
4
6
5
118
SGARTWYLVDEMQFINPH
5
6
2
5
15
9
11
4
11
118
GSVYDTNALRFWCHQEKM
6
3
1
2
5
16
9
6
11
15
118
GSYWTFAVLRDINEHQKMP
7
9
5
2
9
11
6
2
7
19
118
GYSNRDWTEPAHFLQVCIM
8
6
5
5
5
2
11
29
118
YAGWFLDPRSTHCKVE
9
1
4
6
7
118
FLMYVITADGP
10
1
1
1
118
DEGAHCLMNPQ
11
3
13
7
11
60
118
YPVISFLNDHKM
33
41
25
59
121
60
67
48
163
1
1298
Tally of sequences of length 12 # = 154
A
C
D
E
F
G
H
I
K
L
M
#
1
5
31
12
37
6
1
1
7
3
154
GDRESVLHAPMNQTWYIK
2
5
1
7
6
1
25
3
7
3
13
2
154
GSRLPDIQEAVYHKNTMWCF
3
10
2
7
5
1
19
5
4
12
2
154
GRSYLATVPDQEIKWCMNF
4
8
9
6
8
27
6
5
6
1
154
GVSDNAFRTYEILKWPQM
5
18
1
8
5
6
42
1
9
1
7
3
154
GSAIDYLFPTEQVMNWCHK
6
13
12
4
10
23
1
7
8
1
154
GAVDSFYTLPRWINEQHM
7
11
2
4
3
10
15
1
4
12
154
YGSPLRAFWTNVDIECQH
8
3
2
18
3
3
25
4
2
5
6
154
YGDSNLTKRWHPAEFCIQV
9
15
1
2
8
33
4
7
1
5
1
154
GYWARFISPLHTDQCKMN
10
1
1
2
1
79
1
2
5
1
19
26
154
FMLIPYDHVWACEGKNQRST
11
2
135
2
4
2
154
DGYAEHSVNR
12
1
1
6
1
9
16
4
154
YVPIHFSLNCDGW
91
11
236
47
132
252
33
69
21
99
39
N
P
Q
R
S
T
V
W
Y
|
X
#
1
3
4
3
14
10
3
10
2
2
154
GDRESVLHAPMNQTWYIK
2
3
11
7
22
24
3
5
2
4
154
GSRLPDIQEAVYHKNTMWCF
3
2
8
6
17
17
9
9
4
15
154
GRSYLATVPDQEIKWCMNF
4
9
4
4
7
17
7
18
5
7
154
GVSDNAFRTYEILKWPQM
5
3
6
4
20
6
4
2
8
154
GSAIDYLFPTEQVMNWCHK
6
5
8
3
8
11
9
13
8
10
154
GAVDSFYTLPRWINEQHM
7
5
14
2
12
15
6
5
9
24
154
YGSPLRAFWTNVDIECQH
8
10
4
2
5
15
6
2
5
34
154
YGDSNLTKRWHPAEFCIQV
9
1
6
2
10
7
3
18
30
154
GYWARFISPLHTDQCKMN
10
1
4
1
1
1
1
2
2
3
154
FMLIPYDHVWACEGKNQRST
11
1
1
2
2
3
154
DGYAEHSVNR
12
2
18
5
32
1
58
154
YVPIHFSLNCDGW
45
87
34
97
144
53
102
58
198
1848
Tally of sequences of length 13 # = 150
A
C
D
E
F
G
H
I
K
L
M
#
1
4
2
28
9
3
37
8
3
3
5
150
GDTESHRVLPAQFIKCNW
2
11
4
4
1
2
32
3
1
5
11
3
150
GRSPALTKVCDYHMQWFEIN
3
7
2
8
4
4
23
11
1
4
6
2
150
GSYHQTDPRAVLEFKNCMWI
4
6
2
6
4
6
30
1
8
6
1
150
GSWYTIADFLPVEQRCHMNX
5
8
10
4
2
28
1
2
22
3
150
GLSYDATWPREQMNVFIH
6
10
2
11
1
6
21
2
2
5
1
150
GYSPTDAQVFRLNWCIKEM
7
5
1
8
1
4
19
1
6
5
21
2
150
LGYSTDPIRVAKFNWMQCEH
8
7
5
22
5
3
12
3
3
3
8
1
150
YDSGLARTCEQVNPFHIKWM
9
1
2
12
3
1
26
7
2
4
7
2
150
NGYDSWHLPRKETVCIMAFQ
10
19
1
2
2
17
24
5
2
5
1
150
YGAFWHLPTNSVDEIQRCM
11
1
1
105
2
2
1
13
14
150
FMLYGIVAEKPQRSWX
12
130
3
5
1
150
DGYEQNHT
13
1
2
5
5
14
18
1
150
YVLIPSFHTDAMN
80
21
243
38
158
259
46
46
27
127
31
N
P
Q
R
S
T
V
W
Y
|
X
#
1
2
5
4
8
9
11
8
1
150
GDTESHRVLPAQFIKCNW
2
1
13
3
20
17
7
5
3
4
150
GRSPALTKVCDYHMQWFEIN
3
3
8
11
8
16
11
7
2
12
150
GSYHQTDPRAVLEFKNCMWI
4
1
6
4
4
18
10
6
16
14
1
150
GSWYTIADFLPVEQRCHMNX
5
3
6
4
5
19
8
3
7
15
150
GLSYDATWPREQMNVFIH
6
3
15
8
6
16
13
8
3
17
150
GYSPTDAQVFRLNWCIKEM
7
4
7
2
6
15
14
6
4
19
150
LGYSTDPIRVAKFNWMQCEH
8
4
4
5
7
15
7
5
2
29
150
YDSGLARTCEQVNPFHIKWM
9
31
5
1
5
10
3
3
9
16
150
NGYDSWHLPRKETVCIMAFQ
10
3
5
2
2
3
4
3
15
35
150
YGAFWHLPTNSVDEIQRCM
11
1
1
1
1
2
1
3
1
150
FMLYGIVAEKPQRSWX
12
2
3
1
5
150
DGYEQNHT
13
1
14
13
4
21
51
150
YVLIPSFHTDAMN
58
89
48
72
152
93
77
63
220
2
1950
Tally of sequences of length 14 # = 118
A
C
D
E
F
G
H
I
K
L
M
#
1
6
29
7
2
32
8
1
1
2
118
GDVHERTAFLPSIKNQ
2
4
10
1
5
22
7
3
4
7
118
GPDRYSVHLFAKIQTENW
3
11
2
7
2
3
25
5
1
9
2
118
GVARYLSDITFWCEMPK
4
5
2
7
7
3
12
4
4
3
6
118
SGVYPDELRTANHIFKWC
5
6
5
12
2
18
2
2
2
4
1
118
GYSDTVARCLPFHIKNWMQ
6
6
10
5
4
16
5
3
2
1
118
YGSTDRAEIFVKWLPQMN
7
4
4
1
4
32
2
2
2
1
118
GSVTYNADFHIKPQRWEM
8
6
1
5
1
4
18
2
5
3
2
118
GSYTWAPRDIFNVLHMCE
9
5
2
4
1
2
11
2
1
5
9
1
118
YSGTLVAKNRDWCFHPEIM
10
2
5
9
2
3
21
2
2
4
118
YGSDNTCQLRFWAEIKPV
11
12
1
3
5
25
2
2
1
118
YGWAPVFNEHLTDMQR
12
1
64
5
1
5
12
16
118
FMLGIPSVAHQTY
13
3
97
4
5
1
1
1
1
118
DGEANQHIKLV
14
2
3
4
12
6
118
YVPILHFANS
73
17
195
34
104
242
35
48
24
67
25
N
P
Q
R
S
T
V
W
Y
|
X
#
1
1
2
1
7
2
7
10
118
GDVHERTAFLPSIKNQ
2
1
13
2
10
8
2
8
1
10
118
GPDRYSVHLFAKIQTENW
3
2
11
8
4
13
3
10
118
GVARYLSDITFWCEMPK
4
5
8
6
13
6
12
3
12
118
SGVYPDELRTANHIFKWC
5
2
3
1
6
15
10
7
2
18
118
GYSDTVARCLPFHIKNWMQ
6
1
2
2
7
16
12
4
3
19
118
YGSTDRAEIFVKWLPQMN
7
5
2
2
2
18
12
13
2
10
118
GSVTYNADFHIKPQRWEM
8
4
6
6
16
12
4
9
14
118
GSYTWAPRDIFNVLHMCE
9
5
2
5
14
10
8
4
27
118
YSGTLVAKNRDWCFHPEIM
10
6
2
5
4
13
6
2
3
27
118
YGSDNTCQLRFWAEIKPV
11
4
7
1
1
2
6
14
32
118
YGWAPVFNEHLTDMQR
12
4
1
4
1
3
1
118
FMLGIPSVAHQTY
13
2
2
1
118
DGEANQHIKLV
14
2
14
2
20
53
118
YVPILHFANS
38
67
17
65
129
84
111
44
233
1652
Tally of sequences of length 15 # = 125
A
C
D
E
F
G
H
I
K
L
M
#
1
7
26
8
3
29
1
3
10
125
GDLREASTVNFIPYH
2
6
2
3
22
3
4
1
9
125
RGPLNSTYAVIQEHWDK
3
4
4
5
7
2
19
2
6
2
9
2
125
GRYLSVEPIDTACQWFHKMN
4
7
4
14
6
6
15
2
7
5
7
4
125
GDYAILVEFRKSTCMNPWHQ
5
6
3
10
2
5
18
4
2
3
2
125
GSYVDRWAFTICLNEKMP
6
6
2
7
2
5
10
1
5
7
1
125
SRYGTDLWAPFIVNCEQHM
7
8
4
14
2
2
22
3
3
1
9
1
125
GSDLAVRPYCTHIWEFNKM
8
6
2
4
22
2
2
3
125
GYSVWRATDNPLCIKQ
9
4
3
8
4
20
4
3
1
6
125
YGSDLPTRVAFHQCINKW
10
3
4
5
8
8
17
1
3
7
125
YGEFNTLSRDVCPAIWH
11
4
2
15
3
3
17
1
1
1
125
YGDSNPAWEFRTCQHIKV
12
22
3
2
31
3
1
3
3
125
GYAWPSNCHLMFQRVITX
13
71
1
4
6
30
125
FMLISQTVGPRY
14
115
2
1
1
1
125
DNEFGHPQ
15
3
5
1
1
20
7
1
125
YVILPFSCNGHMQ
83
34
225
43
117
245
23
66
15
86
44
N
P
Q
R
S
T
V
W
Y
|
X
#
1
4
3
10
7
6
6
2
125
GDLREASTVNFIPYH
2
8
11
4
23
7
7
5
3
7
125
RGPLNSTYAVIQEHWDK
3
2
7
3
13
9
5
8
3
13
125
GRYLSVEPIDTACQWFHKMN
4
4
4
1
6
5
5
7
3
13
125
GDYAILVEFRKSTCMNPWHQ
5
3
2
8
18
5
11
8
15
125
GSYVDRWAFTICLNEKMP
6
3
6
2
12
24
9
4
7
12
125
SRYGTDLWAPFIVNCEQHM
7
2
6
7
21
4
8
3
5
125
GSDLAVRPYCTHIWEFNKM
8
4
4
2
7
19
5
12
10
21
125
GYSVWRATDNPLCIKQ
9
3
6
4
5
19
6
5
1
23
125
YGSDLPTRVAFHQCINKW
10
8
4
6
7
8
5
2
29
125
YGEFNTLSRDVCPAIWH
11
7
5
2
3
14
3
1
4
39
125
YGDSNPAWEFRTCQHIKV
12
4
7
2
2
6
1
2
8
24
1
125
GYAWPSNCHLMFQRVITX
13
1
2
1
4
2
2
1
125
FMLISQTVGPRY
14
3
1
1
125
DNEFGHPQ
15
2
7
1
5
33
39
125
YVILPFSCNGHMQ
57
74
24
103
165
66
109
52
243
1
1875
Distribution of D-JH with number of cys's
0
1
2
3
4
1248
53
80
1
1
Tally of AAs in the YYCar motif
A
C
D
E
F
G
H
I
K
L
M
#
1
1
1
14
1
1383
YFDEH
2
4
1
92
11
4
1383
YFHCLSWDR
3
1379
1383
CRS
4
1207
3
2
12
2
2
1383
AVTSGNDFILRQX
5
14
1
4
18
17
9
187
4
1
1383
RKTSGHAIVNFLQYPEM|
1221
1383
5
2
112
30
29
11
187
10
1
N
P
Q
R
S
T
V
W
Y
|
X
#
1
1366
1383
YFDEH
2
1
3
2
1265
1383
YFHCLSWDR
3
2
2
1383
CRS
4
4
1
2
17
51
79
1
1383
AVTSGNDFILRQX
5
7
2
3
992
55
56
9
3
1
1383
RKTSGHAIVNFLQYPEM|
11
2
4
997
77
107
88
2
2634
1
1
6915
TABLE 12P
Alignment and tabulation of sequences having 3-22 D segments
D3:3-22_Phz0 YYYDSSGYYY = GLG
Entry
Seq1
L1
Seq2
L2
JH
P
Score
1
hs3d6hcv
GRDYYDSGGYFT
12
GRDYYDSGGYFTVAFDI
17
3
6
1.76D+13
(SEQ ID NO: 334)
(SEQ ID NO: 335)
2
hs6d4xb7
DRHNYYDSSGSYS
13
DRHNYYDSSGSYSDY
15
4
9
4.40D+12
(SEQ ID NO: 336)
(SEQ ID NO: 337)
3
hs6d4xg3
DCPAPAKMYYYGSGICT
17
DCPAPAKMYYYGSGICTFDY
20
4
3
6.55D+04
(SEQ ID NO: 338)
(SEQ ID NO: 339)
4
hs83x6f2
AFYDSAD
7
AFYDSADDY
9
4
−4
2.62D+05
(SEQ ID NO: 340)
(SEQ ID NO: 341)
5
hsa230644
RDYYDSSGPEAG
12
RDYYDSSGPEAGFDI
15
3
3
6.87D+10
(SEQ ID NO: 342)
(SEQ ID NO: 343)
6
hsa239386
DGTLIDTSAYYYL
13
DGTLIDTSAYYYLY
14
4
6
6.87D+10
(SEQ ID NO: 344)
(SEQ ID NO: 345)
7
hsa234232
NSSDSS
6
NSSDSSVLDV
10
6
−4
6.55D+04
(SEQ ID NO: 346)
(SEQ ID NO: 347)
8
hsa239378
DQVFDSGGYNHR
12
DQVFDSGGYNHRFDS
15
4
3
1.07D+09
(SEQ ID NO: 348)
(SEQ ID NO: 349)
9
hsa239367
DLEYYYDSGGHYSP
14
DLEYYYDSGGHYSPFHY
17
4
9
1.10D+12
(SEQ ID NO: 350)
(SEQ ID NO: 351)
10
hsa239339
DDSSGY
6
DDSSGYYYIDY
11
4
−10
1.72D+10
(SEQ ID NO: 352)
(SEQ ID NO: 353)
11
hsa245311
GHYYDSPGQYSYS
13
GHYYDSPGQYSYSEY
15
4
3
1.07D+09
(SEQ ID NO: 354)
(SEQ ID NO: 355)
12
hsa240578
GGFRPPPYDYESSAYRTYR
19
GGFRPPPYDYESSAYRTYRLDF
22
4
21
2.75D+11
(SEQ ID NO: 356)
(SEQ ID NO: 357)
13
hsa245359
DSDTRAY
7
DSDTRAYYWYFDL
13
2
−7
1.68D+07
(SEQ ID NO: 358)
(SEQ ID NO: 359)
14
hsa245028
GRHYYDSSGYYSTPE
15
GRHYYDSSGYYSTPENYFDY
20
4
6
1.80D+16
(SEQ ID NO: 360)
(SEQ ID NO: 361)
15
hsa245019
DPSYYYDSSGLPL
13
DPSYYYDSSGLPLHGMDV
18
6
9
4.40D+12
(SEQ ID NO: 362)
(SEQ ID NO: 363)
16
hsa244991
TYYYDSSGYLLTR
13
TYYYDSSGYLLTRYFQH
17
1
3
4.50D+15
(SEQ ID NO: 364)
(SEQ ID NO: 365)
17
hsa244945
NAPHYDSSGYYQT
13
NAPHYDSSGYYQTFDY
16
4
6
7.04D+13
(SEQ ID NO: 366)
(SEQ ID NO: 367)
18
hsa244943
GYHSSSYA
8
GYHSSSYADAFDI
13
3
−7
6.71D+07
(SEQ ID NO: 368)
(SEQ ID NO: 369)
19
hsa245289
PIGYCSGGSC
10
PIGYCSGGSCYSFDY
15
4
−4
2.62D+05
(SEQ ID NO: 370)
(SEQ ID NO: 371)
20
hsa240554
THGTYVTSGYYPKI
14
THGTYVTSGYYPKI
14
4
6
2.68D+08
(SEQ ID NO: 372)
(SEQ ID NO: 373)
21
hsa279533
GATYYYESSGNYP
13
GATYYYESSGNYPDY
15
4
9
7.04D+13
(SEQ ID NO: 374)
(SEQ ID NO: 375)
22
hsa389177
AFYHYDSTGYPNRRY
15
AFYHYDSTGYPNRRYYFDY
19
4
6
4.29D+09
(SEQ ID NO: 376)
(SEQ ID NO: 377)
23
hsa7321
SYSYYYDSSGYWGG
14
SYSYYYDSSGYWGGYFDY
18
4
9
4.50D+15
(SEQ ID NO: 378)
(SEQ ID NO: 379)
24
hsaj2772
LSPYYYDSSSYH
12
LSPYYYDSSSYHDAFDI
17
3
6
2.62D+05
(SEQ ID NO: 380)
(SEQ ID NO: 381)
25
hsb7g4f08
EEDYYDSSGQAS
12
EEDYYDSSGQASYNWFXP
18
5
6
2.75D+11
(SEQ ID NO: 382)
(SEQ ID NO: 383)
26
hsb7g3b02
ETNYYDSGGYPG
12
ETNYYDSGGYPGFDF
15
4
6
4.40D+12
(SEQ ID NO: 384)
(SEQ ID NO: 385)
27
hsb7g3c12
GDHYYDRSGYRH
12
GDHYYDRSGYRHSYYYYAMDV
21
6
6
2.75D+11
(SEQ ID NO: 386)
(SEQ ID NO: 387)
28
hsb8g3b07
DRSSGN
6
DRSSGNYFDGMDV
13
6
−10
6.55D+04
(SEQ ID NO: 388)
(SEQ ID NO: 389)
29
hsfog1h
GRSRYSGYG
9
GRSRYSGYGFYSGMDV
16
6
−4
2.62D+05
(SEQ ID NO: 390)
(SEQ ID NO: 391)
30
hsgvh0209
DDTSGYGP
8
DDTSGYGPYYFYYGMDV
17
6
−10
2.68D+08
(SEQ ID NO: 392)
(SEQ ID NO: 393)
31
hsgvh55
RAYYDTSFYFEY
12
RAYYDTSFYFEYY
13
4
3
1.72D+10
(SEQ ID NO: 394)
(SEQ ID NO: 395)
32
hsgvh0304
DRIDYYKSGYYLGSA
15
DRIDYYKSGYYLGSADS
17
4
6
1.68D+07
(SEQ ID NO: 396)
(SEQ ID NO: 397)
33
hsgvh0332
DTDSSSHYG
9
DTDSSSHYGRFDP
13
5
−7
1.68D+07
(SEQ ID NO: 398)
(SEQ ID NO:399 )
34
hsgvh0328
VSISHYDSSGRPQRVF
16
VSISHYDSSGRPQRVFYGMDV
21
6
9
1.07D+09
(SEQ ID NO: 400)
(SEQ ID NO: 401)
35
hsgvh536
QARENVFYDSSGPTAP
16
QARENVFYDSSGPTAPFDH
19
4
15
1.72D+10
(SEQ ID NO: 402)
(SEQ ID NO: 403)
36
hshcmg42
VPAGNYYDTSGPDN
14
VPAGNYYDTSGPDNAD
16
4
12
1.72D+10
(SEQ ID NO: 404)
(SEQ ID NO: 405)
37
hsig001vh
WYYFDTSGYYPRNFYYMDV
19
WYYFDTSGYYPRNFYYMDV
19
4
3
2.81D+14
(SEQ ID NO: 406)
(SEQ ID NO: 407)
38
hsig13g10
GYYYDSGGNYNG
12
GYYYDSGGNYNGDY
14
4
3
1.10D+12
(SEQ ID NO: 408)
(SEQ ID NO: 409)
39
hsighpat3
DLRSYDPSGYYN
12
DLRSYDPSGYYNDGFDI
17
3
6
2.75D+11
(SEQ ID NO: 410)
(SEQ ID NO: 411)
40
hsigh13g7
GYYYDRGGNCNG
12
GYYYDRGGNCNGDY
14
4
3
6.87D+10
(SEQ ID NO: 412)
(SEQ ID NO: 413)
41
hsigh13g1
GYYYDRGGNYNG
12
GYYYDRGGNYNGDY
14
4
3
1.10D+12
(SEQ ID NO: 414)
(SEQ ID NO: 415)
42
hsighxx20
THYDSSGL
8
THYDSSGLDAFDI
13
3
−4
1.72D+10
(SEQ ID NO: 416)
(SEQ ID NO: 417)
43
hsihr9
DDSSGS
6
DDSSGSYYFDY
11
4
−10
1.07D+09
(SEQ ID NO: 418)
(SEQ ID NO: 419)
44
hsihv11
LSGGYYS
7
LSGGYYSDFDY
11
4
−13
2.68D+08
(SEQ ID NO: 420)
(SEQ ID NO: 421)
45
hs ej1f
GDYSDSSDSYI
11
GDYSDSSDSYIDAFDV
16
3
3
1.10D+12
(SEQ ID NO: 422)
(SEQ ID NO: 423)
46
hsmvh51
GETYYYDSRGYA
12
GETYYYDSRGYAFDH
15
4
6
2.62D+05
(SEQ ID NO: 424)
(SEQ ID NO: 425)
47
hsmvh517
PTRDSSGY
8
PTRDSSGYYVGY
12
4
−4
1.07D+09
(SEQ ID NO: 426)
(SEQ ID NO: 427)
48
hsmvh0406
GSFYYDSSGYPP
12
GSFYYDSSGYPPFDC
15
4
6
6.87D+10
(SEQ ID NO: 428)
(SEQ ID NO: 429)
49
hst14x14
GPYYYDSSGYYL
12
GPYYYDSSGYYLLDY
15
4
6
1.80D+16
(SEQ ID NO: 430)
(SEQ ID NO: 431)
50
hsvhig2
EEGYYDSSGYYSLGA
15
EEGYYDSSGYYSLGASDY
18
4
6
4.50D+15
(SEQ ID NO: 432)
(SEQ ID NO: 433)
51
hsvhia2
RPDSSGSRW
9
RPDSSGSRWYFDY
13
4
−7
6.71D+07
(SEQ ID NO: 434)
(SEQ ID NO: 435)
52
hsy14936
GYYDISGYYF
10
GYYDISGYYFDAFNI
15
3
−4
2.81D+14
(SEQ ID NO: 436)
(SEQ ID NO: 437)
53
hsy14934
DRGYDSSGYYGN
12
DRGYDSSGYYGNLDC
15
4
3
1.76D+13
(SEQ ID NO: 438)
(SEQ ID NO: 439)
54
hsy14935
DRGYDSIGYYGN
12
DRGYDSIGYYGNLDC
15
4
3
1.10D+12
(SEQ ID NO: 440)
(SEQ ID NO: 441)
55
hsz80519
AEDLTYYYDRSGWGVHGLL
19
AEDLTYYYDRSGWGVHGLLYYFDY
24
4
15
4.40D+12
(SEQ ID NO: 442)
(SEQ ID NO: 443)
56
hsz80429
LYPHYDSSGYYYV
13
LYPHYDSSGYYYVLDY
16
4
6
4.50D+15
(SEQ ID NO: 444)
(SEQ ID NO: 445)
57
hsz80461
DRVGYYDSSGYPPGSP
16
DRVGYYDSSGYPPGSPLDY
19
4
9
1.76D+13
(SEQ ID NO: 446)
(SEQ ID NO: 447)
Frequency of each AA type at each position in 57 Sequences
having D3-22 segments
Pos
A
C
D
E
F
G
H
I
K
L
M
N
P
Q
R
S
T
V
W
Y
|
X
#
1
1
1
2
1
1
3
1
1
1
3
4
1
1
1
1
4
5
5
1
1
2
1
1
1
12
6
3
3
4
6
3
1
2
2
2
1
1
28
x
7
1
5
4
1
7
2
1
1
1
3
5
3
4
1
1
1
41
x
8
2
1
4
1
5
3
1
4
4
1
3
1
3
1
14
48
x
9
4
2
3
5
1
1
1
2
2
2
1
28
52
Y
10
1
4
2
1
1
1
1
4
1
40
56
Y
11
46
2
1
1
1
2
1
3
57
D
12
1
1
1
1
1
1
4
39
7
1
57
S
13
1
8
1
1
1
1
43
1
57
S
14
3
2
1
45
1
1
3
56
G
15
2
2
2
5
3
2
1
4
1
33
55
Y
16
2
1
1
1
2
3
1
1
1
6
3
1
1
1
24
49
x
17
3
1
1
1
5
2
1
4
6
6
2
7
2
1
1
3
46
x
18
8
1
1
2
2
2
4
3
1
3
27
19
2
1
1
1
3
4
1
13
20
2
1
2
1
1
1
1
9
21
1
1
1
3
22
1
1
2
23
1
1
2
24
1
1
25
1
1
Average Dseg = 11.9 Average DJ = 15.7
Median D = 12 12 Shortest 6 Longest 19
Median DJ = 15 15 Shortest 9 Longest 24
TABLE 13P
Frequency of D-segments. “|” stands for a stop codon.
D seg
“0”
%
C %
GLG
“1”
%
C %
GLG
“2”
%
C %
GLG
1-01
1
0.13
0
VQLERX
4
0.53
0.22
GTTGTX
5
0.66
0.34
YNWND
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
132)
133)
134)
1-07
0
0
0
V|LELX
3
0.4
0.11
GITGTX
9
1.19
0.34
YNWNY
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
135)
136)
137)
1-20
0
0
0
V|LERX
1
0.13
0.22
GITGTX
4
0.53
0.45
YNWND
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
138)
139)
140)
1-26
4
0.53
0
V|WELLX
13
1.72
0.90
GIVGATX
36
4.76
0.78
YSGSYY
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
141)
142)
143)
2-02
31
4.1
2.47
GYCSSTSCYT
4
0.53
0.22
RIL||YQLLYX
9
1.19
2.47
DIVVVPAAIX
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
144)
145)
146)
2-08
5
0.66
0.56
GYCTNGVCYT
0
0
0
RILY|WCMLYX
3
0.4
0.56
DIVLMVYAIX
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
147)
148)
149)
2-15
29
3.83
1.57
GYCSGGSCYS
2
0.26
0.11
RIL|WW|LLLX
7
0.92
1.57
DIVVVVAATX
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
150)
151)
152)
2-21
16
2.11
0.67
AYCGGDCYS
0
0
0
SILWW|LLFX
7
0.92
0.67
HIVVVTAIX
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
153)
154)
155)
3-03
32
4.23
2.80
YYDFWSGYYT
7
0.92
0.90
VLRFLEWLLYX
27
3.57
1.12
ITIFGVVIIX
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
156)
157)
158)
3-09
13
1.72
1.35
YYDILTGYYN
5
0.66
0.78
VLRYFDWLL|X
0
0
0
ITIF|LVIIX
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
159)
160)
161)
3-10
42
5.55
4.26
YYYGSGSYYN
13
1.72
0.89
VLLWFGELL|X
11
1.45
2.91
ITMVRGVIIX
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
162)
163)
164)
3-16
18
2.38
0.67
YYDYVWGSYRYT
8
1.06
0
VL|LRLGELSLYX
5
0.66
0.34
IMITFGGVIVIX
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
165)
166)
167)
3-22
57
7.53
3.36
YYYDSSGYYY
1
0.13
0.11
VLL|||WLLLX
6
0.79
0.34
ITMIVVVITX
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
168)
169)
170)
4-04
5
0.66
0.28
DYSNY
2
0.26
0
|LQ|LX
2
0.26
0.06
TTVTX
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
171)
172)
173)
4-17
29
3.83
1.45
DYGDY
0
0
0
|LR|LX
20
2.64
0.90
TTVTX
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
174)
175)
176)
4-23
10
1.32
0.56
DYGGNS
1
0.13
0
|LRW|LX
4
0.53
0.56
TTVVTX
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
177)
178)
179)
5-05
3
0.4
0.06
WIQLWLX
10
1.32
0.39
VDTAMVX
31
4.1
0.73
GYSYGY
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
180)
181)
182)
5-12
0
0
0
WI|WLRLX
8
1.06
0.45
VDIVATIX
14
1.85
1.12
GYSGYDY
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
183)
184)
185)
5-24
11
1.45
0
|RWLQLX
5
0.66
0.34
VEMATIX
13
1.72
0.44
RDGYNY
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
186)
187)
188)
6-06
11
1.45
0.78
SIAARX
9
1.19
0.48
EYSSSS
1
0.13
0.11
V|QLVX
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
189)
190)
191)
6-13
19
2.51
1.01
GIAAAGX
35
4.62
2.13
GYSSSWY
2
0.26
0.31
V|QQLVX
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
192)
193)
194)
6-19
14
1.85
2.12
GIAVAGX
48
6.34
2.02
GYSSGWY
4
0.53
0.56
V|QWLVX
(SEQ ID NO:
(SEQ ID NO:
(SEQ ID NO:
195)
196)
197)
D7:
1
0.13
0
|LGX
2
0.26
0.68
LTGX
2
0.26
0.22
NWG
7-27
(SEQ ID NO:
198)
Total = 757
TABLE 14P
Possible library components.
Component
L
f
D2_2-02_Phz0
xxxYCSSTSCxxx
13,
31,
(SEQ ID NO: 199)
D3_3-16_Phz0
xxxxYVWGSYxxx
13,
18,
(SEQ ID NO: 200)
D5_5-12_Phz2
xxxxxxxSGYxxx
13,
14,
(SEQ ID NO: 201)
D3_3-09_Phz0
xxxYDILTGYYxx
13,
13,
(SEQ ID NO: 202)
D2_2-02_Phz2
xxxVVVPAAxxxx
13,
9,
(SEQ ID NO: 203)
D3_3-22_Phz0
xxxYYDSSGYxx
12,
57,
(SEQ ID NO: 204)
D3_3-03_Phz0
xxxDFWSGxxxx
12,
32,
(SEQ ID NO: 205)
D3_3-03_Phz2
xxxTIFGVxxxx
12,
27,
(SEQ ID NO: 206)
D5_5-12_Phz1
xxxxIVATxxxx
12,
8,
(SEQ ID NO: 207)
D3_3-10_Phz0
xxxYGSGSYYx
11,
42,
!
could add one
x at either end
(SEQ ID NO: 208)
D5_5-05_Phz2
xxxxYSYGxxx
11,
31,
(SEQ ID NO: 209)
D2_2-15_Phz0
xxxCSGxxCYx
11,
29,
(SEQ ID NO: 210)
D6_6-13_Phz0
xxxxAAAGxxx
11,
19,
(SEQ ID NO: 211)
D4_4-23_Phz0
xGxxxGGNxxx
11,
10,
(SEQ ID NO: 212)
D1_1-26_Phz2
xxxSGSYxxx
10,
35,
(SEQ ID NO: 213)
D6_6-13_Phz1
xxxSSSWxxx
10,
35,
(SEQ ID NO: 214)
D4_4-17_Phz2
xxxxTTVTTx
10,
20,
(SEQ ID NO: 215)
D2_2-21_Phz0
xxxC(SG)GDxCx
10,
16,
(SEQ ID NO: 216)
D6_6-19_Phz0
xxx(IV)AVAGxx
10,
14,
(SEQ ID NO: 217)
D3_3-10_Phz1
xxLWFGELxx
10,
13,
(SEQ ID NO: 218)
D5_5-24_Phz0
GxxWLxxxxF
10,
11,
(SEQ ID NO: 219)
D5_5-05_Phz1
xxxDTxMVxx
10,
10,
(SEQ ID NO: 220)
D3_3-16_Phz1
xxxxxGExxx
10,
8,
(SEQ ID NO: 221)
D6_6-19_Phz1
xxxxSGWxx
9,
48,
(SEQ ID NO: 222)
D5_5-24_Phz2
xxxxGYNxx
9,
13,
(SEQ ID NO: 223)
D3_3-10_Phz2
xxxVRGVxx
9,
11,
(SEQ ID NO: 224)
D6_6-06_Phz0
xxxIAAxxx
9,
11,
(SEQ ID NO: 225)
D1_1-07_Phz2
xxYxWNxxx
9,
9,
(SEQ ID NO: 226)
D4_4-17_Phz0
xxxYGDxx
8,
29,
(SEQ ID NO: 227)
D1_1-26_Phz1
xxVGATxx
8,
13,
(SEQ ID NO: 228)
D6_6-06_Phz1
xxxXSSSx
8,
9,
(SEQ ID NO: 229)
TABLE 15P
Lengths of CDRs: 1095 actual VH domains and 51 VH GLGs.
Length
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
CDR1
0
0
10
0
1
820
38
175
1
1
5
1
11
0
23
1
7
0
GLG
0
0
0
0
0
38
3
10
0
0 . . .
CDR2
0
0
0
0
0
2
0
0
0
0
0
0
0
0
0
0
464
579
GLG
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
17
28
CDR3
0
0
0
4
2
8
6
28
40
65
77
90
117
117
88
105
86
81
Length
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
(33 or more)
CDR2
9
31
1
3
3
1
0
0
0
0
2
0
0 . . .
GLG
1
4
0
0 . . .
CDR3
45
36
36
16
16
8
8
2
3
0
2
1
0
0
1
5
TABLE 16P
Library of HC CDR3
Bomponent
Fraction of
Length
#X
Complexity
library
Adjusted
1:
YYCA21111YFDYWG.
8
4
2.6E5
.10 (0-8)
.02
(2 = KR) (SEQ ID NO: 6)
2:
YYCA2111111YFDYWG.
10
6
9.4E7
.14 (9-10)
.14
(2 = KR) (SEQ ID NO: 7)
3:
YYCA211111111YFDYTG.
12
8
3.4E10
.25 (11 + 12 + 13/2)
.25
(2 = KR) (SEQ ID NO: 8)
4:
YYCAR111S2S3111YFDYWG.
14
6
1.9E8
.13 (14 + 13/2)
.14
(2 = SG 3 = YW)
(SEQ ID NO: 9)
5:
YYCA2111CSG11CY1YFDYWG.
15
6
9.4E7
.13 (15 + 16/2)
.14
(2 = KR) (SEQ ID NO: 10)
6:
YYCA211S1TIFG11111YFDYWG.
17
8
1.7E10
.11 (17 + 16/2)
.12
(2 = KR) (SEQ ID NO: 11)
7:
YYCAR111YY2S33YY111YFDYWG.
18
6
3.8E8
.04 (18)
.08
(2 = D|G; 3 = S|G)
(SEQ ID NO: 12)
8:
YYCAR1111YC2231CY111YFDYWG.
19
8
2.0E11
.10 (19 on)
.11
(2 = S|G; 3 = T|D|G)
(SEQ ID NO: 13)
Allowed lengths: 8, 10, 12, 14, 15, 17, 18, & 19
TABLE 17P
vgDNA encoding the CDR3 elements of the library
! CDR3 library components
(Ctop25)
5′-gctctggtcaa C |TTA|A Gg|gct|gag|g-3′ (SEQ ID NO: 40)
(CtprmA)
5′-gctctggtcaa C |TTA|A Gg|gct|gag|gac-
!
AflII...
|acc|gct|gtc|tac|tac|tgc|gcc-3′ (SEQ ID NO: 41)
!
(CBprmB)
[RC] 5′- |tac|ttc|gat|tac|ttg|ggc|caa |GGT|ACC|ct G|GTC|ACC| tcgctccacc-3′ (SEQ ID NO: 42)
!
BstEII...
!
(CBot25)
[RC] 5′- |GG T|ACC|ct G|GTC|ACC| tcgctccacc-3′ (SEQ ID NO: 43)
!
! N.B. [RC] means the the actual oligonucleotide is the reverse complement
! of the one shown.
! N.B. The 20 bases at 3′ end of CtprmA are identical to the most 5′ 20 bases
! of each of the vgDNA molecules.
! N.B. Ctop25 is identical to the most 5′ 25 bases of CtprmA.
! N.B. The 23 most 3′ bases of CBprmB are the reverse complement of the
! most 3′ 23 bases of each of the vgDNA molecules.
! N.B. CBot25 is identical to the 25 bases at the 5′ end of CBprmB.
!
(C1t08)
5′- cc|gct|gtc|tac|tac|tgc|gcc|-
<2>|<1>|<1>|<1>|<1>-
|tac|ttc|gat|tac|ttg|ggc|caa|GG -3′ (SEQ ID NO: 44)
! 2 = KR, 1 = 0.27Y + 0.27G + 0.027{ADEFHIKLMNPQRSTVW} no C
!
(C2t10)
5′-cc|gct|gtc|tac|tac|tgc|gcc|-
<2>|<1>|<1>|<1>|<1>|<1>|<1>|-
tac|ttc|gat|tac|ttg|ggc|caa|GG -3′ (SEQ ID NO: 45)
! 2 = KR, 1 = 0.27Y + 0.27G + 0.027{ADEFHIKLMNPQRSTVW} no C
!
(C3t12)
5′-cc|gct|gtc|tac|tac|tgc|gcc|-
<2>|<1>|<1>|<1>|<1>|<1>|<1>|<1>|<1>|-
tac|ttc|gat|tac|ttg|ggc|caa|GG -3′ (SEQ ID NO: 46)
! 2 = KR, 1 = 0.27Y + 0.27G + 0.027{ADEFHIKLMNPQRSTVW} no C
!
(C4t14)
5′-cc|gct|gtc|tac|tac|tgc|gcc|cgt|-
|<1>|<1>|<1>|tct|<2>|tct|<3>|<1>|<1>|<1>|-
tac|ttc|gat|tac|ttg|ggc|caa|GG -3′ (SEQ ID NO: 47)
! 2 = SG, 1 = 0.27Y + 0.27G + 0.027{ADEFHIKLMNPQRSTVW} no C, 3 = YW
!
(C5t15)
5′-cc|gct|gtc|tac|tac|tgc|gcc|-
<2>|<1>|<1>|<1>|tgc|tct|ggt|<1>|<1>|tgc|tat|<1>|-
tac|ttc|gat|tac|ttg|ggc|caa|GG -3′ (SEQ ID NO: 48)
! 2 = KR, 1 = 0.27Y + 0.27G + 0.027{ADEFHIKLMNPQRSTVW} no C
!
(C6t17)
5′-cc|gct|gtc|tac|tac|tgc|gcc|-
<2>|<1>|<1>|tct|<1>|act|atc|ttc|ggt|<1>|<1>|<1>|<1>|<1>|-
tac|ttc|gat|tac|ttg|ggc|caa|GG-3′ (SEQ ID NO: 49)
! 2 = KR, 1 = 0.27Y + 0.27G + 0.027{ADEFHIKLMNPQRSTVW} no C
!
(C7t18)
5′-cc|gct|gtc|tac|tac|tgc|gcc|cgt|-
|<1>|<1>|<1>|tat|tac|<2>|tct|<3>|<3>|tac|tat|<1>|<1>|<1>|-
tac|ttc|gat|tac|ttg|ggc|caa|GG-3′ (SEQ ID NO: 50)
! 2 = DG, 1 = 0.27Y + 0.27G + 0.027{ADEFHIKLMNPQRSTVW} no C, 3 = SG
!
(c8t19)
5′-cc|gct|gtc|tac|tac|tgc|gcc|cgt|-
|<1>|<1>|<1>|<1>|tat|tgc|<2>|<2>|<3>|<1>|tgc|tat|<1>|<1>|<1>|-
tac|ttc|gat|tac|ttg|ggc|caa|GG-3′ (SEQ ID NO: 51)
! 2 = SG, 1 = 0.27Y + 0.27G + 0.027{ADEFHIKLMNPQRSTVW} no C, 3 = TDG
!
TABLE 19
Names of 1398 GeneBank entries examined
haj10335
hsa006167
hsa234193
hsa234294
hsa239370
hsa241345
hsa244970
hs201e3
hsa006169
hsa234194
hsa234296
hsa239371
hsa241346
hsa244971
hs201g1
hsa006171
hsa234196
hsa234298
hsa239372
hsa241347
hsa244972
hs201m2
hsa006173
hsa234197
hsa235649
hsa239373
hsa241348
hsa244973
hs202e2
hsa131921
hsa234199
hsa235658
hsa239375
hsa241349
hsa244974
hs202g3
hsa132847
hsa234202
hsa235662
hsa239376
hsa241350
hsa244975
hs202g9
hsa132849
hsa234203
hsa235664
hsa239377
hsa241351
hsa244976
hs202m3
hsa132850
hsa234205
hsa235665
hsa239378
hsa241353
hsa244977
hs203e1
hsa132851
hsa234206
hsa235667
hsa239379
hsa241354
hsa244978
hs203g1
hsa132852
hsa234207
hsa235671
hsa239380
hsa241355
hsa244979
hs203m5
hsa224746
hsa234208
hsa235675
hsa239381
hsa241356
hsa244980
hs204e1
hsa225092
hsa234209
hsa235677
hsa239382
hsa241357
hsa244981
hs204g1
hsa225093
hsa234211
hsa238036
hsa239383
hsa241420
hsa244982
hs3d6hcv
hsa230634
hsa234212
hsa238037
hsa239384
hsa241421
hsa244983
hs6d4xa7
hsa230635
hsa234214
hsa238038
hsa239385
hsa242555
hsa244984
hs6d4xb7
hsa230636
hsa234217
hsa238039
hsa239386
hsa242556
hsa244985
hs6d4xf1
hsa230637
hsa234221
hsa238040
hsa239387
hsa243108
hsa244986
hs6d4xf2
hsa230638
hsa234224
hsa238326
hsa239388
hsa243110
hsa244987
hs6d4xg3
hsa230639
hsa234227
hsa238327
hsa239390
hsa244928
hsa244988
hs6d4xh5
hsa230640
hsa234229
hsa238328
hsa239391
hsa244929
hsa244989
hs83x6b2
hsa230641
hsa234230
hsa239330
hsa240553
hsa244930
hsa244990
hs83x6b5
hsa230643
hsa234232
hsa239331
hsa240554
hsa244931
hsa244991
hs83x6c3
hsa230644
hsa234235
hsa239332
hsa240555
hsa244932
hsa244992
hs83x6c4
hsa230645
hsa234238
hsa239333
hsa240556
hsa244933
hsa244993
hs83x6c5
hsa230646
hsa234239
hsa239334
hsa240557
hsa244934
hsa244994
hs83x6d4
hsa230647
hsa234242
hsa239335
hsa240558
hsa244935
hsa244995
hs83x6f1
hsa230648
hsa234245
hsa239336
hsa240559
hsa244936
hsa244996
hs83x6f2
hsa230649
hsa234248
hsa239337
hsa240560
hsa244937
hsa244997
hs83x6f3
hsa230650
hsa234249
hsa239338
hsa240561
hsa244938
hsa244998
hs83x6f5
hsa230651
hsa234251
hsa239339
hsa240562
hsa244939
hsa244999
hs83x6h3
hsa230652
hsa234252
hsa239340
hsa240563
hsa244940
hsa245000
hs83x9a6
hsa230653
hsa234255
hsa239341
hsa240564
hsa244941
hsa245001
hs83x9b6
hsa230654
hsa234256
hsa239342
hsa240565
hsa244942
hsa245002
hs83x9b9
hsa230655
hsa234257
hsa239343
hsa240566
hsa244943
hsa245003
hs83x9c8
hsa230656
hsa234258
hsa239344
hsa240567
hsa244944
hsa245004
hs83x9d6
hsa230657
hsa234259
hsa239345
hsa240568
hsa244945
hsa245005
hs83x9d7
hsa230658
hsa234260
hsa239346
hsa240569
hsa244946
hsa245006
hs83x9e6
hsa234156
hsa234262
hsa239347
hsa240570
hsa244947
hsa245007
hs83x9e8
hsa234158
hsa234263
hsa239348
hsa240571
hsa244948
hsa245008
hs83x9e9
hsa234160
hsa234264
hsa239349
hsa240572
hsa244949
hsa245009
hs83x9f6
hsa234161
hsa234266
hsa239350
hsa240573
hsa244950
hsa245010
hs83x9g6
hsa234163
hsa234268
hsa239351
hsa240575
hsa244951
hsa245011
hs9d4x10
hsa234164
hsa234269
hsa239353
hsa240576
hsa244952
hsa245012
hs9d4x7
hsa234166
hsa234270
hsa239354
hsa240578
hsa244953
hsa245013
hs9d4x8
hsa234168
hsa234272
hsa239355
hsa240580
hsa244954
hsa245014
hs9d4x9
hsa234169
hsa234273
hsa239356
hsa240581
hsa244955
hsa245015
hs9d4xa6
hsa234171
hsa234274
hsa239357
hsa240582
hsa244956
hsa245016
hs9d4xa7
hsa234172
hsa234276
hsa239358
hsa240585
hsa244957
hsa245017
hs9d4xb6
hsa234175
hsa234277
hsa239359
hsa240586
hsa244958
hsa245018
hs9d4xc2
hsa234178
hsa234279
hsa239360
hsa240588
hsa244959
hsa245019
hs9d4xd6
hsa234180
hsa234281
hsa239361
hsa240589
hsa244960
hsa245020
hs9d4xe6
hsa234181
hsa234282
hsa239362
hsa240590
hsa244961
hsa245021
hs9d4xf3
hsa234183
hsa234283
hsa239363
hsa240592
hsa244962
hsa245022
hs9d4xh4
hsa234184
hsa234284
hsa239364
hsa240593
hsa244963
hsa245023
hs9d4xh5
hsa234186
hsa234286
hsa239365
hsa240594
hsa244965
hsa245024
hsa005975
hsa234187
hsa234287
hsa239366
hsa240595
hsa244966
hsa245025
hsa005977
hsa234189
hsa234288
hsa239367
hsa240599
hsa244967
hsa245026
hsa006161
hsa234190
hsa234290
hsa239368
hsa240604
hsa244968
hsa245027
hsa006165
hsa234191
hsa234291
hsa239369
hsa241344
hsa244969
hsa245028
hsa245029
hsa245225
hsa245319
hsa279536
hsasighc
hsb8g3g01
hsfs11hc
hsa245030
hsa245226
hsa245320
hsa279537
hsavh510
hsb8g3g03
hsfs9whc
hsa245031
hsa245228
hsa245321
hsa279543
hsavh512
hsb8g3g05
hsgad2h
hsa245032
hsa245229
hsa245322
hsa279544
hsavh513
hsb8g3g10
hsgvh0117
hsa245033
hsa245230
hsa245323
hsa279545
hsavh514
hsb8g3h01
hsgvh0118
hsa245034
hsa245231
hsa245325
hsa279552
hsavh515
hsb8g4c02
hsgvh0119
hsa245035
hsa245232
hsa245326
hsa389169
hsavh516
hsb8g4e01
hsgvh0120
hsa245036
hsa245233
hsa245338
hsa389170
hsavh517
hsb8g4e05
hsgvh0121
hsa245037
hsa245234
hsa245342
hsa389171
hsavh519
hsb8g4f11
hsgvh0122
hsa245039
hsa245235
hsa245343
hsa389172
hsavh520
hsb8g4h09
hsgvh0123
hsa245040
hsa245236
hsa245345
hsa389173
hsavh523
hsb8g4h10
hsgvh0124
hsa245041
hsa245237
hsa245346
hsa389174
hsavh524
hsb8g5d10
hsgvh0201
hsa245042
hsa245238
hsa245347
hsa389175
hsavh526
hsb8g5h08
hsgvh0202
hsa245043
hsa245239
hsa245348
hsa389176
hsavh529
hsbel1
hsgvh0203
hsa245044
hsa245240
hsa245349
hsa389177
hsavh53
hsbel14
hsgvh0204
hsa245045
hsa245241
hsa245350
hsa389178
hsavh56
hsbel28
hsgvh0205
hsa245046
hsa245246
hsa245352
hsa389179
hsb3g4a07
hsbel29
hsgvh0206
hsa245047
hsa245251
hsa245353
hsa389180
hsb73g04n
hsbel3
hsgvh0207
hsa245048
hsa245255
hsa245355
hsa389181
hsb74a08n
hsbel34
hsgvh0208
hsa245049
hsa245258
hsa245356
hsa389182
hsb7g1a11
hsbel43
hsgvh0209
hsa245050
hsa245260
hsa245357
hsa389183
hsb7g2b01
hsbel45
hsgvh0210
hsa245051
hsa245261
hsa245358
hsa389184
hsb7g3a01
hsbel5
hsgvh0211
hsa245052
hsa245262
hsa245359
hsa389185
hsb7g3a05
hsbel54
hsgvh0213
hsa245053
hsa245263
hsa249378
hsa389186
hsb7g3a10
hsbel69
hsgvh0214
hsa245054
hsa245265
hsa249628
hsa389187
hsb7g3b02
hsbo1vhig
hsgvh0215
hsa245055
hsa245266
hsa249629
hsa389188
hsb7g3b03
hsbo3vhig
hsgvh0216
hsa245056
hsa245268
hsa249630
hsa389190
hsb7g3b05
hsbr1vhig
hsgvh0217
hsa245057
hsa245272
hsa249631
hsa389191
hsb7g3c03
hsbradh3
hsgvh0218
hsa245058
hsa245273
hsa249632
hsa389192
hsb7g3c12
hscal4ghc
hsgvh0219
hsa245059
hsa245275
hsa249633
hsa389193
hsb7g3d07
hsd4xd10
hsgvh0220
hsa245060
hsa245277
hsa249634
hsa389194
hsb7g3e01
hsd4xf21
hsgvh0221
hsa245061
hsa245278
hsa249635
hsa389195
hsb7g3f02
hsd4xg2
hsgvh0222
hsa245062
hsa245279
hsa249636
hsa389927
hsb7g3f10
hsd4xi10
hsgvh0223
hsa245063
hsa245280
hsa249637
hsa389929
hsb7g3g02
hsd4xi4
hsgvh0224
hsa245064
hsa245281
hsa271600
hsa6351
hsb7g3g04
hsd4xk9
hsgvh0302
hsa245065
hsa245282
hsa271601
hsa7321
hsb7g4a08
hsd4xl3
hsgvh0304
hsa245066
hsa245283
hsa271602
hsa7322
hsb7g4c05
hsd5hc
hsgvh0306
hsa245067
hsa245284
hsa271603
hsa7323
hsb7g4d09
hsdo1vhig
hsgvh0307
hsa245068
hsa245285
hsa271604
hsa7325
hsb7g4f08
hseliepa1
hsgvh0308
hsa245069
hsa245286
hsa279513
hsa7326
hsb7g4g07
hseliepa3
hsgvh0309
hsa245071
hsa245287
hsa279514
hsa7328
hsb7g5g03
hseliepa4
hsgvh0310
hsa245072
hsa245288
hsa279515
hsa7438
hsb8g1c04
hseliepb2
hsgvh0311
hsa245073
hsa245289
hsa279516
hsa7440
hsb8g1e04
hseliepd2
hsgvh0312
hsa245201
hsa245290
hsa279517
hsa7441
hsb8g1f03
hselilpb1
hsgvh0314
hsa245203
hsa245291
hsa279519
hsa7442
hsb8g1g04
hsevh51a1
hsgvh0315
hsa245204
hsa245292
hsa279520
hsa7443
hsb8g1h02
hsevh51b1
hsgvh0318
hsa245208
hsa245294
hsa279521
hsa7444
hsb8g2f09
hsevh52a1
hsgvh0320
hsa245209
hsa245298
hsa279522
hsaarma1
hsb8g2g08
hsevh52a2
hsgvh0321
hsa245210
hsa245299
hsa279523
hsabhiv8
hsb8g3b07
hsevh52a3
hsgvh0322
hsa245214
hsa245301
hsa279524
hsadeigvh
hsb8g3c07
hsevh52a4
hsgvh0323
hsa245215
hsa245305
hsa279526
hsaj2768
hsb8g3c08
hsevh52a5
hsgvh0324
hsa245217
hsa245307
hsa279527
hsaj2769
hsb8g3c12
hsevh52b1
hsgvh0325
hsa245218
hsa245309
hsa279528
hsaj2771
hsb8g3d03
hsevh53a1
hsgvh0326
hsa245219
hsa245311
hsa279529
hsaj2772
hsb8g3d04
hsevh53a2
hsgvh0327
hsa245220
hsa245312
hsa279530
hsaj2773
hsb8g3d07
hsfog1h
hsgvh0328
hsa245221
hsa245313
hsa279531
hsaj2776
hsb8g3d08
hsfog3h
hsgvh0329
hsa245222
hsa245315
hsa279532
hsaj2777
hsb8g3e02
hsfogbh
hsgvh0330
hsa245223
hsa245317
hsa279533
hsaj4083
hsb8g3e03
hsfom1h
hsgvh0331
hsa245224
hsa245318
hsa279535
hsaj4899
hsb8g3f03
hsfs10hc
hsgvh0332
hsgvh0333
hsigathc
hsighxx10
hsigvhc26
hsld1117
hsmvh51
hst14x23
hsgvh0334
hsigdvrhc
hsighxx11
hsigvhc27
hsld152
hsmvh510
hst14x24
hsgvh0335
hsigg1kh
hsighxx12
hsigvhc28
hsld21
hsmvh511
hst14x25
hsgvh0336
hsigg1kl
hsighxx14
hsigvhc29
hsld217
hsmvh512
hst14x3
hsgvh0419
hsigg1lh
hsighxx16
hsigvhc30
hsld218
hsmvh515
hst14x6
hsgvh0420
hsigghc85
hsighxx18
hsigvhc31
hsld25
hsmvh516
hst14x7
hsgvh0421
hsigghcv3
hsighxx2
hsigvhc32
hsmad2h
hsmvh517
hst14x8
hsgvh0422
hsigghevr
hsighxx20
hsigvhc33
hsmbcl5h4
hsmvh53
hst14x9
hsgvh0423
hsiggvdj1
hsighxx21
hsigvhc35
hsmica1h
hsmvh54
hst22x1
hsgvh0424
hsiggvdj2
hsighxx22
hsigvhc36
hsmica3h
hsmvh55
hst22x11
hsgvh0428
hsiggvhb
hsighxx23
hsigvhc37
hsmica4h
hsmvh56
hst22x12
hsgvh0429
hsiggvhc
hsighxx25
hsigvhc38
hsmica5h
hsmvh57
hst22x13
hsgvh0430
hsigh10g1
hsighxx26
hsigvhc39
hsmica6h
hsmvh58
hst22x14
hsgvh0517
hsigh10g2
hsighxx28
hsigvhc40
hsmica7h
hsmvh59
hst22x15
hsgvh0519
hsigh10g3
hsighxx29
hsigvhc41
hsmt11ige
hsnamembo
hst22x18
hsgvh0522
hsigh10g4
hsighxx3
hsigvhc42
hsmt12ige
hsnpb346e
hst22x20
hsgvh0523
hsigh10g5
hsighxx30
hsigvhc43
hsmt13ige
hsoak3h
hst22x21
hsgvh0526
hsigh10g7
hsighxx31
hsigvhls
hsmt14ige
hsog31h
hst22x22
hsgvh0527
hsigh10g8
hsighxx32
hsigvhttd
hsmt15ige
hspag1h
hst22x23
hsgvh0531
hsigh10g9
hsighxx34
hsigvp151
hsmt16ige
hsrael
hst22x25
hsgvh511
hsigh13g1
hsighxx36
hsigvp152
hsmt17ige
hsregah
hst22x26
hsgvh512
hsigh13g7
hsighxx37
hsigvp153
hsmt21ige
hsrfabh37
hst22x27
hsgvh513
hsigh14g1
hsighxx38
hsigvp154
hsmt22ige
hsrighvja
hst22x28
hsgvh515
hsigh14g2
hsighxx5
hsigvp155
hsmt23ige
hsrighvjb
hst22x30
hsgvh519
hsigh2f2
hsighxx6
hsigvp156
hsmt24ige
hsrou10
hst22x9
hsgvh521
hsigh3135
hsighxx7
hsigvp157
hsmt25ige
hsrou11
hsu24687
hsgvh526
hsigh35
hsighxx8
hsigvp158
hsmt26ige
hsrou111
hsu24688
hsgvh530
hsigh44
hsighxx9
hsigvp251
hsmt27ige
hsrou112
hsu24690
hsgvh533
hsigh4c2
hsigkrf
hsigvp255
hsmutuiem
hsrou119
hsu24691
hsgvh534
hsigh9e1
hsigmhavh
hsigvp256
hsmvh0001
hsrou122
hsv52a512
hsgvh535
hsighadi2
hsigrhe15
hsigvp257
hsmvh0002
hsrou126
hsvdj10h
hsgvh536
hsighadi3
hsigtgk1h
hsigvp360
hsmvh0003
hsrou127
hsvdj12h
hsgvh55
hsighcvr
hsigtgk4h
hsigvp363
hsmvh0004
hsrou129
hsvgcg1
hsh217e
hsighcza
hsigtgl9h
hsigvp369
hsmvh0005
hsrou13
hsvgcm1
hsh241e
hsighczb
hsigvarh1
hsigvp39
hsmvh0006
hsrou131
hsvgcm1
hsh28e
hsighczc
hsigvhc
hsihr8
hsmvh0007
hsrou18
hsvh1djh6
hsha3d1ig
hsighczd
hsigvhc01
hsihr9
hsmvh0009
hsrou219
hsvh3djh4
hshambh
hsighczf
hsigvhc02
hsihv1
hsmvh0010
hsrou221
hsvh4dj
hshcmg42
hsighczg
hsigvhc03
hsihv11
hsmvh0011
hsrou222
hsvh4djh6
hshcmg43
hsigheavy
hsigvhc04
hsihv18
hsmvh0012
hsrou233
hsvh4r
hshcmg44
hsighpat2
hsigvhc05
hsim9vch
hsmvh0401
hsrt792hc
hsvh52a43
hshcmg46
hsighpat3
hsigvhc06
hsimghc1
hsmvh0403
hsrt79hc
hsvh52a55
hshcmt42
hsighpat4
hsigvhc07
hsimghc2
hsmvh0404
hssm1vhig
hsvh5dj
hshcmt47
hsighpat5
hsigvhc08
hsimghc3
hsmvh0405
hssp46a
hsvh5djh5
hsig001vh
hsighpat6
hsigvhc09
hsimghc4
hsmvh0406
hst14vh
hsvh710p1
hsig030vh
hsighpat7
hsigvhc10
hsimghc5
hsmvh0501
hst14x1
hsvheg7
hsig033vh
hsighpat8
hsigvhc11
hsin42p5
hsmvh0502
hst14x10
hsvhfa2
hsig039vh
hsighpat9
hsigvhc12
hsin51p7
hsmvh0503
hst14x11
hsvhfa7
hsig040vh
hsighpt11
hsigvhc14
hsin51p8
hsmvh0504
hst14x12
hsvhfb5
hsig055vh
hsighpt12
hsigvhc16
hsin78
hsmvh0505
hst14x13
hsvhfc2
hsig057vh
hsighpta1
hsigvhc17
hsin87
hsmvh0506
hst14x14
hsvhfd7
hsig1059
hsighvb5
hsigvhc18
hsin89p2
hsmvh0507
hst14x15
hsvhfe5
hsig10610
hsighvca
hsigvhc19
hsin92
hsmvh0508
hst14x16
hsvhfg9
hsig13g10
hsighvcb
hsigvhc20
hsin98p1
hsmvh0509
hst14x17
hsvhgd8
hsig473
hsighvcc
hsigvhc21
hsjac10h
hsmvh0510
hst14x18
hsvhgd9
hsig7sa11
hsighvcd
hsigvhc22
hsjhba1f
hsmvh0511
hst14x19
hsvhgh7
hsigaehc
hsighvce
hsigvhc23
hsjhbr2f
hsmvh0513
hst14x20
hsvhha10
hsigaf2h2
hsighvm
hsigvhc24
hsjhej1f
hsmvh0515
hst14x21
hsvhia2
hsigashc
hsighxx1
hsigvhc25
hsld1110
hsmvh0529
hst14x22
hsvhia5
hsvhib12
hsvhp46
hsx98948
hsz74671
hsz80393
hsz80438
hsz80489
hsvhib6
hsvhp48
hsx98950
hsz74672
hsz80394
hsz80439
hsz80492
hsvhib8
hsvhp53
hsx98951
hsz74682
hsz80397
hsz80441
hsz80495
hsvhic1
hsvhp7
hsx98952
hsz74688
hsz80400
hsz80442
hsz80496
hsvhic10
hsvigd9
hsx98953
hsz74690
hsz80403
hsz80443
hsz80499
hsvhic11
hswad35vh
hsx98954
hsz74693
hsz80406
hsz80445
hsz80500
hsvhic2
hswanembo
hsx98955
hsz74695
hsz80407
hsz80458
hsz80502
hsvhic3
hswo1vhig
hsx98956
hsz80363
hsz80409
hsz80459
hsz80504
hsvhid1
hsww1p10e
hsx98958
hsz80364
hsz80411
hsz80460
hsz80507
hsvhid5
hsx98932
hsx98963
hsz80365
hsz80412
hsz80461
hsz80509
hsvhid7
hsx98933
hsy14934
hsz80367
hsz80414
hsz80462
hsz80512
hsvhid9
hsx98934
hsy14935
hsz80368
hsz80415
hsz80463
hsz80513
hsvhie4
hsx98935
hsy14936
hsz80372
hsz80416
hsz80465
hsz80517
hsvhif10
hsx98936
hsy14937
hsz80375
hsz80417
hsz80466
hsz80519
hsvhif3
hsx98938
hsy14938
hsz80377
hsz80418
hsz80473
hsz80520
hsvhif7
hsx98939
hsy14939
hsz80378
hsz80421
hsz80474
hsz80527
hsvhig2
hsx98940
hsy14940
hsz80383
hsz80422
hsz80475
hsz80534
hsvhp2
hsx98941
hsy14943
hsz80385
hsz80424
hsz80476
hsz80538
hsvhp29
hsx98943
hsy14945
hsz80386
hsz80426
hsz80477
hsz80544
hsvhp30
hsx98944
hsy18120
hsz80388
hsz80427
hsz80480
hsz80545
hsvhp32
hsx98945
hsz74663
hsz80390
hsz80429
hsz80482
hsvhp34
hsx98946
hsz74665
hsz80391
hsz80433
hsz80483
hsvhp4
hsx98947
hsz74668
hsz80392
hsz80436
hsz80487
TABLE 20P
Human GLG CDR1 & CDR2 AA seqs
CDR2
CDR1
1 1 1
Name
1234567
1234567890123456789
1-02
GYY--MH
WINPNSGG--TNYAQKFQG
(SEQ ID NO: 231)
1-03
SYA--MH
WINAGNGN--TKYSQKFQG
(SEQ ID NO: 233)
1-08
SYD--IN
WMNPNSGN--TGYAQKFQG
(SEQ ID NO: 235)
1-18
SYG--IS
WISAYNGN--TNYAQKLQG
(SEQ ID NO: 237)
1-24
ELS--MH
GFDPEDGE--TIYAQKFQG
(SEQ ID NO: 239)
1-45
YRY--LH
WITPFNGN--TNYAQKFQD
(SEQ ID NO: 241)
1-46
SYY--MH
IINPSGGS--TSYAQKFQG
(SEQ ID NO: 243)
1-58
SSA--VQ
WIVVGSGN--TNYAQKFQE
(SEQ ID NO: 245)
1-69
SYA--IS
GIIPIFGT--ANYAQKFQG
(SEQ ID NO: 247)
1-e
SYA--IS
GIIPIFGT--ANYAQKFQG
(SEQ ID NO: 249)
1-f
DYY--MH
LVDPEDGE--TIYAEKFQG
(SEQ ID NO: 251)
2-05
TSGVGVG
LIYWNDDK---RYSPSLKS
(SEQ ID NO: 253)
2-26
NARMGVS
HIFSNDEK---SYSTSLKS
(SEQ ID NO: 255)
2-70
TSGMRVS
RIDWDDDK---FYSTSLKT
(SEQ ID NO: 257)
3-07
SYW--MS
NIKQDGSE--KYYVDSVKG
(SEQ ID NO: 259)
3-09
DYA--MH
GISWNSGS--IGYADSVKG
(SEQ ID NO: 261)
3-11
DYY--MS
YISSSGST--IYYADSVKG
(SEQ ID NO: 263)
3-13
SYD--MH
AIGTAGD---TYYPGSVKG
(SEQ ID NO: 265)
3-15
NAW--MS
RIKSKTDGGTTDYAAPVKG
(SEQ ID NO: 267)
3-20
DYG--MS
GINWNGGS--TGYADSVKG
(SEQ ID NO: 269)
3-21
SYS--MN
SISSSSSY--IYYADSVKG
(SEQ ID NO: 271)
3-23
SYA--MS
AISGSGGS--TYYADSVKG
(SEQ ID NO: 273)
3-30
SYG--MH
VISYDGSN--KYYADSVKG
(SEQ ID NO: 275)
3303
SYA--MH
VISYDGSN--KYYADSVKG
(SEQ ID NO: 277)
3305
SYG--MH
VISYDGSN--KYYADSVKG
(SEQ ID NO: 279)
3-33
SYG--MH
VIWYDGSN--KYYADSVKG
(SEQ ID NO: 281)
3-43
DYT--MH
LISWDGGS--TYYADSVKG
(SEQ ID NO: 283)
3-48
SYS--MN
YISSSSST--IYYADSVKG
(SEQ ID NO: 285)
3-49
DYA--MS
FIRSKAYGGTTEYTASVKG
(SEQ ID NO: 287)
3-53
SNY--MS
VIYSGGS---TYYADSVKG
(SEQ ID NO: 289)
3-64
SYA--MH
AISSNGGS--TYYANSVKG
(SEQ ID NO: 291)
3-66
SNY--MS
VIYSGGS---TYYADSVKG
(SEQ ID NO: 293)
3-72
DHY--MD
RTRNKANSYTTEYAASVKG
(SEQ ID NO: 295)
3-73
GSA--MH
RIRSKANSYATAYAASVKG
(SEQ ID NO: 297)
3-74
SYW--MH
RINSDGSS--TSYADSVKG
(SEQ ID NO: 299)
3-d
SNE--MS
SISGGS----TYYADSRKG
(SEQ ID NO: 301)
4-04
SSNW-WS
EIYHSGS---TNYNPSLKS
(SEQ ID NO: 303)
4-28
SSNW-WG
YIYYSGS---TYYNPSLKS
(SEQ ID NO: 305)
4301
SGGYYWS
YIYYSGS---TYYNPSLKS
(SEQ ID NO: 307)
4302
SGGYSWS
YIYHSGS---TYYNPSLKS
(SEQ ID NO: 309)
4304
SGDYYWS
YIYYSGS---TYYNPSLKS
(SEQ ID NO: 311)
4-31
SGGYYWS
YIYYSGS---TYYNPSLKS
(SEQ ID NO: 313)
4-34
GYY--WS
EINHSGS---TNYNPSLKS
(SEQ ID NO: 315)
4-39
SSSYYWG
SIYYSGS---TYYNPSLKS
(SEQ ID NO: 317)
4-59
SYY--WS
YIYYSGS---TNYNPSLKS
(SEQ ID NO: 319)
4-61
SGSYYWS
YIYYSGS---TNYNPSLKS
(SEQ ID NO: 321)
4-b
SGYY-WG
SIYHSGS---TYYNPSLKS
(SEQ ID NO: 323)
5-51
SYW--IG
IIYPGDSD--TRYSPSFQG
(SEQ ID NO: 325)
5-a
SYW--IS
RIDPSDSY--TNYSPSFQG
(SEQ ID NO: 327)
6-1
SNSAAWN
RTYYRSKWY-NDYAVSVKS
(SEQ ID NO: 329)
74.1
SYA--MN
WINTNTGN--PTYAQGFTG
(SEQ ID NO: 331)
A
C
D
E
F
G
H
I
K
L
M
N
P
Q
R
S
T
V
W
Y
—
Consens.
CDR1 of human GLGs
1
7
1
3
2
35
2
1
Sd x
2
2
6
1
1
4
1
7
29
Ysg x
3
11
3
1
10
2
1
6
1
5
11
YAGS x
4
1
2
1
2
7
38
—
5
1
2
1
1
5
41
—
6
6
1
28
4
12
Mwi
7
1
5
16
5
1
23
SHng
CDR2 of human GLGs
1
3
2
1
5
1
2
3
1
7
4
6
7
9
X
2
1
46
1
2
1
I
3
4
1
1
2
2
8
3
12
1
1
1
15
ysn x
4
2
2
4
1
10
1
11
2
1
5
12
ysp x
5
1
8
2
1
6
2
4
8
1
17
1
sd x
6
3
7
2
26
3
8
2
Gsd x
7
4
1
17
1
2
24
1
1
SG x
8
1
3
3
3
10
9
4
1
2
15
—ns
9
2
3
46
—
10
1
3
47
—
11
2
4
5
1
1
35
3
T
12
1
2
2
1
3
2
1
11
2
3
1
22
Yn x
13
51
Y
14
31
11
1
6
1
1
An x
15
4
16
1
1
1
14
11
2
1
dpq x
16
1
11
1
38
Sk
17
13
15
1
22
Vlf
18
37
13
1
Kq
19
1
1
34
14
1
GS
TABLE 21P
Tallies of Amino-acid frequencies in mature CDR1 and CDR2
A
C
D
E
F
G
H
I
K
L
M
N
P
Q
R
S
T
V
W
Y
|
X
Tally of 23 examples with length 14
1
8
2
13
2
3
15
3
2
3
2
1
14
1
5
4
2
2
11
5
3
5
7
1
1
13
1
6
1
4
3
12
2
1
7
3
1
1
2
1
5
10
8
6
1
1
2
1
6
4
2
9
1
5
1
3
1
4
7
1
10
1
8
3
1
2
1
4
1
2
11
1
1
1
1
2
1
16
12
1
2
1
1
1
1
1
1
14
13
4
2
17
14
4
1
5
4
5
4
Tally of 11 examples with length 12
1
4
7
2
1
4
4
2
3
7
4
4
1
1
1
5
2
1
5
1
9
1
6
2
1
3
2
3
7
3
1
3
1
3
8
1
3
2
1
2
2
9
1
1
9
10
1
10
11
11
12
2
1
7
1
Tally of 175 examples with length 7
1
2
1
1
2
1
3
2
153
10
2
3
2
1
87
1
10
1
5
61
2
2
3
3
26
1
54
1
5
1
2
76
3
1
2
4
6
1
1
6
1
2
1
11
1
145
5
5
2
13
2
2
3
6
2
140
6
1
1
1
13
159
7
2
1
67
1
10
88
5
1
Tally of 38 examples with length 6
1
2
34
2
2
1
2
1
8
4
22
3
3
26
9
4
1
1
29
7
5
38
6
10
3
22
3
Tally of 820 examples with length 5
A
C
D
E
F
G
H
I
K
L
M
N
P
Q
R
S
T
V
W
Y
Seen
1
8
81
10
151
4
8
5
3
100
4
15
364
55
8
4
SGNDT
15
x
2
7
5
12
24
1
30
1
1
5
26
1
1
23
2
681
Y
15
3
202
4
24
13
13
133
10
2
7
5
2
3
32
14
13
112
231
YAGW
17
x
4
6
172
2
7
409
3
16
205
MWI
8
5
8
6
1
1
49
241
2
79
1
3
367
56
2
4
SHNT x
14
CDR2
A
C
D
E
F
G
H
I
K
L
M
N
Tally of 31 examples with CDR2 of length 19
1
11
1
1
2
1
28
3
9
1
4
1
2
6
5
1
1
1
22
1
6
16
1
1
1
1
7
1
9
7
8
23
1
9
2
18
10
4
1
1
1
1
11
1
3
1
12
2
11
9
1
1
1
1
13
1
1
14
29
15
25
3
1
16
1
17
1
1
18
1
27
19
1
30
Tally of 579 (n > 50, bold; over 400, underscored) examples with length 17
1
44
1
1
2
11
81
5
69
1
14
6
41
2
7
522
1
10
17
1
3
3
1
22
5
7
6
51
25
1
76
4
39
2
8
6
16
64
9
3
2
3
15
5
3
194
6
1
70
6
44
6
4
1
55
6
3
1
75
4
45
326
1
6
43
7
8
24
5
226
3
3
3
4
24
8
4
2
57
37
5
22
4
18
18
2
2
161
9
56
11
2
63
157
1
3
3
10
1
14
2
13
30
23
6
29
2
3
110
11
1
2
7
5
1
4
3
12
405
2
18
1
6
2
13
7
323
22
7
4
1
4
14
2
5
6
3
123
1
4
15
1
1
188
2
1
22
3
16
1
13
1
1
332
3
2
1
17
11
1
565
Tally of 464 (over 50, bold; over 400, underscored)
1
5
13
184
8
1
7
1
2
15
6
2
6
429
3
4
3
1
13
13
4
10
5
154
4
1
12
2
6
199
2
1
3
5
5
20
1
1
18
4
9
6
13
8
439
1
7
20
2
14
2
4
2
26
8
13
2
4
8
1
2
9
10
4
1
10
1
8
1
245
10
6
2
2
2
11
14
3
1
1
8
408
12
4
13
4
2
1
13
2
2
14
2
2
441
15
18
413
3
5
16
1
1
31
2
2
P
Q
R
S
T
V
W
Y
X
Tally of 31 examples with CDR2 of length 19
1
1
15
1
1
RF x
2
2
I
3
18
1
1
1
Rk
4
21
1
S
5
1
1
1
1
1
K x
6
3
1
6
1
A x
7
3
1
10
y x
8
1
5
1
G
9
1
1
1
7
1
G
10
1
21
1
T
11
26
T
12
2
1
2
x
13
29
Y
14
1
1
A
15
1
1
A
16
10
20
Sp
17
29
V
18
1
2
K
19
G
Tally of 579 (n > 50, bold; over 400, underscored) examples with
length 17
1
1
4
34
30
19
118
66
31
VGIW x
2
3
8
10
I
3
8
262
19
1
46
46
SNI x
4
178
23
6
50
11
8
16
120
PYG x
5
4
8
133
9
7
1
27
DSGN x
6
1
63
8
1
2
GDS x
7
2
11
245
14
6
1
SG x
8
1
4
11
106
90
2
1
32
NST X
9
11
5
13
4
242
8
TKIA x
10
3
52
20
10
1
1
259
YNR x
11
5
551
Y
12
3
1
89
8
44
A
13
66
138
3
1
3
DQP x
14
2
7
421
1
2
2
SK x
15
1
357
2
1
VF
16
1
199
21
4
KQ x
17
1
1
G
Tally of 464 (over 50, bold; over 400, underscored)
1
3
26
65
9
14
105
EYSL x
2
1
2
19
I
3
1
12
1
250
YN x
4
4
5
2
19
28
15
165
YH x
5
1
22
365
16
1
1
S x
6
1
1
1
G
7
1
12
357
20
1
2
1
S x
8
4
3
6
420
1
T
9
13
9
3
1
1
157
NY x
10
1
7
444
Y
11
4
21
2
2
N
12
418
14
7
1
P
13
6
452
1
1
S
14
1
18
L
15
11
10
1
2
1
K
16
3
419
5
S
TABLE 22P
Tally of VH types
1-02
16
1-03
16
1-08
13
1-18
27
1-24
5
1-45
0
1-46
14
1-58
1
1-69
37
1-e
16
1-f
1
2-05
13
2-26
1
2-70
2
3-07
33
3-09
13
3-11
15
3-13
4
3-15
10
3-20
4
3-21
25
3-23
85
3-30
55
3303
59
3305
0
3-33
42
3-43
1
3-48
24
3-49
11
3-53
12
3-64
4
3-66
4
3-72
3
3-73
3
3-74
12
3-d
0
4-04
29
4-28
3
4301
46
4302
7
4304
37
4-31
0
4-34
184
4-39
65
4-59
45
4-61
9
4-b
11
5-51
55
5-a
13
6-1
7
74.1
3
TABLE 23P
Oligonucleotides used to variegate CDR1 and CDR2 of human HC
(name) 5′-....DNA sequence....-3′
everything to right of an exclamation point is commentary
[RC] means “reverse complement” of sequence shown
If last non-comment and non-blank character is “-”, then continue
on next line.
Ignore case, “a” = “A”, “c” = “C”, etc.
Ignore “|” and blanks.
<number> means incorporate trinucleotide mixtue of given number.
CDR1
(ON-R1V1vg)
5′-ct|TCC|GGA|ttc|act|ttc|tct|-
<1>|tac|<1>|atg|<1>|-! CDR1 of length 5, ON = 55 bases
tgg|gtt|cgC|CAa|gct|ccT|GG-3′
<1> =
ADEFGHIKLMNPQRSTVWY no C
(ON-R1top)
5′-cctactgtct |TCC|GGA|ttc|act|ttc|tct-3′
(ON-R1bot)
[RC] 5′-tgg|gtt|cgC|CAa|gct|ccT|GG ttgctcactc-3′
(ON-R1V2vg)
5′-ct|TCC|GGA|ttc|act|ttc|tct|-
<6>|<7>|<7>|tac|tac|tgg|<7>|-! CDR1 of length 7, ON = 61 bases
tgg|gtt|cgC|CAa|gct|ccT|GG-3′
<6> =
ST, 1:1
<7> =
0.2025(SG) + 0.035(ADEFHIKLMNPQRTVWY) no C
(ON-R1V3vg)
5′-ct|TCC|GGA|ttc|act|ttc|tct|-
|atc|agc|ggt|ggt|tct|atc|tcc|<1>|<1>|<1>|tac|tac|tgg|<1>|-! CDR1, L = 14
tgg|gtt|cgC|CAa|gct|ccT|GG-3′ ! ON = 82 bases
CDR2
(ON-R2V1vg)
5′- ggt|ttg|gag|tgg|gtt|tct| -
<2>|atc|<2>|<3>|tct|ggt|ggc|<1>|act|<1>|-
tat|gct|gac|tcc|gtt|aaa|gg -3′ ! ON = 68 bases, CDR2 = 17 AA
(ON-R2top)
5′-ct|tgg|gtt|cgC|CAa|gct|ccT|GGt|aaa| ggt|ttg|gag|tgg|gtt|tct -3′
(ON-R2bot)
[RC] 5′- tat|gct|gac|tcc|gtt|aaa|gg t|-
cgc|ttc|act|atc|TCT|AGA|ttcctgtcac-3′ ! XbaI plus 10 bases of scab
(ON-R2V2vg)
5′- ggt|ttg|gag|tgg|gtt|tct| -
<1>|atc|<4>|<1>|<1>|ggt|<5>|<1>|<1>|<1>|-
tat|gct|gac|tcc|gtt|aaa|gg -3′ ! ON = 68 bases, CDR2 = 17 AA
<4> =
DINSWY, equimolar
<5> =
SGDN, equimolar
(ON-R2V3vg)
5′- ggt|ttg|gag|tgg|gtt|tct| -
<1>|atc|<4>|<1>|<1>|ggt|<5>|<1>|<1>|-
tat|aac|cct|tcc|ctt|aag|gg -3′ ! ON = 65 bases, CDR2 = 16 AA
(ON-R2bo3)
[RC] 5′- tat|aac|cct|tcc|ctt|aag|gg t|-
cgc|ttc|act|atc|TCT|AGA|ttcctgtcac-3′ ! XbaI plus 10 bases of scab
(ON-R2V4vg)
5′- ggt|ttg|gag|tgg|gtt|tct| -
<1>|atc|<8>|agt|<1>|<1>|<1>|ggt|ggt|act|act|<1>
tat|gcc|gct|tcc|gtt|aag|gg -3′ ! ON = 74 bases, CDR2 = 19 AA
(ON-R2bo4)
[RC] 5′- tat|gcc|gct|tcc|gtt|aag|gg t|-
cgc|ttc|act|atc|TCT|AGA|ttcctgtcac-3′ ! XbaI plus 10 bases of scab
TABLE 25P
Lengths of CDRs in 285 human kappa chains
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
CDR1
0
0
0
0
0
0
0
0
0
0
0
154
73
3
0
0
28
27
0
0
CDR2
0
0
0
0
0
0
0
285
0
0
0
0
0
0
0
0
0
0
0
0
CDR3
0
5
0
0
1
0
3
2
28
166
63
12
1
1
0
0
0
0
0
1
TABLE 26P
Tally of kappa types: V and J
V genes:
O12
59
O2
0
O18
0
O8
0
A20
0
A30
0
L14
0
L1
2
L15
0
L4
2
L18
0
L5
4
L19
0
L8
4
L23
0
L9
1
L24
0
L11
4
L12
8
O11
10
O1
0
A17
5
A1
0
A18
3
A2
0
A19
13
A3
0
A23
4
A27
79
A11
26
L2
28
L16
0
L6
11
L20
0
L25
0
B3
22
B2
0
A26
0
A10
0
A14
0
JH#
1
2
3
4
5
tally
105
64
29
78
9
TABLE 27P
Names of Kappa chains analyzed
AB022651
AB022653
AB022654
AB022656
AF007572
AF021036
AF103499
AF103500
AF103527
AF103873
AF107244
AF107245
AF107246
AF107247
AF115361
AF165099
AF165101
AF165103
AF165108
AF165110
AF165111
AF184763
AF184767
hsa004955
hsa004956
hsa011133
HSA241367
HSA241375
HSA388639
HSA388640
HSA388641
HSA388642
HSA388643
HSA388644
HSA388645
HSA388646
HSA388647
HSA388648
HSA388650
HSA388651
HSA388652
HSA388653
HSA388654
HSA388655
HSA388656
HSA388657
hsew1vk
hsew3vk
hsew4vk
hsigdpk13
hsigg1kl
HSIGGVKA
hsigk123
hsigk319
hsigklc14
hsigklc28
hsigklc5
hsigklg31
hsigklv01
hsigklv02
hsigklv03
hsigklv04
hsigklv05
hsigklv06
hsigklv07
hsigklv09
hsigklv10
hsigklv12
hsigklv13
hsigklv14
hsigklv15
hsigklv16
hsigklv17
hsigklv18
hsigklv19
hsigklv20
hsigklv21
hsigklv22
hsigklv23
hsigklv24
hsigklv25
hsigklv27
hsigklv28
hsigklv29
hsigklv31
hsigklv32
hsigklv33
hsigklv34
hsigklv35
hsigklv36
hsigklv37
hsigklv38
hsigklv39
hsigklv40
hsigklv41
hsigklv42
hsigklv43
hsigklv44
hsigklv45
hsigklv46
hsigklv49
hsigklv50
hsigklv51
hsigklv52
hsigklv53
hsigklv54a
hsigklv56
hsigklv57
hsigklv58
hsigklv59
hsigklv60
hsigklv61
hsigklv62
hsigklv63
hsigklv65
hsigklv66
hsigklv68
hsigklv69
hsigklv71
hsigkvba
hsigkvbb
hsigkvbc
hsigkvbd
hsigkvbe
hsigkvbf
hsigkvc01
hsigkvc03
hsigkvc06
hsigkvc11
hsigkvc12
hsigkvc20
hsigkvc23
hsigkvc27
hsigkvc29
hsigrklc
hsikcvjp1
hsikcvjp2
hsikcvjp3
hsikcvjp6
hsikcvjp7
hsld110vl
hsld117vl
hsld128vl
hsld140vl
hsld152vl
hsld184vl
hsld198vl
hsld24vl
hsmbcl1k1
hsmbcl1k2
hsmbcl2k2
hsmbcl5k4
hssl0avl
hss17bvl
hss1a15vl
HSU44792
HSU44794
HSU94422
hsz84852
hsz84853
humigk1dm
humigk3am
humigk3bm
humigk3cm
humigkacoa
humigkacob
humigkacoc
humigkacoe
humigkacof
humigkb1aa
humigkb1ab
humigkb1ac
humigkvra
humigkvrb
humigkvrc
humigkvrd
humigkvre
humigkvrg
humigkvrh
humigkvri
humigkx
humigky1
humigky2
humigky4
humigky5
humigky6
humigl3ac
humikc
humikca
humikcad
humikcaf
humikcag
humikcah
humikcai
humikcaj
humikcal
humikcam
humikcan
humikcas
humikcau
humikcav
humikcaw
humikcax
humikcay
humikcaz
humikcb
humikcba
humikcbb
humikcbc
humikcbd
humikcbe
humikcbf
humikcbg
humikcbh
humikcbi
humikcbj
humikcbl
humikcbm
humikcbn
humikcbo
humikcbp
humikcbq
humikcbs
humikcbt
humikcbu
humikcbv
humikcbw
humikcbx
humikcbz
humikcc
humikcca
humikccb
humikccc
humikccd
humikcce
humikccf
humikccg
humikcch
humikcci
humi kccj
humikcck
humikcco
humikccp
humikccq
humikccr
humikccs
humikcct
humikccu
humikccv
humikccw
humikcd
humikcf
humikcg
humikch
humikci
humikck
humikcm
humikcn
humikco
humikcp
humikcq
humikcr
humikcs
humikct
humikcu
humikcv
humikcva
humikcvb
humikcvc
humikcvd
humikcve
humikcvf
humikcvg
humikcvh
humikcvi
humikcvj
humikcw
humikcx
humikcy
humikcz
S46248
582746
S82747
SU96396
SU96397
TABLE 28P
AA types seen in 154 kappa sequences having CDR1 of length 11
Tally
A
C
D
E
F
G
H
I
K
L
M
N
P
Q
R
S
T
V
W
Y
1
11
143
R
2
148
1
2
2
1
A
3
152
2
S
4
1
3
3
147
Q
5
12
1
27
7
3
99
4
1
S
6
1
81
1
71
V
7
2
4
18
5
1
2
9
12
97
3
1
S
8
3
5
1
2
1
31
1
10
87
12
1
S
9
2
7
10
1
6
29
1
8
13
77
Y
10
2
150
1
1
L
11
96
4
2
46
2
1
3
A
TABLE 30P
Synthetic Kappa light chain gene
!
!
! A27::JH1 with all CDRs replaced by stuffers.
! Each stuffer contains at least one stop codon and a
! restriction site that will be unique within the diversity vector.
!
1 GAGGACCATt GGGCCCC ctccgagact
! Scab...... EcoO109I
! ApaI.
!-----------------------------------
!
28 CTCGAG cgca
! XhoI..
!-----------------------------------
!
38 acgcaatTAA TGTgagttag ctcactcatt aggcacccca ggcTTTACAc tttatgcttc
! ..-35.. Plac ..-10.
!-----------------------------------
!
98 cggctcgtat gttgtgtgga attgtgagcg gataacaatt tc
!-----------------------------------
!
140 acacagga aacagctatgac
!-----------------------------------
!
160 catgatta cgCCAAGCTT TGGagccttt tttttggaga ttttcaac
! PflMI.......
! Hind3.
!-----------------------------------
!
! M13 III signal sequence (AA seq)--------------------------->
! 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
! M K K L L F A I P L V V P F Y
206 gtg aag aag ctc cta ttt gct atc ccg ctt gtc gtt ccg ttt tac
!-----------------------------------
!
! --Signal--> FR1------------------------------------------->
! 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
! S H S A Q S V L T Q S P G T L
251 |agc|cat|aGT|GCA|Caa|tcc|gtc|ctt|act|caa|tct|cct|ggc|act|ctt|
! ApaLI...
!-----------------------------------
!
! ----- FR1 ------------------------------------->| CDR1------>
! 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
! S L S P G E R A T L S C R A S
|tcG|CTA|AGC|CCG|GGt|gaa|cgt|gct|acC|TTA|AGt|tgc|cgt|gct|tcc|
! EspI..... AflII...
! XmaI....
!
!-----------------------------------
! For CDR1:
! <1> ADEFGHIKLMNPQRSTVWY equimolar
! <2> S(0.2) ADEFGHIKLMNPQRTVWY (0.044 each)
! <3> Y(0.2) ADEFGHIKLMNPQRSTVW (0.044 each)
! In a preferred embodiment, we omit codon 52 in vgDNA for CDR1.
!
! ------- CDR1 --------------------->|--- FR2 ---------------->
! <1> <2> <2> xxx <3>
! 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
! Q S V S S S Y L A W Y Q Q K P
! |cag|tct|gtt|tcc|tct|tct|tat|ctt|gct|tgg|tat|caa|cag|aaA|CCT|
! SexAI...
!-----------------------------------
! For CDR2:
! <1> ADEFGHIKLMNPQRSTVWY equimolar
! <2> S(0.2) ADEFGHIKLMNPQRTVWY (0.044 each)
! <4> A(0.2) DEFGHIKLMNPQRSTVWY (0.044 each)
! ----- FR2 ------------------------->|------- CDR2 ---------->
! <1> <2> <4>
! 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
! G Q A P R L L I Y G A S S R A
|GGT|caG|GCG|CCg|cgt|tta|ctt|att|tat|ggt|gct|tct|tcc|cgc|gct|
! SexAI .... KasI .... (CDR1 installed as AflII-(SexAI or KasI) cassette.)
!
!-----------------------------------
!
! CDR2-->|--- FR3 ----------------------------------------------->
! <1>
! 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
! T G I P D R F S G S G S G T D
|act|gGG|ATC|CCG|GAC|CGt|ttc|tct|ggc|tct|ggt|tca|ggt|act|gac|
! BamHI...
! RsrII.....
! (CDR2 installed as (SexAI or KasI) to (BamHI or RsrII) cassette.)
!-----------------------------------
!
! ------ FR3 ------------------------------------------------->
! 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105
! F T L T I S R L E P E D F A V
477 |ttt|acc|ctt|act|att|TCT|AGA|ttg|gaa|cct|gaa|gac|ttc|gct|gtt|
! XbaI...
!
!-----------------------------------
!
! ----------->|----CDR3-------------------------->|-----FR4--->
! <3> <1> <1> <1> <1>
! 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120
! Y Y C Q Q Y G S S P E T F G Q
|tat|tat|tgC|CAa|cag|taT|GGt|tct|tct|cct|gaa|act|ttc|ggt|caa|
! BstXI...........
!
!-----------------------------------
!
! -----FR4------------------->| <------- Ckappa ------------
! 121 122 123 124 125 126 127 128 129 130 131 132 133 134
! G T K V E I K R T V A A P S
510 |ggt|aCC|AAG|Gtt|gaa|atc|aag| |CGT|ACG|gtt|gcc|gct|cct|agt|
! StyI.... BsiWI..
!
! (CDR3 installed as XbaI to (StyI or BsiWI) cassette.)
!
! 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149
! V F I F P P S D E Q L K S G T
552 |gtg|ttt|atc|ttt|cct|cct|tct|gac|gaa|CAA|TTG|aag|tca|ggt|act|
! MfeI...
!
! 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164
! A S V V C L L N N F Y P R E A
597 |gct|tct|gtc|gta|tgt|ttg|ctc|aac|aat|ttc|tac|cCT|CGT|Gaa|gct|
! BssSI...
!
! 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179
! K V Q W K V D N A L Q S G N S
642 |aaa|gtt|cag|tgg|aaa|gtc|gat|aAC|GCG|Ttg|cag|tcg|ggt|aac|agt|
! MluI....
!
! 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194
! Q E S V T E Q D S K D S T Y S
687 |caa|gaa|tcc|gtc|act|gaa|cag|gat|agt|aag|gac|tct|acc|tac|tct|
!
! 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209
! L S S T L T L S K A D Y E K H
732 |ttg|tcc|tct|act|ctt|act|tta|tca|aag|gct|gat|tat|gag|aag|cat|
!
! 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224
! K V Y A C E V T H Q G L S S P
777 |aag|gtc|tat|GCt|TGC|gaa|gtt|acc|cac|cag|ggt|ctG|AGC|TCc|cct|
! SacI....
!
! 225 226 227 228 229 230 231 232 233 234
! V T K S F N R G E C . . (SEQ ID NO: 332)
822 |gtt|acc|aaa|agt|ttc|aaC|CGT|GGt|gaa|tgc|taa|tag GGCGCGCC
! DsaI.... AscI....
! BssHII
!
866 acgcatctctaa GCGGCCGC aacaggaggag (SEQ ID NO: 333)
! NotI....
! EagI..
TABLE 31P
Tally of 285 CDR2s of length 7 in human kappa
Tally
A
C
D
E
F
G
H
I
K
L
M
N
P
Q
R
S
T
V
W
Y
1
51
62
7
95
1
11
15
2
1
2
6
6
3
22
1
x
2
225
18
5
5
2
1
1
3
16
9
A
3
2
9
1
2
267
2
1
1
S
4
2
1
5
4
9
1
77
4
93
80
2
7
Sx
5
1
2
80
200
2
R
6
162
7
36
4
4
1
3
3
63
2
Ax
7
5
1
3
1
1
2
2
1
125
144
x
TABLE 32P
Tally of 166 CDR3s of length 9 from human kappa.
Tally
A
C
D
E
F
G
H
I
K
L
M
N
P
Q
R
S
T
V
W
Y
1
4
8
21
131
1
1
Q
2
1
9
2
1
153
Q
3
14
4
4
3
6
4
1
1
3
21
16
3
4
82
Yx
4
1
9
1
2
37
4
2
2
15
1
33
2
20
7
1
29
x
5
2
2
6
3
4
5
3
28
17
7
65
19
1
1
3
x
6
7
1
11
2
3
8
1
4
3
41
33
5
28
19
x
7
1
2
6
146
2
2
5
2
P
8
2
4
1
2
21
7
3
5
1
38
7
4
25
1
3
1
16
25
x
9
3
2
1
1
2
157
T
TABLE 33P
lengths of CDRs in 93 human lambda chains
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18+
CDR1
0
0
0
0
0
0
0
0
0
0
0
23
7
15
46
0
0
0
2
CDR2
5
0
0
1
0
0
0
80
2
0
0
1
4
0
0
0
0
0
1
CDR3
0
0
0
0
0
0
0
0
1
16
28
27
6
1
0
4
6
4
0
TABLE 34P
Tally of 46 CDR1s of length 14 from human lambda chains
Tally
A
C
D
E
F
G
H
I
K
L
M
N
P
Q
R
S
T
V
W
Y
1
2
2
1
41
T
2
43
3
G
3
2
1
1
6
36
TGx
4
1
45
S
5
5
1
40
S
6
39
1
4
2
DNx
7
8
1
37
V
8
1
42
2
1
G
9
4
1
35
1
2
3
TGx
10
1
1
3
1
2
38
Yx
11
4
1
35
6
DNx
12
3
1
2
1
1
2
36
Yx
13
1
2
43
V
14
1
4
41
S
TABLE 35P
Synthtic human lambda-chain gene
! Lambda 14-7(A) 2a2 ::JH2::Clambda
! AA sequence tested
!
! 1 GAGGACCATt GGGCCCC ttactccgtgac
! Scab...... EcoO109I
! ApaI..
!-----------------------------------------------
!
! -----------FR1-------------------------------------------->
! 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
! S A Q S A L T Q P A S V S G S P G
30 aGT|GCA|Caa|tcc|gct|ctc|act|cag|cct|GCT|AGC|gtt|tcc|gGG|TcA|CCt|GGT|
! ApaLI... NheI... BstEII...
! SexAI....
!-----------------------------------------------
!
! For CDR1,
! <1> = 0.27 T, 0.27 G, 0.027 {ADEFHIKLMNPQRSVWY} no C
! <2> = 0.27 D, 0.27 N, 0.027 {AEFGHIKLMPQRSTVWY} no C
! <3> = 0.36 Y, 0.0355{ADEFGHIKLMNPQRSTVW} no C
! T G <1> S S <2> V G
! ------FR1------------------> |-----CDR1---------------------
! 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
! Q S I T I S C T G T S S D V G
|caa|agt|atc|act|att|tct|TGT|ACA|ggt|act|tct|tct|gat|gtt|ggc|
! BsrGI..
!
! a second vg scheme for CDR1 gives segments of length 11:
! G 23 <2><4>L<4><4><4><3><4><4> where
! <4> = equimolar {ADEFGHIKLMNPQRSTVWY} no C
!-------------------------------------------------------
!
! <1> <3> <2> <3> V S = vg Scheme #1, length = 14
! -----CDR1------------->|--------FR2-------------------------
! 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
! G Y N Y V S W Y Q Q H P G K A
|ggt|tac|aat|tac|gtt|tct|tgg|tat|caa|caa|caC|CCG|GGc|aaG|GCG|
! XmaI.... KasI.....
! AvaI....
!-------------------------------------------------------------------
!
! <4> <4> <4> <2> R P S
! --FR2-----------------> |------CDR2--------------->|-----FR3--
! 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
! P K L M I Y E V S N R P S G V
|CCg|aag|ttg|atg|atc|tac|gaa|gtt|tcc|aat|cgt|cct|tct|ggt|gtt|
! KasI....
!-------------------------------------------------------------------
!
! -------FR3----------------------------------------------------
! 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
! S N R F S G S K S G N T A S L
|agc|aat|cgt|ttc|TCC|GGA|tct|aaa|tcc|ggt|aat|acc|gcA|AGC|TTa|
! BspEI.. | HindIII.
! BsaBI........(blunt)
!------------------------------------------------------------------
!
! -------FR3--------------------------------------------------->|
! 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
! T I S G L Q A E D E A D Y Y C
|act|atc|tct|ggt|CTG|CAG|gct|gaa|gac|gag|gct|gac|tac|tat|tgt|
! PstI...
!
!------------------------------------------------------------------
!
! <5> = 0.36 S, 0.0355{ADEFGHIKLMNPQRTVWY} no C
!
! <4> <5> <4> <2> <4> S <4> <4> <4> <4> V
! -----CDR3---------------------------------->|---FR4---------
! 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105
! S S Y T S S S T L V V F G G G
|tct|tct|tac|act|tct|tct|agt|acc|ctt|gtt|gtc|ttc|ggc|ggt|GGT|
! KpnI...
!
!------------------------------------------------------------------------
!
! -------FR4-------------->
! 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120
! T K L T V L G Q P K A A P S V
279 |ACC|aaa|ctt|act|gtc|ctc|gGT|CAA|CCT|aAG|Gct|gct|cct|tcc|gtt|
! KpnI... HincII..
! Bsu36I...
!
! 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135
! T L F P P S S E E L Q A N K A
324 |act|ctc|ttc|cct|cct|agt|tct|GAA|GAG|Ctt|caa|gct|aac|aag|gct|
! SapI.....
!
! 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150
! T L V C L I S D F Y P G A V T
369 |act|ctt|gtt|tgc|tTG|ATC|Agt|gac|ttt|tat|cct|ggt|gct|gtt|act|
! BclI....
!
! 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165
! V A W K A D S S P V K A G V E
414 |gtc|gct|tgg|aaa|gcc|gat|tct|tct|cct|gtt|aaa|gct|ggt|gtt|GAG|
! BsmBI...
!
! 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180
! T T T P S K Q S N N K Y A A S
459 |ACG|acc|act|cct|tct|aaa|caa|tct|aac|aat|aag|tac|gct|gcG|AGC|
! BsmBI.... SacI....
!
! 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195
! S Y L S L T P E Q W K S H K S
504 |TCt|tat|ctt|tct|ctc|acc|cct|gaa|caa|tgg|aag|tct|cat|aaa|tcc|
! SacI...
!
! 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210
! Y S C Q V T H E G S T V E K T
549 |tat|tcc|tgt|caa|gtt|acT|CAT|GAa|ggt|tct|acc|gtt|gaa|aag|act|
! BspHI...
!
! 211 212 213 214 215 216 217 218 219
! V A P T E C S . . (SEQ ID NO: 57)
594 |gtt|gcc|cct|act|gag|tgt|tct|tag|tga|GGCGCGCC
! AscI....
! BssHII
!
629 aacgatgttc aag GCGGCCGC aacaggaggag (SEQ ID NO: 56)
! NotI.... Scab.......
TABLE 36P
Tally of 23 CDR1s of length 11 from human lambda chains
Tally
A
C
D
E
F
G
H
I
K
L
M
N
P
Q
R
S
T
V
W
Y
1
1
6
10
6
x
2
1
1
21
G
3
15
1
7
DNx
4
2
1
1
3
7
1
8
X
5
7
16
L
6
11
1
2
8
1
X
7
1
1
1
2
2
1
14
1
X
8
1
10
1
1
1
2
7
X
9
2
6
15
Yx
10
11
1
11
X
11
3
7
9
2
2
X
TABLE 37P
Tally of 80 CDR2s of length 7 from human lambda chains
Tally
A
C
D
E
F
G
H
I
K
L
M
N
P
Q
R
S
T
V
W
Y
1
1
14
32
1
13
3
1
4
5
1
2
3
X
2
18
2
8
16
2
34
X
3
1
2
1
31
39
4
2
X
4
6
4
1
14
1
41
8
1
1
2
1
DNx
5
1
1
78
R
6
1
77
2
P
7
2
78
S
TABLE 38P
Tally of 27 CDR3s of length 11 from human lambda chains
Tally
A
C
D
E
F
G
H
I
K
L
M
N
P
Q
R
S
T
V
W
Y
1
4
5
6
5
4
3
X
2
3
1
2
14
5
2
Sx
3
1
7
13
6
X
4
19
2
1
1
4
DNx
5
1
4
2
2
2
1
13
2
X
6
1
3
1
21
1
S
7
1
7
12
1
4
2
X
8
2
1
10
1
6
6
1
X
9
3
1
8
10
3
1
1
X
10
1
4
1
1
1
3
1
1
6
5
3
X
11
2
25
V
TABLE 40P
Synthetic Kappa light chain gene with stuffers
!
! A27::JH1 with all CDRs replaced by stuffers.
! Each stuffer contains at least one stop codon and a restriction
! site that will be unique within the diversity vector.
1 GAGGACCATt GGGCCCC ctccgagact
! Scab...... EcoO109I
! ApaI.
!-----------------------------------
!
28 CTCGAG cgca
! XhoI..
!-----------------------------------
!
38 acgcaatTAA TGTgagttag ctcactcatt aggcacccca ggcTTTACAc tttatgcttc
! ..-35.. Plac ..-10.
!-----------------------------------
!
98 cggctcgtat gttgtgtgga attgtgagcg gataacaatt tc
!-----------------------------------
!
140 acacagga aacagctatgac
!-----------------------------------
!
160 catgatta cgCCAAGCTT TGGagccttt tttttggaga ttttcaac
! PflMI.......
! Hind3.
!-----------------------------------
!
! M13 III signal sequence (AA seq)--------------------------->
! 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
! M K K L L F A I P L V V P F Y
206 gtg aag aag ctc cta ttt gct atc ccg ctt gtc gtt ccg ttt tac
!-----------------------------------
!
! --Signal--> FR1------------------------------------------->
! 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
! S H S A Q S V L T Q S P G T L
251 |agc|cat|aGT|GCA|Caa|tcc|gtc|ctt|act|caa|tct|cct|ggc|act|ctt|
! ApaLI...
!-----------------------------------
!
! ----- FR1 --------------------------------->|-------Stuffer->
! 31 32 33 34 35 36 37 38 39 40 41 42 43
! S L S P G E R A T L S | |
296 |tcG|CTA|AGC|CCG|GGt|gaa|cgt|gct|acC|TTA|AGt|TAG|TAA|gct|ccc|
! EspI..... AflII ...
! XmaI....
!-----------------------------------
!
! ------- Stuffer for CDR1------------------------->|- FR2 -->
! 59 60
! K P
341 |AGG|CCT|ctt|TGA|tct| g|aaA|CCT|
! StuI... SexAI ...
!-----------------------------------
!
! ----- FR2 ------|-----------Stuffer for CDR2---------------->
! 61 62 63 64 65 66
! G Q A P R | |
363 |GGT|caG|GCG|CCg|cgt|TAA|TGA|a AGCGCT aa TGGCCA aca gtg
! SexAI.... KasI.... AfeI.. MscI..
!-----------------------------------
!
! Stuffer-->|--- FR3 ----------------------------------------------->
! <1>
! 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
! T G I P D R F S G S G S G T D
405 |act|gGG|ATC|CCG|GAC|CGt|ttc|tct|ggc|tct|ggt|tca|ggt|act|gac|
! BamHI...
! RsrII.....
!-----------------------------------
!
! ------ FR3 ---------------------STUFFER for CDR3------------------>
! 91 92 93 94 95 96 97
! F T L T I S R | |
450 |ttt|acc|ctt|act|att|TCT|AGA|TAA|TGA| GTTAAC TAG acc TACGTA acc tag
! XbaI... HpaI.. SnaBI.
!-----------------------------------
!
! -----------------CDR3 stuffer------------------>|-----FR4--->
! 118 119 120
! F G Q
501 |ttc|ggt|caa|
!-----------------------------------
!
! -----FR4------------------->| <------- Ckappa ------------
! 121 122 123 124 125 126 127 128 129 130 131 132 133 134
! G T K V E I K R T V A A P S
510 |ggt|aCC|AAG|Gtt|gaa|atc|aag| |CGT|ACG|gtt|gcc|gct|cct|agt|
! StyI.... BsiWI..
!
! (CDR3 installed as XbaI to (StyI or BsiWI) cassette.)
! 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149
! V F I F P P S D E Q L K S G T
552 |gtg|ttt|atc|ttt|cct|cct|tct|gac|gaa|CAA|TTG|aag|tca|ggt|act|
! MfeI...
!
866 acgcatctctaa GCGGCCGC aacaggaggag (SEQ ID NO: 95)
! NotI....
! EagI..
TABLE 41P
Variegated DNA for kappa chains
!----------------------------------------------------------------
! Kappa chains
! For CDR1:
! <1> ADEFGHIKLMNPQRSTVWY equimolar
! <2> S(0.2) ADEFGHIKLMNPQRTVWY (0.044 each)
! <3> Y(0.2) ADEFGHIKLMNPQRSTVW (0.044 each)
! <4> A(0.2) DEFGHIKLMNPQRSTVWY (0.044 each)
(Ka1vg600) 5′-gct|acC|TTA|AGt|tgc|cgt|gct|tcc|cag-
|<1>|gtt|<2>|<2>| <3>|ctt|gct|tgg|tat|caa|cag|aaA|CC-3′ (SEQ ID NO: 66)
(Ka2vg650) 5′-caG|GCG|CCg|cgt|tta|ctt|att|tat|<1>|gct|tct|<2>|cgc|<4>|-
|<1>|gGG|ATC|CCG|GAC|CGt|ttc|tct|ggt|tctcacc-3′ (SEQ ID NO: 71)
(Ka3vg670) 5′- gac|ttc|gct|gtt|-
|tat|tat|tgC|CAa|cag|<3>|<1>|<1>|<1>|cct|<1>|act|ttc|ggt|caa|-
|ggt|aCC|AAG|Gtt|g-3′ (SEQ ID NO: 77)
TABLE 42P
Variegated DNA for lambda chains
!------------------------
! For CDR1,
! <1> = 0.27 T, 0.27 G, 0.027 {ADEFHIKLMNPQRSVWY} no C
! <2> = 0.27 D, 0.27 N, 0.027 {AEFGHIKLMPQRSTVWY} no C
! <3> = 0.36 Y, 0.0355{ADEFGHIKLMNPQRSTVW} no C
! <4> = equimolar {ADEFGHIKLMNPQRSTVWY} no C
! <5> = 0.36 S, 0.0355{ADEFGHIKLMNPQRTVWY} no C
(Lm1vg710) 5′-gt|atc|act|att|tct|TGT|ACA|ggt|<1>|tct|tct|<2>|gtt|ggc|-
|<1>|<3>|<2>|<3>|gtt|tct|tgg|tat|caa|caa|caC|CC-3′ (SEQ ID NO: 83)
!------------------------------------------
(Lm2vg750) 5′-G|CCg|aag|ttg|atg|atc|tac|-
<4>|<4>|<4>|<2>|cgt|cct|tct|ggt|gtc|agc|aat|c-3′ (SEQ ID NO: 88)
(Lm3vg817) 5′-gac|gag|gct|gac|tac|tat|tgt|-
|<4>|<5>|<4>|<2>|<4>|tct|<4>|<4>|<4>|<4>|gtc|ttc|ggc|ggt|GGT|-
|ACC|aaa|ctt|ac-3′ (SEQ ID NO: 93)
!----------------------------------------------------------------
TABLE 43P
Constant DNA for Synthetic Library
!CDR3 library components
(Ctop25) 5′-gctctggtcaa C|TTA|AG g|gct|gag|g-3′ (SEQ ID NO: 58)
(CtprmA) 5′-gctctggtcaa C|TTA|AG g|gct|gag|gac-
! AflII...
|acc|gct |gtc|tac|tac|tgc|gcc -3′ (SEQ ID NO: 59)
!
(CBprmB) [RC] 5′- |tac|ttc|gat|tac|ttg|ggc|caa|GG T|ACC|ct G|GTC|ACC| tcgctccacc-3′ (SEQ ID NO: 60)
! BstEII...
(CBot25) [RC] 5′- |GG T|ACC|ct G|GTC|ACC| tcgctccacc-3′ (SEQ ID NO: 61)
!-----------------------------------------------------------------
!Kappa chains
(Ka1Top610) 5′-ggtctcagtt-
G|CTA|AGC|CCG|GGt|gaa|cgt|gct|acC|TTA|AGt|tgc|cgt|gct|tcc|cag-3′ (SEQ ID NO: 62)
(Ka1STp615) 5′-ggtctcagtt-
G|CTA|AGC|CCG|GGt|g-3′ (SEQ ID NO: 63)
(Ka1Bot620) [RC] 5′-ctt|gct|tgg|tat|caa|cag|aaA|-
CCt|GGT|caG|GCG|CC aagtcgtgtc-3′ (SEQ ID NO: 64)
(Ka1SB625) [RC] 5′-cct|GGT|caG|GCG|CC aagtcgtgtc-3′ (SEQ ID NO: 65)
(Ka2Tshort657) 5′-cacgagtcctA|CCT|GGT|-
!
caG|GC-3′ (SEQ ID NO: 68)
(Ka2Tlong655) 5′-cacgagtcctA|CCT|GGT|-
caG|GCG|CCg|cgt|tta|ctt|att|tat-3′ (SEQ ID NO: 69)
(Ka2Bshort660) [RC] 5′- |GAC|CGt|ttc|tct|ggt|tctcacc-3′ (SEQ ID NO: 70)
!----------------------------------------------------------------
(Ka3Tlon672) 5′- gacgagtcct TCT|AGA|ttg|gaa|cct|gaa|gac|ttc|gct|gtt|-
|tat|tat|tgC|CAa|c-3′ (SEQ ID NO: 72)
(Ka3BotL682) [RC] 5′-act|ttc|ggt|caa|-
|ggt|aCC|AAG|Gtt|gaa|atc|aag| |CGT|ACG| tcacaggtgag-3′ (SEQ ID NO: 73)
(Ka3Bsho694) [RC] 5′- gaa|atc|aag| |CGT|ACG| tcacaggtgag-3′ (SEQ ID NO: 74)
!----------------------------------------------------------------
(Lm1TPri75) 5′-gacgagtcct GG|TcA|CCt|GGT|-3′ (SEQ ID NO: 78)
(Lm1TLo715) 5′-gacgagtcct GG|TcA|CCt|GGT|-
caa|agt|atc|act|att|tct|TGT|ACA|ggt-3′ (SEQ ID NO: 79)
(Lm1BLo724) [RC] 5′-gtt|tct|tgg|tat|caa|caa|caC|CCG|GGc|aaG|GCG|-
AGA TCT tcacaggtgag-3′ (SEQ ID NO: 80)
(Lm1BSh737) [RC] 5′- Gc|aaG|GCG|-
AGA TCT tcacaggtgag-3′ (SEQ ID NO: 81)
!-------------------------------------------------
(Lm2TSh757) 5′-gagcagagga C|CCG|GGc|aaG|GC-3′ (SEQ ID NO: 84)
(Lm2TLo753) 5′-gagcagagga C|CCG|GGc|aaG|GCG|CCg|aag|ttg|atg|atc|tac|-3′ (SEQ ID NO: 85)
(Lm2BLo762) [RC] 5′-cgt|cct|tct|ggt|gtc|agc|aat|cgt|ttc|TCC|GGA|tcacaggtgag-3′ (SEQ ID NO: 86)
(Lm2BSh765) [RC] 5′- cgt|ttc|TCC|GGA|tcacaggtgag-3′ (SEQ ID NO: 87)
!--------------------------------------------------
(Lm3TSh822) 5′-CTG|CAG|gct|gaa|gac|gag|gct|gac -3′ (SEQ ID NO: 89)
(Lm3TLo819) 5′-CTG|CAG|gct|gaa|gac|gag|gct|gac|tac|tat|tgt|-3′ (SEQ ID NO: 90)
(Lm3BLo825) [RC] 5′-gtc|ttc|ggc|ggt|GGT|-
|ACC|aaa|ctt|act|gtc|ctc|gGT|CAA |CCT|aAG|G acacaggtgag-3′ (SEQ ID NO: 91)
(Lm3BSh832) [RC] 5′- c|gGT|CAA |CCT|aAG|G acacaggtgag-3′ (SEQ ID NO: 92)
!----------------------------------------------------------------
TABLE 48P
Synthtic human lambda-chain gene with stuffers in place of CDRs
! Lambda 14-7(A) 2a2 ::JH2::Clambda
! AA sequence tested
!
1 GAGGACCATt GGGCCCC ttactccgtgac
! Scab...... EcoO109I
! ApaI..
!-----------------------------------------------
!
! -----------FR1-------------------------------------------->
! 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
! S A Q S A L T Q P A S V S G S P G
! 30 aGT|GCA|Caa|tcc|gct|ctc|act|cag|cct|GCT|AGC|gtt|tcc|gGG|TcA|CCt|GGT|
! ApaLI... NheI... BstEII...
! SexAI....
!-----------------------------------------------
!
! ------FR1------------------> |-----stuffer for CDR1---------
! 16 17 18 19 20 21 22 23
! Q S I T I S C T
81 |caa|agt|atc|act|att|tct|TGT|ACA|tct TAG TGA ctc
! BsrGI..
!------------------------------------------------------
!
! -----Stuffer--------------------------->--------------------
! 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
! R S | | P | H P G K A
117 AGA TCT TAA TGA ccg tag caC|CCG|GGc|aaG|GCG|
! BglII XmaI.... KasI.....
! AvaI....
!-------------------------------------------------------------------
!
! --|-------------Stuffer ------------------------------------->
! P
150 |CCg|TAA|TGA|atc tCG TAC G ct|ggt|gtt|
! KasI.... BsiWI...
!-------------------------------------------------------------------
!
! -------FR3----------------------------------------------------
! 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
! S N R F S G S K S G N T A S L
177 |agc|aat|cgt|ttc|TCC|GGA|tct|aaa|tcc|ggt|aat|acc|gcA|AGC|TTa|
! BspEI.. | HindIII.
! BsaBI........(blunt)
!-------------------------------------------------------------------
!
! -------FR3------------->|--Stuffer-------------------------->|
! 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
! T I S G L Q
222 |act|atc|tct|ggt|CTG|CAG|gtt ctg tag ttc CAATTG ctt tag tga ccc
! PstI... MfeI..
!-------------------------------------------------------------------
!
! -----Stuffer------------------------------->|---FR4---------
! 103 104 105
! G G G
270 |ggc|ggt|GGT|
! KpnI...
!------------------------------------------------------------------------
! -------FR4-------------->
! 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120
! T K L T V L G Q P K A A P S V
279 |ACC|aaa|ctt|act|gtc|ctc|gGT|CAA|CCT|aAG|Gct|gct|cct|tcc|gtt|
! KpnI... HincII..
! Bsu36I...
!
! 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135
! T L F P P S S E E L Q A N K A
324 |act|ctc|ttc|cct|cct|agt|tct|GAA|GAG|Ctt|caa|gct|aac|aag|gct|
! SapI.....
!
! 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150
! T L V C L I S D F Y P G A V T (SEQ ID NO: 97)
369 |act|ctt|gtt|tgc|tTG|ATC|Agt|gac|ttt|tat|cct|ggt|gct|gtt|act| (SEQ ID NO: 97)
! BclI....
TABLE 50P
3-23::CDR3::JH4 Stuffers in place of CDRs
FR1(DP47/V3-23)---------------
20 21 22 23 24 25 26 27 28 29 30
A M A E V Q L L E S G
ctgtctgaac CC atg gcc gaa|gtt|CAA|TTG|tta|gag|tct|ggt|
Scab...... NcoI.... | MfeI |
--------------FR1--------------------------------------------
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
G G L V Q P G G S L R L S C A
|ggc|ggt|ctt|gtt|cag|cct|ggt|ggt|tct|tta|cgt|ctt|tct|tgc|gct|
----FR1-------------------->|...CDR1 stuffer....|---FR2------
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
A S G F T F S S Y A | | W V R
|gct|TCC|GGA|ttc|act|ttc|tct|tCG|TAC|Gct |TAG|TAA |tgg|gtt|cgC|
| BspEI | | BsiWI| |BstXI.
-------FR2-------------------------------->|...CDR2 stuffer.
61 62 63 64 65 66 67 68 69 70 71 72 73 74 75
Q A P G K G L E W V S | p r |
|CAa|gct|ccT|GGt|aaa|ggt|ttg|gag|tgg|gtt|tct|TAA|CCT|AGG|TAG|
...BstXI | AvrII..
.....CDR2 stuffer....................................|---FR3---
--------FR3-------------------------------------------------
91 92 93 94 95 96 97 98 99 100 101 102 103 104 105
T I S R D N S K N T L Y L Q M
|act|atc|TCT|AGA|gac|aac|tct|aag|aat|act|ctc|tac|ttg|cag|atg|
| XbaI |
---FR3-----------..> Stuffer------------->|
106 107 108 109 110
N S L R A (SEQ ID NO: 53)
|aac|agC|TTA|AGg|gct|TAG TAA AGG cct TAA (SEQ ID NO: 52)
|AflII | StuI...
|----- FR4 ---(JH4)-----------------------------------------
Y F D Y W G Q G T L V T V S S (SEQ ID NO: 26)
|tat|ttc|gat|tat|tgg|ggt|caa|GGT|ACC|ctG|GTC|ACC|gtc|tct|agt|... (SEQ ID NO: 25)
| KpnI | | BstEII |
|
Focused libraries of vectors or genetic packages that display, display and express, or comprise a member of a diverse family of antibody peptides, polypeptides or proteins and collectively display, display and express, or comprise at least a portion of the focused diversity of the family. The libraries have length and sequence diversities that mimic that found in native human antibodies.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/726,316, filed Dec. 2, 2003, entitled “Method for Defining a Data Mapping Between Two or More Data Structure”, which claims the benefit of United Kingdom Application No. 0229724.0, filed Dec. 19, 2002. U.S. patent application Ser. No. 10/726,316 is hereby incorporated by reference for all purposes as if fully set forth herein.
FIELD OF INVENTION
[0002] The invention relates to the field of data transformations or mapping, and more specifically to the definition of such transformations.
BACKGROUND OF THE INVENTION
[0003] Distributed systems typically comprise a multitude of heterogeneous applications all communicating using different languages. In order for two such different applications to communicate with one another, it is necessary that data in a format A from the first application is transformed into data in a format B understood by the second application. FIG. 1 a shows a first example of the components that enable such a transformation to take place.
[0004] Application 10 , by way of example, uses a SAP internal data format. In order to communicate with application 50 , a request from application 10 may go via a message broker/intermediary system 30 . Adapter 20 interfaces with Application 10 and transfers the SAP internal formatted message to broker 30 . At the broker it is determined that the message is destined for application 50 which uses an Ariba internal format. The broker therefore transforms the message received from application 10 into an Ariba internal message format suitable for transferring the message to application 50 . Upon receipt of this message, adapter 40 interfaces with application 50 and communicates the Ariba formatted message.
[0005] It should however be appreciated from the above that the number of individual transformations required can be huge. A formula for determining the number of transformations is n*n−1, where n is the number of data types used (e.g. message sets, where a message set is the set of messages understood by one application), and we are defining transformations in both directions.
[0006] For this reason an alternative solution was developed. Referring to FIG. 1 b , a “standard” format for communication is agreed upon by adapters 20 and 40 . One example of such a format is the Business Object Document (BOD) specification defined by the Open Applications Group. When application 10 wishes to communicate with application 50 , adapter 20 converts the data into BOD form which is received by adapter 40 and transformed into the Ariba data format. The number of transformations now is 2*n. Therefore for small numbers of applications there is no benefit, (e.g. 2 applications=4 transformations vs. 2 in the original design of FIG. 1 a ), but for larger numbers of applications the benefits are important (e.g. 5 applications=10 transformations vs. 20 in the original design of FIG. 1 a ). While FIGS. 1 a and 1 b show different integration topologies, this is not relevant to the transformation reduction. It is possible, for example, to achieve the same results by transforming to the “standard” format in the intermediary system.
[0007] Nevertheless, it will be appreciated that a highly labour intensive activity when performing Enterprise Application Integration is the definition of data/message transformations. Each message set can be large and complex and typically consists of a number of different messages each containing a variety of different fields. For example, the OAG BOD standard version 7.1 has over 180 different messages. Ordinarily the user selects source and target messages and a tool presents them side by side. The user then defines the relationships between fields in the source message and fields in the target message.
[0008] With reference to FIG. 2 it can be seen that message set A has a “part” message containing the fields “name”; “id”; “price”; and “description”. Message set B has a corresponding message and fields but uses different terms to refer to these. Thus a user has to identify that the “part” message in message set A corresponds to the “item” message in message set B. The user then has to map the fields within the “part” message to the fields within the “item” message. Thus “name” is mapped to “prodname”; and “ID” is mapped to “identifier” etc.
[0009] This example is simple in that there is only one message in each set and there is a one to one correspondence between the fields. The reality is however typically far more complicated in that there may be numerous message sets; messages and fields to contend with and that there is not necessarily a one to one correspondence between the fields in two messages. Thus it is typically an onerous task to define the required transformations between messages in different message sets.
SUMMARY OF THE INVENTION
[0010] The present invention is directed to a computer system and a computer program for defining data mappings between data elements in a first data structure and data elements in a second data structure. The computer system executes instructions for selecting a first data element in the first data structure for mapping, suggesting a first possible data mapping definition to a user based on a first previous data mapping definition, the first possible data mapping definition defining a mapping from the first data element in the first data structure to a first data element in the second data structure, and mapping the first data element in the first data structure to the first data element in the second data structure according to the first possible data mapping definition in response to acceptance of the first possible data mapping definition by the user, wherein the first previous data mapping definition defines a mapping from a data element in a third data structure to a data element in a fourth data structure, at least one of the third and fourth data structures being different from the first and second data structures.
DESCRIPTION OF DRAWINGS
[0011] FIGS. 1 a and 1 b illustrate an overview of enterprise application integration (which includes message transformation) according to the prior art.
[0012] FIG. 2 illustrates a defined correspondence between two message sets according to the prior art.
[0013] FIGS. 3 3 a , 3 b , 4 and 5 illustrate message transformation according to embodiments of the present invention.
DETAILED DESCRIPTION
[0014] The present invention relates to defining data mappings between data structures. The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. Various modifications to the preferred embodiment and the generic principles and features described herein will be readily apparent to those skilled in the art. Thus, the present invention is not intended to be limited to the embodiment shown but is to be accorded the widest scope consistent with the principles and features described herein.
[0015] Throughout the specification, the terms transformation and mapping will be used interchangeably. In the preferred embodiment, the data structures can be treated as message sets. With reference to FIGS. 3 a and 3 b , two message sets (MS) are selected by a user (A and B, step 100 ; 105 ). A source message and a target message are then selected by the user (step 110 ). (In this example the source message is Part and the target message is Item.) From message Part a field (Name) is chosen (step 120 ).
[0016] It is determined whether there is any previous transformation definition information which might be of use here (step 130 ) and since there is not, the user defines this transformation, mapping the Name field to ProdName in the Item message of message set B (step 140 ). Information regarding this transformation is held in non-volatile storage for possible future use (step 140 ). (Note, there may not always be a corresponding field to map to in a target message—see below.) Following the same process, the user also defines Part.ID and Part.Price. As can be seen from FIG. 3 b , these are mapped to Item.Identifier and Item.Price (steps 160 ; 120 ; 130 ; 140 ). There is no corresponding field for Part.Description in the Item message and so the transformation for this field is not defined.
[0017] Having defined transformations for all the fields in the Part message for which there are corresponding fields in the Item message, it is determined at step 170 that there is another source message (Order) in set A and a target message in set B between which transformations are to be defined (step 110 ). Field ID is selected from this message (step 120 ). Part.ID was previously defined as mapping to Item.Identifer, thus it is deduced that any field named ID in message set A is likely to map to any field named Identifier in message set B (step 130 ).
[0018] In message set B a PurchaseOrder message exists and this message includes the field Identifier. Thus a suggestion is made to the user that Order.ID might map to PurchaseOrder.Identifer. The user chooses to accept PurchaseOrder.Identifier as the correct definition of Order.ID and thus this recommendation is executed and information regarding this choice is added to non-volatile memory (step 155 ; 165 ).
[0019] The next field in message Order is Quantity (steps 160 ; 120 ). Quantity is not a field that has been seen before and so the user defines its correspondence to PurchaseOrder.Quantity and information regarding this is added to non-volatile memory (steps 130 , 140 ). However with Order.Price, the system has previously seen that Part.Price maps to Item.Price and therefore suggests that Order.Price might map to PurchaseOrder.Price (steps 160 ; 120 ; 130 ; 150 ). The user then chooses to accept this recommendation and it is executed and information regarding this choice added to non-volatile memory (step 155 , 165 ).
[0020] The process continues with StockCheck.ID (steps 160 ; 170 ; 110 ; 120 ). Previously Part.ID was mapped to Item.Identifer; and Order.ID was mapped to PurchaseOrder.Identifer. The system thus deduces that StockCheck.ID might well map to StockLevel.Identifier (steps 130 ; 150 ). In this example, the user chooses to accept the recommendation and this is executed and information regarding this action is stored in non-volatile memory (steps 155 , 165 ). Finally StockCheck.Quantity possibly maps to StockLevel.Quantity based on the previous transformation of Order.Quantity to PurchaseOrder.Quantity (steps 160 ; 120 ; 130 ; 150 ). Again this is accepted and executed (step 155 , 165 ).
[0021] Because there are now no more messages in set A (step 170 ), it is determined whether there are any more message sets for which transformation are to be defined (step 180 ). Note this may mean defining a transformation between a current message set and a new message set or between two completely new message sets. If there are any more message sets, then the process returns to step 105 starts over again. Otherwise, the process ends at step 190 .
[0022] The preferred embodiment of the present invention can aid the user in a number of different ways. Prioritization of recommendations is discussed in more detail later; however it will be briefly discussed here. For example, if the user has defined Order.ID as mapping to PurchaseOrder.Identifier, thus it is known to the system that there is a correspondence between the Order message in set A and the PurchaseOrder message in set B. It can use this information to prioritize suggestions about possible future transformation definitions (e.g. Order in message set A might map to PurchaseOrder in previously unseen message set C).
[0023] Further, the storage of information at step 165 can be used to prioritize suggestions. For example, the previous definition information used to make the current recommendation may have come from a transformation between two different messages sets (see below), if the user selects that recommendation for messages sets A and B this information can be stored to prioritize this recommendation for other transformation definitions relating to the same two message sets (A & B).
[0024] It will now be appreciated by one skilled in the art that the flow described above relates to just one way in which the invention could be implemented. For example, in an alternative embodiment, the tool first analyses all the messages in two message sets and makes a series of recommendations. The user can then address recommendations for each field in turn, choosing to accept or reject these. Any fields for which there are no recommendations, or for which the user does not like the suggested recommendations, are left to the user to define.
[0025] It will no doubt also now be appreciated by one skilled in the art that transformations for all messages in a message set may not be required. Further, a one to one mapping has been shown here. In practice n messages may be mapped to m messages (for example three messages may map to two messages.)
[0026] The suggestions for possible transformation definitions do not have to come from the same message set. FIG. 4 shows message sets C, D, E, F and G. Sets C and D relate to personnel records and the correspondence between messages (one shown) in the two sets have been defined prior to defining mappings for message sets E and F. Message sets E and F relate to catering records. The fact that Name in the employee message of set C is defined as mapping to FullName in the PersonnelNumber message of set D is used to suggest to the user that Employee.Name in message set E may map to PersonnelNumber.FullName in message set F. Further if the transformations between messages in set C and D are being defined, information from previous transformation definitions involving another set and C or D can be used.
[0027] In the example, StaffNumber.TimeServed (message set G) has been mapped to Employee.YrsServ (message set C). This information can be used to suggest that Employee.YrsServ may map to PersonnelNumber.TimeServed in message set D. (This assumes that the previously defined mapping works in reverse.)
[0028] Correspondence between message names as well as message fields may also be used. For example, the fact that the user has defined a link between the Employee message in set C and the PersonnelNumber message in set D may be used to suggest a link between the Employee message in set E and the PersonnelNumber message in set F. Such information is useful in prioritising suggestions to the user regarding field definitions.
[0029] When defining transformations between two message sets C and D, suggestions could be prioritised to the user based on some predefined rules. For example the priorities could be as follows:
1. Information from existing C and D message set transformation definitions has top priority. 2. Information from transformation definitions including one of message set C or D is prioritised next (e.g. C and G) 3. Information from any other transformation definition is prioritised last (e.g. E and F).
[0033] A tool implementing the invention is preferably implemented in computer software. This tool could be provided with the message broker/intermediary system, or adapter software (e.g. as shown in FIGS. 1 a and 1 b . The components of such a tool according to a preferred embodiment are shown in FIG. 5 .
[0034] The tool 200 comprises a selection component 210 . Using this component, the user can select two message sets between which to define transformations. Having made this selection, an analyser 220 component is invoked which scans messages in the selected message sets.
[0035] For each message and field, within the message sets, the analyzer determines whether it knows of previous transformation information which might be useful with regard to defining each message and field transformation. In order to do this, analyzer component 220 consults previous transformation definition information held in non-volatile storage 230 . If it finds helpful information within storage 230 , it uses such information to suggest possible definitions to the user via suggestion component 240 . The user can then use selection component 210 to choose one of the suggested definitions.
[0036] If on the other hand no such useful information is held within storage 230 , user definitions component 250 enables the user to define the correspondence between a message/field in the source message set and a message/field in the selected destination message set. This definition is then stored in storage 230 for possible future use.
[0037] Through aspects of the preferred embodiment of the present invention, mapping definitions from previous defining sessions are stored for future sessions. In this way the previously onerous task of defining transformation information is alleviated.
[0038] The present invention has been described in accordance with the embodiment shown, and one of ordinary skill in the art will readily recognize that there could be variations to the embodiments. For example, while the invention has been defined in terms of messages and messaging systems, the invention is not limited to such and is applicable to any environment where data of one format needs to be converted to data of another format. Accordingly, many modifications may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims.
|
Computer system and program for defining data mappings between data elements in a first data structure and data elements in a second data structure are provided. The computer system executes instructions for selecting a first data element in the first data structure for mapping, suggesting a first possible data mapping definition to a user based on a first previous data mapping definition, the first possible data mapping definition defining a mapping from the first data element in the first data structure to a first data element in the second data structure, and mapping the first data element in the first data structure to the first data element in the second data structure according to the first possible data mapping definition in response to acceptance of the first possible data mapping definition by the user.
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The United States Government has rights in this invention pursuant to Contract No. DE-AC04-76DP00789 between the Department of Energy and American Telephone and Telegraph Company.
BACKGROUND OF THE INVENTION
This invention relates generally to a controllable feeder for thin wire, and more particularly to a precision wire feeder for small diameter wire, particularly for welding operations.
High-energy density welding (HEDW) processes (i.e., electron beam and laser beam) are normally used autogenuously, without filler metal. However, the use of a filler wire is desirable when the geometry of a weld joint and an inherent gap or mismatch at the joint requires the use of a filler to provide joint closure or the desired weld geometry, or when the chemistry of the base metals is such that a filler metal is needed to adjust the chemical composition so that a crack-free weld can be attained.
U.S. Pat. No. 4,333,594 of E. Cloos discloses a prior art welding wire feeder having opposed planet guide rollers to drive a weld wire that is fed between the rollers.
U.S. Pat. No. 4,160,151 of P. Tonita discloses another welding wire feeder using opposed power driven wheels to drive the wire therebetween.
A synopsis of various drive mechanisms is provided by K. Brown, "Wire drive mechanisms", Metal Construction and British Welding Journal, Sept. 1969, page 407-412. One of these systems, the rotary wedge, is discussed in detail by K. Brown, "Fine wire feeder for microplasma welding", Metal Construction and British Welding Journal, Apr. 1969, pages 169-173.
The evolution of the rotary wedge, including a stepper motor drive, is discussed by K. Brown, "Wire feeders step out? Concept and prototype construction", The Welding Institute Research Bulletin, Jul. 1986, pages 223-228. The device discussed in this article uses a reserve loop between a constant speed capstan and a pulse driven capstan.
A wire feeder for HEDW processes must be capable of delivering a wire having a small diameter on the order of 0.25 mm (10 mils), or less, to a very small weld pool. The accurate, controlled, delivery of the free end of the wire to a precise location at a weld zone on a joint between adjacent pieces at a work station has been difficult to attain because of the obvious problems of kinking, breaking, and bending associated with this small wire. In addition, small diameter wire is notoriously difficult to accurately position.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a compact wire feeder for small diameter wire.
It is another object of this invention to provide a wire feeder which keeps the wire taut.
It is also an object of this invention to accurately deliver a small diameter wire to a precise location.
It is still another object of this invention to provide a feeder capable of pulse-feeding a small diameter wire.
Additional objects, advantages, and novel features of the invention will become apparent to those skilled in the
art upon examination of the following description or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
To achieve the foregoing and other objects, and in accordance with the purpose of the present invention, as embodied and broadly described herein, the present invention may comprise a source of small diameter wire having a free end; a driving means for controllably applying a driving force to the wire to move the free end of the wire towards a weld zone and apparatus for constantly applying a reverse force to the wire in opposition to the driving force to keep the wire taut.
BRIEF DESCRIPTION OF THE DRAWING
The accompanying drawing, which is incorporated in and forms part of the specification, illustrates an embodiment of the present invention and, together with the description, serves to explain the principles of the invention.
The FIGURE shows a schematic view of a wire feeder in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
As shown in the FIGURE 1 a precision feeder 10 for small diameter wire 20-27 having a diameter less than 0.04 mm (16 mil) to a welding station 80 includes a base plate 12 upon which wire source 14, wire guide 40, idler 30, capstan drive 33, bias device 50 and output feed means 60 are mounted. Typically, plate 12 is small enough (on the order of 16 by 12.5 cm (6.5 by 5 inches)) that it may be mounted by known means near high energy density welder 82.
In the following description, there is only one spool 15 of wire 20 having a free end 27 at welding station 80. However, portions of the wire between the free end 27 and the spool 15 are designated by numbers indicative of a location along the path of the wire.
At welding station 80, an X-Y table 95 may move two adjacent pieces of metal to be welded, 91, 92, in a predetermined path such that a weld pool 85 caused by the focused energy from welder 82 forms at the joint between pieces 91, 92. Alternatively, welder 82 may be moved by known means along the joint between pieces 91, 92.
In either of the aforementioned embodiments, precision feeder 10 must accurately place free end 27 at weld pool 85.
Wire source 14 includes a spool 15 of small diameter wire 20 mounted on plate 12 and freely rotatable about an axis 18. As discussed in greater detail hereinafter, axis 18 represents the output shaft of a torque motor 19 mounted to the opposite side of plate 12 from spool 15.
Wire guide 40 is illustrated as including a cylindrical tube 41 fastened to plate 12 by clamp 42 and fastener 43 to guide wire 21 from spool 20 to a surface 22 of idler pulley 31, which pulley is freely rotatably mounted to plate 12 for rotation about axis 32. Because of the change in wire direction caused by idler 30, wire 23 approaches capstan drive 33 from a direction sufficient to ensure that drive 33 imparts traction over an appreciable length of wire 24.
Capstan drive 33 includes a drive wheel 35 having a diameter much larger than the diameter of wire 20. Wheel 35 is mounted for rotation about an axis 36 representative of the drive shaft of a stepper motor 39 mounted to plate 12 opposite wheel 35. A sufficient length of wire 24 is in friction contact with the circumference of wheel 35 to ensure that wire 20 is moved toward weld zone at weld pool 85 when motor 39 causes axis 36 to rotate in a clockwise direction, as viewed in FIGURE 1.
Although the capstan drive is well known in the art, the drive wheel 35 of this invention is uniquely constructed for improved performance. In particular, the circumference of metal drive wheel 35 includes a layer 38 of polyurethane or other elastomer upon which wire 24 rests when in contact with capstan drive 33. Although wire 24 eventually cuts a track in material 38, the material still grips wire 24 and imparts the improved traction of the invention.
Pressure assembly 50 keeps wire 24 in contact with layer 38 of capstan wheel 35. Assembly 50 preferably includes a support arm 51 attached to plate 12 at one end by pivot 55. The opposite end of arm 51 includes two opposed fingers 52 having a unidirectional ball bearing 54 mounted for rotation in only the counter-clockwise direction around axis 53. The surface of bearing 54 is pressed against wire 24 and capstan wheel 35 by a spring-loaded plunger 56, contained in block 58, fastened to plate 12 by fasteners 59. Bearing 54, which may be grooved to help keep wire 24 from sliding axially along the circumference of wheel 35, allows wire 20 to be driven by wheel 35 towards the weld zone at weld pool 85, but prevents torque motor 19 from moving wire 20 away from the weld zone when motor 39 is not operating.
Once wire 25 leaves capstan drive 33, successful operation requires a delivery system that accurately places wire end 27 at a desired location. However, the delivery system also must impart only a minimum friction to the wire, to prevent it from buckling as it is pushed towards weld pool 85.
As shown in FIGURE 1, wire 25 feeds through a plastic inlet adapter 61 and a teflon guide tube 74. Adapter 61 has a longitudinal slot 62 for the operator's use in placing tube 74 (containing wire 25) in adapter 61 Clamp 63 is attached to plate 12 by fastener 64 to hold adapter 61 rigidly against plate 12. The end of tube 74 is aligned tangentially with the point of contact of bearing 54 on wheel 35, and extends towards that point to minimize the unsupported distance wire 25 will be pushed by wheel 35.
Guide tube 74 is sized to guide wire 26 to the weld zone with minimal friction, as discussed hereinafter. The output of adapter 61 may be aligned with a second, concentric, outer Teflon support tube 72, to optionally provide physical support for guide tube 74.
As shown in the enlarged portion of FIGURE 1, the output end of tube 74 is connected to a conventional medical hypodermic needle 78 by a hollow brass fitting 76 that slides into tube 74 and screws into one end of hollow phenolic adapter 77. The other end of adapter 77 has a Luer taper 79 that fastens to the input end of hypodermic needle 78 in a conventional manner.
Needle 78 is rigidly affixed to move with welder 82 by rigid mounting arms 86, 89 and X-Y-Z positioner 84, a commercially available device with manual adjustments to permit the operator to accurately position needle 78 such that the wire output 27 from needle 78 is at the proper angle and location for feeding weld pool 85.
A wire feeder 10 in accordance with this invention has been constructed using the following components:
Stepper motor 39 -- Compumotor Model 57-102; 25,000 steps per revolution, 120 ounce force inches torque at <6 rps.
Torque motor 19 -- Bodine Model KLI-16, set to apply approximately 4 ounces tension to wire 20.
Capstan drive Wheel 35 -- 0 4.7 cm (1.85 inch) diameter by 2.5 cm (1 inch) wide anodized aluminum; outer surface coated with polyurethane and machined to a final diameter of 5 cm (2 inches).
Pressure roller 54 -- 19 mm (0.75 inch) by 13 mm (0.5 inch) unidirectional ball bearing spring loaded against wheel 35 with 90 ounce force.
Outer tube 72 -- AWG 15; 1.4 mm (0.054 inch) i.d.×2.3 mm (0.089 inch) o.d.
Inner tube 74 -- AWG 24; (0.5 mm (0.02 inch) i.d.×1.1 mm (0.044 inch) o.d.
Hypodermic needle 78 -- B-D Yale, 25 gauge.
Stepper motor 39 is controlled either by a Compumotor Model 21 manual indexer or a Compumotor Model 32 microprocessor The particular device used to control motor 39 is well within the ordinary skill of the motor control art, and does not constitute a part of this invention.
The most notable advantage of this invention is that it works. Small diameter wires are inherently subject to deformation by the drive rollers, breakage caused by suddenly removing slack in the line when the drive motor starts, kinking caused by any friction in the line, and difficult accurate placement of the tip. Unlike a conventional friction brake which would require a higher initial pull on the wire to overcome static friction against supply spool 15 than the subsequent pull necessary to keep the spool rotating against dynamic friction, torque motor 19 provides a constant, accurate, control of the reverse force. The combination of torque motor 19 pulling wire 20 in the reverse direction against the force of one-way bearing 54, which bearing does not permit the wire to go away from weld zone at weld pool 85, eliminates the possibility of slack between spool 15 and capstan 33 when motor 39 is stopped.
In addition, the use of torque motor 19 eliminates the need for spring-biased idler wheels or friction brakes, as is conventional in the art. The variations in spring tensions and friction of such devices are often not sensitive enough for reliable operation with small diameter wire.
In addition, the use of a relatively soft coating on drive wheel 35 has been found to accurately and positively drive wire 20 without deformation of the wire.
Finally, the use of hypodermic needle 78 to inexpensively and accurately deliver the wire to the weld pool is another unique feature of this invention.
Tests of the device at wire feed speeds up to 13 meters/ minute (500 in/min) yielded satisfactory welds. By changing only the hypodermic needle 78 from one having an inside diameter of 0.33 mm 0.013 inch) to one having an inside diameter of 0.2 mm (0.008 inch), wire having a diameter of 0.13 mm (0.005 inch) was fed at a rate of 2.5 meters/minute (100 in/min).
Satisfactory welds were demonstrated using a CO 2 laser beam welder at table travel speeds from 50 to 100 cm/min (20 to 40 in/min) at a wire feed speed of 5 meters/minute (200 in/min). The direction of feeding the wire into the weld pool (relative to the motion of table 95) was found to be insignificant, as was the angle of the needle to the table within a range of 20° to 50° to the horizontal.
The tests did show that the wire tip 27 must be placed in and be melted by weld pool 85 to avoid interrupting the weld, as occurred when the wire was fed directly into the beam from welder 82. Since a 1000 watt welder does not form a large weld pool, the tip of needle 78 must be within 3 mm (0.125 inch) of the weld pool to ensure accurate wire placement.
Tests were made on joint gaps in stainless steel in the range of 0.25 mm 0.01 in) to 0.75 mm (0.03 in) wide and 0.25 mm (0.01 in) to 2.5 mm (0.1 in) deep. Gaps as large as 0.03 by 0.03 inches are readily filled, but gaps 0.1 inches deep could only be bridged by focusing the beam adjacent to the groove and adding wire to achieve a weld of adequate size to fuse the joint.
A complete discussion of the tests of the wire feeder was done by E. Brandon et al., "Characterization of a Precision Wire Feeder for Small-Diameter Wire", SAND89-0235, Dec. 1989, the text of which report is incorporated herein by reference.
The particular sizes and equipment discussed above are cited merely to illustrate a particular embodiment of this invention. It is contemplated that the use of the invention may involve components having different sizes and shapes as long as the principle discussed herein is followed. For example, a curve could be placed in needle 78 for more accurate placement of wire 20. In addition, a continuous drive motor could be used in place of stepper motor 39. Also, heat-shrink tubing could be placed over wheel 35 in place of polyurethane coating 38. It is intended that the scope of the invention be defined by the claims appended hereto.
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A device for feeding small diameter wire having a diameter less than 0.04 mm (16 mil) to a welding station includes a driving wheel for controllably applying a non-deforming driving force to the wire to move the free end of the wire towards the welding station; and a tension device such as a torque motor for constantly applying a reverse force to the wire in opposition to the driving force to keep the wire taut.
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FIELD OF THE INVENTION
The invention relates generally to extruding plastics, and more specifically, to preparation of a thermoplastics adhesive for lamination of a composite.
BACKGROUND OF THE INVENTION
To extrude plastics, one may use an extruder, sheet die, and an embossing-stack. In one example, a thermoplastic adhesive is extruded through the die into cylinders of the embossing-stack, where the adhesive is formed into a film. The surface of the film is embossed with a finish and then the film is cooled. The cylinders of the embossing-stack have an embossed surface, which they impart onto a thermoplastic sheet. The cooled thermoplastic sheet may be collected on a roll or cut using a single layer of interleaf material to separate consecutive wraps or layers.
In another example, film is extruded from an extruder through sheet die onto one interleaf while the film is still thermoplastic. From a position that is near to the sheet die, the film and the interleaf layer are simultaneously pulled by a set of nip rolls that press the film and interleaf layer together while the film is still relatively warm. During this process, the texture of the interleaf layer is impressed in the film. The film and interleaf layer are lightly bonded together so that the interleaf layer can later be peeled.
It is believed that in the above method of preparing a thermoplastic sheet, stress is added to the sheet when the film is pulled off of the collection roll and this stress adversely affects the performance of the sheet in the preparation of a laminate. Consequently, the adverse effects from the stress may show up in the final laminated product.
SUMMARY OF THE INVENTION
The present invention provides methods for preparing laminating materials and composites produced from the methods. In one embodiment, the method includes providing at least one layer of interleaf, extruding a thermoplastic adhesive with a die, forming a composite by applying the at least one layer of interleaf to the adhesive before cooling the adhesive, and pressing the composite with rolls to adhere the at least one layer of interleaf to the adhesive.
In a second embodiment, the method includes providing a pair of polyethylene layers of interleaf with a textured surface and a thickness of about 0.5–15 mils, extruding a polyurethane film, having a thickness of about 0.5–250 mils, with a die, forming a composite by applying the layers of interleaf to the polyurethane film, pressing the composite between rolls of an embossing stack, having an embossing surface, adhering the layers of interleaf to the film, impressing the textured surface of the layers of interleaf and the embossing surface into the film, passing the composite into pressure contact with a cooling surface to cool the film on the composite, and collecting the composite.
In a third embodiment, the composite includes at least two layers of interleaf with a surface and an adhesive adhered between the at least two layers. The adhesive is conformed thermoplastically to the surface of each layer.
In a fourth embodiment, the composite includes a pair of layers of polyethylene interleaf, where each layer has a textured surface, and a polyurethane film adhered between the layers of polyethylene interleaf. The film is thermoplastically adhered to the textured surface of each layer.
In a fifth embodiment, the composite includes at least one layer of interleaf with a surface and an adhesive adhered to the at least one layer. The adhesive is conformed thermoplastically to the surface of the at least one layer of interleaf.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated herein and constitute a part of this specification, illustrate the presently preferred embodiments of the invention and, together with the general description given above and the detailed description given below, serve to explain the features of the invention.
In the drawings:
FIG. 1 is a schematic diagram illustrating one embodiment of a method of the invention;
FIG. 2 is a side view of one embodiment of a composite prepared from the method of FIG. 1 ;
FIG. 3 is a side view of another embodiment of a composite; and
FIG. 4 is a schematic diagram illustrating another embodiment of a method of the invention for preparing the embodiment of a composite of FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. It is to be understood that the Figures and description of the invention included herein illustrate and describe elements that are of particular relevance to the present invention, while eliminating, for purposes of clarity, other elements found in typical extruders.
The invention provides a method for preparing laminating materials, or a film, tape, or sheet of plastic, to improve the lamination of a composite product. These laminating materials may be made by extrusion, both vertically and horizontally. As shown in FIG. 1 , extruder 10 melts adhesive resin and forms a thermoplastic adhesive layer, or polyurethane film, 20 by passing the molten adhesive through sheet die 25 . The extrudate melt temperature may range from about 200° F. to about 500° F., but the preferred temperature is material dependent. The adhesive resin in adhesive 20 may be made of any material that is melt processible or solvent casted and can be formed into a sheet. For example, the adhesive resin may be made of polyurethane, polyvinylbutyrate, polyvinylacetate, polyester, or combinations thereof. The thickness of the adhesive 20 , preferably, is controlled by adjusting the speed of production or varying the die opening. In one embodiment, the thickness of the adhesive 20 , preferably, is about 0.5 to 250 mils, or more preferably, about 2 to 100 mils.
In one embodiment, rolls 30 and 31 of interleaf layers 32 and 33 , respectively, are simultaneously pulled by a roll stack 40 . Roll stack 40 includes rolls 41 and 42 . In one embodiment, interleaf layers 32 and 33 , preferably, have a textured surface 32 a or 33 a, however, the interleaf layers 32 and 33 may have any desired surface, including no texture or a smooth, or glossy, surface. The desired surface may be chosen to obtain an appearance of the final laminate product. Textured surface 32 a or 33 a, preferably, has a depth of about 5% to 100% of the thickness of the interleaf layer and, more preferably, has a depth of about 20% to 80% of the thickness of the interleaf layer. Textured surface 32 a or 33 a may have a random pattern, a diamond pattern, or any other desirable pattern. A pattern allows the adhesive 20 to de-air, which squeezes the air out of the space between interleaf layers 32 and 33 and adhesive 20 , as the interleaf layers 32 and 33 come in contact with the adhesive 20 . This de-airing will eliminate air bubble defects in the final laminate product. One textured surface 32 a may have a different pattern from the other textured surface 33 a. Interleaf layers 32 and 33 are preferably polyethylene; however, polypropylene, polyethylene terepthalate (“PET”), and other similar materials that allow interleaf layers 32 and 33 to maintain intimate contact with adhesive 20 , maintain its physical properties during pressing, maintain an embossed pattern, and/or have the flexibility to be rolled may be used.
In a preferred embodiment, interleaf layers 32 and 33 each have a thickness of about 0.5 to 15 mils. In a more preferred embodiment, interleaf layers 32 and 33 each have a thickness of about 2 to 6 mils.
Rolls 41 and 42 include metal, silicone and/or rubber outer portions for contacting a laminated product. Rolls 41 and 42 press interleaf layers 32 and 33 to adhesive 20 , while adhesive 20 is still heated from the extrusion, to adhere interleaf layers 32 and 33 to adhesive 20 and form a composite 50 . While interleaf layers 32 and 33 are pressed against adhesive 20 , preferably, textured surfaces 32 a and 33 a of interleaf layers 32 and 33 are impressed into adhesive 20 . This impression of texture decreases the shininess, or glossiness, of adhesive 20 . This allows the surface of adhesive 20 to de-air when it is laminated into a composite, provides a surface with a greater roughness, allows adhesive 20 to be more easily positioned during use, and allows for easier de-airation when bonding adhesive 20 to another surface. During de-airation, the texture allows the air to channel out of adhesive 20 as pressure is applied to the surface of adhesive 20 . This must be accomplished before adhesive 20 becomes tacky and traps the air.
During pressing, interleaf layers 32 and 33 will not transfer any material to the adhesive 20 that could affect the performance of adhesive 20 . In a preferred embodiment, the pressing prevents air from being trapped between adhesive 20 and interleaf layers 32 and 33 , which allows for an intimate contact between adhesive 20 and interleaf layers 32 and 33 .
Composite 50 then comes into pressure contact with a cooling surface 58 of roll 60 to cool adhesive 20 in composite 50 . The temperature of cooling surface 58 effects the surface characteristics of adhesive 20 , so the temperature must allow for cooling of interleaf layers 32 and 33 and texturing of adhesive 20 . Accordingly, the temperature is selected depending upon the physical and chemical attributes of the interleaf layer(s) and the adhesive. In a preferred embodiment, cooling surface 58 has a temperature between 40° F. and 200° F., and in a more preferred embodiment, cooling surface 58 has a temperature between about 60° F. and 150° F. After composite 50 moves along roll 60 , composite 50 is collected as a unit onto roll 65 . Alternatively, composite 50 may be cut to size and stacked as flat sheets without sticking together. In one embodiment, composite 50 , as shown in FIG. 2 , has interleaf layers 32 and 33 and adhesive 20 therebetween.
In one example using the above method, a composite 50 of AG-5050 0.050×39″, an optical urethane provided by Thermedics Polymer Products, Woburn, Mass., was made using two outside interleaf layers 32 and 33 of polyethylene film. The interleaf layers 32 and 33 were 0.004 inches thick and had a random texture on the surface. The AG-5050 extrudate left the sheet die 25 at 340° F. and was joined with the interleaf layers 32 and 33 at rolls 41 and 42 . The temperature of roll 41 was 100° F. and roll 42 was 120° F. Composite 50 was then rolled up as finished rolls and packaged for use in security glazing.
In another example using the above method, a composite 50 of AG-5050 0.050×50″ was made using two outside interleaf layers 32 and 33 of film. One interleaf layer was 0.004 inch thick polyethylene film that had a random texture. The other interleaf layer was 0.002 inch thick polypropylene film that had a random texture. The AG-5050 extrudate left the sheet die 25 at 335° F. and was joined with the interleaf layers 32 and 33 at rolls 41 and 42 . The temperature of roll 41 was 105° F. and roll 42 was 120° F. The composite 50 was then rolled up as finished rolls and packaged for use in security glazing.
In another embodiment, as shown in FIG. 3 , the composite 150 has one interleaf layer 132 adhered to the adhesive 120 , where interleaf layer 132 may be located on either the top or the bottom of adhesive 120 . Similar to the method of making a composite with two interleaf layers described above, extruder 110 melts adhesive resin and forms adhesive layer 120 , as shown in FIG. 4 . Roll 130 of single interleaf layer 132 is pulled by roll stack 140 , which includes rolls 141 and 142 . As described above, interleaf layer 132 may have any desired surface and be made of any material that allows interleaf layer 132 to maintain intimate contact with adhesive 120 , maintain its physical properties during pressing, maintain an embossed pattern, and/or have the flexibility to be rolled.
Rolls 141 and 142 press interleaf layer 132 to adhesive 120 , while adhesive 120 is still heated from the extrusion to adhere interleaf layer 132 to adhesive 120 and form composite 150 . While interleaf layer 132 is pressed against adhesive 120 , preferably, any textured surface of interleaf layer 132 is impressed into adhesive 120 . Interleaf layer 132 will not transfer any material to adhesive 120 that could affect the performance of adhesive 120 .
Composite 150 then comes into pressure contact with cooling surface 158 of roll 160 to cool adhesive 120 in composite 150 . The temperature of cooling surface 158 must allow for cooling of interleaf layer 132 and texturing of adhesive 120 . After composite 150 moves along roll 160 , composite 150 is collected as a unit onto roll 165 or cut to size and stacked as flat sheets without sticking together.
During the lamination process, interleaf layers 32 and 33 or 132 are removed so that adhesive 20 or 120 may bond to other materials. When interleaf layers 32 and 33 or 132 are removed, adhesive 20 or 120 may be used in many manufactured products. For example, adhesive 20 or 120 may be used in touch screens, EMI screens, windows, car side windows, computer screens, monitors, television screens, bullet resistant laminates, and many other applications. Composite 50 or 150 is stiffer than adhesive 20 or 120 alone and thus allows for easier handling of adhesive 20 or 120 . Interleaf layers 32 and 33 or 132 maintain adhesive 20 or 120 in a clean, uncontaminated state and provide less internal stress on adhesive 20 or 120 by allowing adhesive 20 or 120 to lay flat, or be stacked, during the construction of the final laminate product. By maintaining a low internal stress on adhesive 20 or 120 , wrinkles and other defects are prevented, which results in a less stressed final laminate product.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. Thus, it is intended that the invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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A method for preparing laminating materials and a composite prepared therefrom, the method including providing at least one layer of interleaf, extruding a thermoplastic adhesive with a die, forming a composite by applying the at least one layer of interleaf to the adhesive before cooling the adhesive, and pressing the composite with rolls to adhere the at least one layer of interleaf to the adhesive.
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FIELD OF THE INVENTION
The present invention relates to streetlights or the like provided with a matrix of light emitting diodes. More specifically, the present invention is concerned with a system and method for controlling such matrix.
BACKGROUND OF THE INVENTION
The conventional streetlight, provided with metal halide, mercury or sodium filled bulb suffers from few disadvantages. A first disadvantage is the relatively high energy consumption. Another one is the relatively short life of the bulb. Indeed, after a few years of operation the bulb fails and needs to be replaced.
Matrices of light emitting diodes (LEDs) have been introduced in streetlights as a replacement solution to the conventional bulbs. However, the power controlling of current LED matrix in streetlight has been found inefficient, resulting in lost of energy and of light flux for a given input power consumption.
More efficient system and method for controlling a matrix of light emitting diodes are thus desirable.
OBJECTS OF THE INVENTION
An object of the present invention is therefore to provide an improved system and method for controlling a matrix of light emitting diodes.
Another object of the present invention is to provide improved streetlights or improved lights provided with a light emitting diode matrix.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a method and system for controlling a matrix of light emitting diodes in a streetlight or the like. The present method and system allows maximizing the energy savings. Moreover, it allows controlling current flowing in the diodes so as to obtain the maximum flux of light with the minimum energy and also allows meeting all safety, EMI, reliability and robustness requirements.
For example, a streetlight provided with a matrix of light emitting diodes and a system for controlling such a matrix according to the present invention provides significant energy savings and a useful life that is more then 10 times higher compared to the conventional high pressure sodium or mercury lamps. One major advantage is that the light efficiency is much higher. Therefore a streetlight according to the present invention generates a large economy of energy in the order of 80% compared to streetlights provided with bulb lamps. A second advantage is the longer life of the diodes matrix. A high pressure sodium bulb has only a few years of useful life while the light emitting diode has more then 20 years of useful life. This allows significantly reducing the maintenance cost, reducing the scrap and increasing the road safety.
More specifically, in accordance with the present invention, there is provided a system for controlling a matrix of light emitting diodes (LED) connected to an input line, the system comprising:
a power converter for connecting to the matrix of LEDs and to the input line there between and for receiving from the input line an input current and an input voltage characterized by a shape and a frequency and for providing a direct current (D.C.) output for powering up the LEDs, yielding an operating current through the LEDs; the power converter including a first current sensor for sensing the input current and a second current sensor for sensing the operating current;
a controller for connecting to both the input line and to the power converter; the controller including a voltage sensor for sensing the input voltage and a pre-regulator i) for receiving the operating current, the input current and the input voltage, ii) for biasing the operating current towards a target current, and iii) for regulating the power converter to cause the input current to follow the shape and frequency of the input voltage, yielding a unity power factor and minimizing the input current harmonic distortion.
According to a second aspect of the present invention, there is provided a system for controlling a matrix of light emitting diodes (LEDs) connected to an input line, the system comprising:
converter means for connecting to the matrix of LEDs and to the input line there between and for receiving from the input line an input current and an input voltage characterized by a shape and a frequency and for providing a direct current (D.C.) output for powering up the LEDs, yielding an operating current through the LEDs;
first sensing means for sensing the input current;
second sensing means for sensing the operating current;
third sensing means for sensing the input voltage; and
controller means for connecting to both the input line and to the converter means i) for receiving the operating current, the input current and the input voltage, ii) for biasing the operating current towards a target current, and iii) for regulating the converter means to cause the input current to follow the shape and frequency of the input voltage, yielding a unity power factor and minimizing the input current harmonic distortion.
According to a third aspect of the present invention, there is provided a method for controlling a matrix of light emitting diodes (LED) connected to an input line, the method comprising:
measuring from the input line an input current;
measuring from the input line an input voltage characterized by a shape and a frequency;
providing a LED target current;
converting the input line voltage into a direct current (D.C.) output voltage for powering up the LEDs, yielding an operating current through the LEDs, by forcing the input current to follow the shape and frequency of the input voltage, yielding a unity power factor and minimizing the input current harmonic distortion;
measuring an operating current through the LEDs; and
biasing the operating current towards the LED target current.
Other objects, advantages and features of the present invention will become more apparent upon reading the following non restrictive description of illustrated embodiments thereof, given by way of example only with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the appended drawings:
FIG. 1 is a schematic view of a streetlight unit according to a first illustrative embodiment of the present invention;
FIG. 2 is a circuit diagram illustrating the electromagnetic interference (EMI) filter of the streetlight unit from FIG. 1 ;
FIG. 3 is a circuit diagram illustrating the power converter of the streetlight unit from FIG. 1 ;
FIG. 4 is a circuit diagram illustrating an auxiliary power supply of the streetlight unit from FIG. 1 ;
FIGS. 5A-5B are circuit diagrams illustrating the power converter controller of the streetlight unit from FIG. 1 ;
FIGS. 6A , 6 B, 6 C and 6 D are graphs illustrating respectively the steady state wave forms at nominal input utility line, the start up wave forms at low utility line, the load transient wave forms and the utility line drop out wave forms of the streetlight unit from FIG. 1 ; channel 1 representing the input voltage measurement, channel 2 representing the output voltage measurement, channel 3 representing the input current measurement and channel 4 representing the output current measurement;
FIG. 7 is a circuit diagram illustrating an electromagnetic interference (EMI) filter part of a system for controlling a matrix of light emitting diodes according to a second illustrative embodiment of the present invention;
FIG. 8 is a circuit diagram illustrating a power converter part of the system for controlling a matrix of light emitting diodes according to the second illustrative embodiment of the present invention;
FIGS. 9A-9B are circuit diagrams illustrating a power converter controller part of the system for controlling a matrix of light emitting diodes according to the second illustrative embodiment of the present invention; and
FIGS. 10A , 10 B and 10 C are graphs illustrating respectively the steady state wave forms at nominal input utility line (input current and voltage), the start up wave forms at low utility line (input voltage and output current) and the flyback main transistor wave forms (voltage and current) of the streetlight according to the second illustrative embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A streetlight unit 10 according to a first illustrative embodiment of the present invention will now be described with reference to FIG. 1 of the appended drawings.
The streetlight unit 10 comprises a matrix of light emitting diodes (LEDs) 12 connected to the A.C. (alternating current) utility network 14 via a power converter 16 , and a controller 18 for the power converter 16 .
The matrix of LEDs 12 includes a combination of diodes connected in series and in parallel (not shown). This connection arrangement of diodes provides a significant improvement to the reliability and life of the streetlight 10 compare with a conventional streetlight provided with a matrix of LEDs. Indeed, the parallel connection of the diodes (for example 2 to 20) assures that even if one diode is failing short or open, the remaining matrix is not affected by the failure; the streetlight 10 can still operate, with only a small degradation of luminescence. The streetlight 10 can however operate beyond its stated and rated life if the LEDs would all have been connected in series.
The series connections (for example 2 to 250) allow driving the LEDs 12 with a high DC voltage and therefore simplifying the power converter 16 and improving its efficiency.
The streetlight unit 10 will now be described in more detail with reference to FIGS. 2 to 6 .
The streetlight unit 10 further includes an electromagnetic interference (EMI) filter 20 , which is illustrated in FIG. 2 , connected to the A.C. utility 14 at the input of the power converter 16 . The EMI filter 20 together with the power converter 16 and controller 18 define a system for controlling a matrix of LEDs.
The filter 20 includes two differential mode capacitors C 2 and C 3 , five common mode capacitors C 9 , C 10 , C 11 , C 12 and C 13 and a common mode inductor L 2 , the leakage inductor of this magnetic element L 2 further acting as a differential mode filter. It is to be noted that the capacitor C 4 and C 5 of the power converter 18 are also used for the EMI concerns. The EMI filter 20 , in association with the proper layout, such as the one described in FIGS. 1-4 , renders the unit 10 conformed to the EMI American and European specifications (FCC part 15, EN55022/CISPR 22 and CSA C108). Since such specifications are believed to be well known in the art, and for concision purposes, they will not be described herein in more detail.
The unit 10 is also designed to be conformed to the well-known IEEE C62.41 specifications allowing it to handle most type of utility disturbances without any damage, including lightning strikes (typically 6000V, 3000 A, 50 microseconds). For that purposes, the EMI filter 20 includes three transient voltage suppressors MOV 1 , MOV 2 and MOV 3 (see FIG. 2 ) which are coupled to a diode D 1 of the power converter 16 . The diode D 1 helps transferring some of the lightning energy to the output capacitor formed by C 1 and C 6 in series (see FIG. 3 ). This allows increasing the MOV's life time and decreasing the over voltage stress on all the power converter semiconductors including its input diode bridge D 4 , D 5 , D 8 and D 9 . Indeed, decreasing the maximum voltage constraint on the power semiconductor contribute to increasing their life time and also the overall efficiency of the converter 16 .
Returning to FIG. 2 , two input line fuses F 1 and F 2 are used to prevent damage inside the unit 10 . A gas arrester GA 1 is also provided to minimize the leakage current of the transient voltage suppressors MOV 2 and MOV 3 , thereby increasing their life time and permitting to test the line to chassis isolation without damaging the MOVs. Then, for the safety, the converter further has the VDE, CSA and UL certifications.
Finally, the input 22 of the power converter 16 includes a negative temperature coefficient (NTC) resistor to control the inrush current during the start-up. The unit 10 is configured conformably to the specifications IEC-1000-2-3 and EN60555 part 2, regarding the quality of the input current wave form. Since such specifications are believed to be well known in the art, and for concision purposes, they will no be described herein in more detail.
The input 22 of the power converter 16 is connected at the AC utility 14 (VAC 1 , VAC 2 ). The converter 16 provides a DC output that is used to power up the LEDs 12 . The input frequency and input voltage is converted into DC voltage and current to properly drive the LEDs 12 to maximize the luminescence. As will be explained herein below in more detail, measures of both the input voltage and current are sent to the controller 18 to allow for a unity power factor and to minimize the input current harmonic distortion. The controller 18 forces the input current to follow the input voltage, forces also the LEDs current set pointo extract a maximum luminescence and manages all the utility 14 disturbances (Start-Stop, Swell, Sag and Surge). This provides the robustness to withstand the utility transient.
Turning now to FIG. 3 , the power converter 16 will now be described in more detail. As will become more apparent upon reading the following description, the converter 16 is in the form of a boost converter, adapted for a matrix of LEDs including a large number of LEDs, such as 200 or more. In addition to a streetlight, applications for a matrix including such a large number of LEDs includes without limitations lights for a highway, a play-ground, a monument, an indoor parking, pathways, building, and flood and area type lighting fixtures and luminaries.
The power converter 16 includes an input diode bridge formed by diodes D 4 , D 5 , D 8 and D 9 , the primary of a transformer L 1 , an active switch M 1 and a boost converter output diode D 2 . Any transistor technology, such as IGBT (insulated gate bipolar transistor), MOSFET (metal-oxide semiconductor field-effect transistor) or bipolar transistor (BIPOLAR) can be used for the active switch M 1 .
The switch M 1 is modulated at high fixed frequency to force the input current to follow the input voltage. The current for the LEDs is set for maximum luminescence and minimum input power. The input current is sensed by three resistors connected in parallel R 16 , R 17 and R 18 , while the LEDs operating current is sensed by R 11 and R 12 in parallel. Both current measurements are sent to the controller 18 .
FIG. 4 illustrates a low cost high frequency auxiliary power supply 24 including the L 1 secondary winding associated with the network, resistor devices R 22 , R 23 , R 26 , R 27 and R 33 , diodes D 12 and D 15 , capacitors C 20 , C 21 , C 22 and C 23 . The power supply 24 is configured so that its output voltage is automatically regulated proportionally to the output voltage of the power converter 16 .
The controller 18 of the converter 16 will now be described in more detail with reference to FIGS. 5A-5B .
The controller 18 includes a power factor pre-regulator 26 and an input line voltage sensor 28 in the form of three resistors in series (R 38 , R 39 and R 40 ) connected to the pre-regulator 26 as an input thereof. The controller 18 biased the power converter 16 towards a unity power factor and a low THD (total harmonic distortion). The controller 18 senses via the sensor 28 the input line voltage and regulates the converter 16 to cause the input current to follow the shape and frequency of the input voltage. It is to be noted that the zero and pole for the input current controller are fixed by R 24 , R 31 , R 34 , C 15 and C 17 . This yields a unity power factor (higher then 0.99 at nominal AC line input voltage, higher then 0.97 for all input voltage range “nominal voltage±15%”) and also a low THD, which is less then 5% at nominal AC line input voltage.
Even though the illustrative embodiment of FIG. 5A includes a UCC3817 from Texas Instrument as the pre-regulator 26 , any power factor pre-regulator can be used to control the input current wave shape and to regulate the input power.
As described hereinabove, the output voltage (+VDC) is in the form of a high voltage DC output. One conventional way to drive the LEDs 12 is to insert a resistor in series with the diodes 12 and then to drive the LEDs 12 by a voltage source. The disadvantage of such method is a variation of current through the LEDs 12 with the input voltage, the component variations and the temperature. This variation of current through the LEDs 12 would cause a variation of luminescence from the diodes 12 . The flux of light would then vary with some internal and external parameters. Since the voltage drop of the LEDs 12 varies with the temperature, the resulting current would then vary accordingly. Also the luminescence of the diode decreases with temperature.
Since the LEDs 12 require a specific current to generate the light, the controller 18 according to the present invention is configured to drive the LEDs 12 with a precise current as opposed to a precise voltage.
FIG. 5B illustrates a LEDs voltage and current controller 30 , part of the power converter controller 18 . In a nutshell, the current of the LEDs matrix 12 is monitored as well as the temperature of the diodes. The controller 18 processes this information and controls the converter 16 to assure that the LEDs 12 are driven by a DC current with a maximum of luminescence. This allows optimizing the light output of the LEDs 12 while taking a minimum input power.
The zero and pole for the LEDs voltage and current controller 30 are determined by R 30 , R 43 , C 24 and C 27 from the controller 18 .
Turning back briefly to FIG. 3 , a measure of the current is performed at R 11 and R 12 in parallel and transmitted to UlA 32 by V_IOUT. The output voltage of UlA 32 is proportional to the LEDs current [IOUT×(1+R 29 /R 28 )]. UlA 32 allows the controller 18 to maintain the current to a very stable nominal target value.
A temperature sensor 33 (see FIG. 1 ) detects the operating temperature of the LEDs 12 and a modification to the nominal target current is done to assure the optimum luminescence of the LEDs 12 is achieved with different ambient temperature. The temperature sensor 33 may take measures at fixed or variable time intervals. Those intervals may also vary depending on the climate where the light 10 is installed. Of course, more precise temperature measurements may yield both a better luminescence and a better life time of the light 10 .
The resistor R 28 can be replaced by a digitally controlled variable resistor EEPOT (Electrically Erasable Potentiometers), allowing to selectively increase the LEDs current by increasing the variable resistor.
In addition, the nominal target current may be adjusted with time to cope with the aging of the LED matrix 12 . The target values or a predetermined algorithm allowing to obtained such values may be stored in a memory (not shown) coupled with the controller 18 . The time adjustment may be based on the number of powering ups of the matrix 10 . This feature allows uniform luminescence over time even though the luminescence of the diodes may vary with time.
The controller 18 offers a dual mode of regulation. Indeed, as described hereinabove, the normal regulation is with the LEDs 12 current. But to protect the LEDs 12 from failing and to avoid a high voltage thereon, which can damage them, the controller 18 is configured to switch over a voltage regulation mode. UlB 34 (see FIG. 5B ) then regulates the controller 18 to assure a selected voltage is not surpassed and indeed will protect the LEDs 12 if multiple failures occur. UlA 32 sends the information to the controller 18 when the output voltage reaches a pre-determined safety value.
As stated hereinabove, the power converter 16 is rugged under AC line voltage disturbances. Indeed, the controller 18 offers protection in case of high voltage present on the input or high current being drawn from the line 14 . In such cases the switch Ml momentarily stops functioning to assure the disturbance is passing through without overstressing any components.
Experimental wave form results obtained using the streetlight unit 10 are shown in FIGS. 6A-6D .
More precisely, FIGS. 6A , 6 B, 6 C and 6 D are graphs illustrating respectively the steady state wave forms at nominal input utility line, the start up wave forms at low utility line, the load transient wave forms and the utility line drop out wave forms of the streetlight unit 10 .
In FIGS. 6A-6D , channel 1 represents the input voltage measurement, channel 2 represents the output voltage measurement, channel 3 represents the input current measurement and channel 4 represents the output current measurement.
The experimental values have been obtained using a system for controlling a matrix of LEDs according to the first illustrative embodiment of the present invention similar to the system 10 , configured to control a matrix of LEDs of 90 Watts and having an operating range between 176 Vrms and 295 Vrms.
FIG. 6A shows that the waveforms of the input current (channel 3 ) and of the input voltage (channel 1 ) are identical, yielding a unity power factor and allowing to minimize the harmonic distortion. FIG. 6A also shows that the output current (channel 4 ) is a well-controlled D.C. current.
FIG. 6B shows a minimum of a bout 10 to 20 minutes are required, in the case of sodium or mercury-based bulb, to achieve a maximum of illumination intensity when an input voltage is applied. Less than two (2) seconds are required to achieve maximum illumination using a controlling system according to the present invention.
FIG. 6C shows that both the input and output currents remain under control even when the matrix of LEDs is connected or disconnected while the converter remains alive.
Finally, FIG. 6D illustrates the controlled extinction of the matrix during a utility power outage
A system for controlling a matrix of LEDs according to a second illustrative embodiment of the present invention will now be described with reference to FIGS. 7 to 9B . Since the LEDs matrix controlling system according to this second illustrative embodiment is similar to the one described in reference to the streetlight 10 , and for concision purposes, only the differences between the two systems will be described herein in more detail.
The LEDs matrix controlling system according to the second illustrative embodiment shares the same general layout as the unit 10 as described shown in FIG. 1 . It includes an EMI filter 36 (see FIG. 7 ) at the input stage, which, in association with proper layout, allows the unit to be conformed to the EMI American and the European specifications (FCC part 15, EN55022/CISPR 22 and CSA C108, a power converter 38 (see FIG. 8 ), in the form of a flyback converter, and a controller 40 for the converter (see FIGS. 9A-9B ). While the filter 20 , power converter 16 and controller 18 are together particularly suitable for controlling a matrix having a large number of LEDs 12 , such as 200 or more, the filter 36 , power converter 38 and converter 40 are together particularly suitable for controlling a matrix having a number of LEDs lower than 5000. Applications for such a controlling system includes traffic signal lights, train signalization lights, residential lights, industrial building lights, office lights, etc.
The filter 36 includes two differential mode capacitors C 1 and C 2 , and a differential mode inductor L 1 . The capacitors C 10 and C 5 , which are part of the converter 40 (see FIG. 8 ) are also used for the EMI concerns. The unit is designed to prevent damage under utility disturbances. More specifically, the filter 36 includes two transient voltage suppressors MOV 1 , MOV 2 coupled to the resistors R 1 , R 2 , R 5 and R 6 , which would generate for example less then a quarter watt losses for a matrix including 400 LEDs. These resistors limit lightning current circulating into MOV 1 and MOV 2 . This technique allows decreasing the over voltage stress on all the semiconductors of the power converter 38 . Two input line fuse F 1 and F 2 are used to prevent any catastrophic damage inside the LEDs controlling system. For further safety purposes, the converter can have the VDE, CSA and UL certifications. Since VDE, CSA and UL certifications are believed to be well known in the art, and for concision purposes, they will not be described herein in more detail.
The power converter 38 will now be described in more detail with reference to FIG. 8 . The power converter is in the form of a flyback converter having an input diode bridge 42 (D 1 , D 2 , D 6 and D 7 ), a transformer T 1 , an active switch Q 1 and two output diodes D 3 and D 4 . The active switch Q 1 can take many forms, including without limitations IGBT, MOSFET and BIPOLAR.
The transformer T 1 extra secondary winding associated with D 5 and C 8 represents a low cost high frequency auxiliary power supply. According to this configuration, the output voltage of the auxiliary power supply is automatically regulated proportionally to the output voltage.
The network formed by D 8 , D 9 , R 7 , R 10 , R 12 , R 14 and C 6 helps to clamp the voltage across the switch Q 1 ; the transformer leakage inductor energy being damped by this network.
The switch Q 1 is modulated at a high predetermined frequency to force the input current, in association with the input EMI filter 36 , to follow the input voltage. The current for the LEDs is set at the optimal point for maximum luminescence and minimum input power.
The converter controller 40 will now be described with reference to FIGS. 9A-9B .
The controller 40 is configured so as to yield a unity power factor and a low THD. Considering a maximum duty cycle of 50% and that this duty cycle is fixed for at least half period of the utility frequency (10 or 8.33 milliseconds for 50 Hz or 60 Hz respective frequency), this yields a unity power factor (higher then 0.97 at nominal AC line input voltage, higher then 0.95 for all input voltage range “nominal voltage±15%”) and also a low THD, which will be less then 10% at nominal AC line input voltage. To achieve these performances, any fixed frequency pulse width modulator with 50% maximum duty cycle can be used to control the input current wave shape and to regulate the output current. For example, the UCC3851 from Texas Instrument 44 can be used for such purposes.
To ensure high robustness against line disturbances some extra protections are implemented. Then to avoid transformer saturation, the transistor peak current limit is implemented. More specifically, a measurement network is formed in the power converter 38 by R 17 , R 16 , C 9 , and the threshold is set by Vref, R 41 , R 42 and C 27 . To keep the main transistor 44 in a safe operating area, fast high input voltages detect is implemented via R 28 , R 29 , R 30 and C 21 . It is to be noted that the duty cycle can be limited cycle by cycle.
Experimental wave form results obtained using the LEDs matrix controlling system according to the second illustrative embodiment of the present invention are illustrated in FIGS. 10A-10C .
FIGS. 10A , 10 B and 10 C are graphs illustrating respectively the steady state wave forms at nominal input utility line (input current and voltage), the start up wave forms at low utility line (input voltage and output current) and the flyback main transistor wave forms (voltage and current) of the streetlight according to the second illustrative embodiment of the present invention.
The experimental values have been obtained using a controlling system according to the present invention having components similar to those described with reference to FIGS. 7-9B configured to control a matrix of LED of 16 Watts and having an operating range between 176 Vrms and 300 Vrms.
FIG. 10A shows that the waveforms of the input current (channel 2 ) and of the input voltage (channel 1 ) are identical, yielding a unity power factor and allowing to minimize the harmonic distortion.
FIG. 10B shows that a maximum delay of about 0.3 second is required to achieve maximum illumination after applying the input voltage. This is one of the reasons why the system for controlling a matrix of LEDs according to the second illustrative embodiment of the present invention is particularly interesting in signalization applications (including road, railway and ocean signalization).
FIG. 10C shows that the cycle ratio is fixed and inferior to 50% (on at least half a cycle), that the current is discontinuous, and that the voltage at the transistor's terminal is clamped.
Even though the present invention has been described by way of reference to illustrative embodiments wherein the input line has been in the form of an A.C. utility line, it can be connected to any type of input line, including a D.C. line.
Although the present invention has been described hereinabove by way of illustrative embodiments thereof, it can be modified without departing from the spirit and nature of the subject invention, as defined in the appended claims.
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A system and method for controlling a matrix of light emitting diodes (LED) connected to an input line comprises a power converter for connecting to the matrix of LEDs and to the input line therebetween and for receiving from the input line an input current and an input voltage characterized by a shape and a frequency and for providing a direct current (D.C.) output for powering up the LEDs, yielding an operating current through the LEDs. The power converter includes a first current sensor for sensing the input current and a second current sensor for sensing the operating current. The system further comprises a controller for connecting to both the input line and to the power converter. The controller includes a voltage sensor for sensing the input voltage and a pre-regulator i) for receiving the operating current, the input current and the input voltage, ii) for biasing the operating current towards a target current value, and iii) for regulating the power converter to cause the input current to follow the shape and frequency of the input voltage, yielding a unity power factor and minimizing the input current harmonic distortion. The present method and system allows maximizing the energy savings, controlling current flowing in the diodes so as to obtain the maximum flux of light with the minimum energy and also allows meeting all safety, EMI, reliability and robustness requirements.
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RELATED APPLICATIONS
This application claims priority to U.K. Patent Application Serial No. 0102139.3, filed Jan. 27, 2001, which is hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention is directed at a PDA enabled telephone system which eliminates the necessity of a PC and allows the PDA user to control operation of the telephone system directly from the PDA via a telephone set, which functions as a portal to the telephone system. Thus, the user is not required to be at a specific location before using the PDA to dial a telephone number. The PDA controls the telephone system via telephony applications stored within. Moreover, these applications may be downloaded to the PDA.
BACKGROUND OF THE INVENTION
Palm-top or hand-held PDA'such as the Palm Pilot® PC or the Casio® E-10 PDA provide a mobile user with “pocket” applications which are controlled using a pen-based input device, buttons and an LCD output. These devices are enjoying increased popularity because of their lightweight construction and compact design (e.g. the devices can fit easily in a jacket pocket or purse and provide useful features such as contact data bases, address books, schedulers, notepads, etc.).
Quite independently of the palm-top PDAs discussed above, CTI systems are known for integrating telephony features with a PC. For example, the Mitel Personal Assistant® integrated telephony system includes a telephone which is connected to a workstation PC via a serial bus or USB, and software for integrating applications running on the desktop PC with telephony features offered by the attached telephone. Thus, for example, the CTI software can be configured so that when an incoming call is received with CLID (Calling Line Identification), a contacts database is accessed and information about the calling party is displayed while the telephone rings. Or, soft keys can be programmed on the telephone, via the computer, to launch an application on the computer, such as a spreadsheet.
An earlier invention, set forth in U.S. Pat. No. 6,647,0103 to Pinard et al. describes the interconnection of a palm-top PDA or computer to a desktop PC which has an attached telephone under its control. In order to control telephony features via the PDA, a communication protocol is used between the PDA and PC for exchanging messages and commands. The PC then processes the call commands received from the PDA and issues further messages and commands to the telephone using a further protocol which is entirely independent of the protocol used to communicate between the PDA and the PC. This introduces complexities and costs in implementing PDA enabled telephony.
SUMMARY OF THE INVENTION
The present invention is directed at a PDA enabled telephone which eliminates the necessity of a PC and allows the PDA user to control operation of a telephone set directly from the PDA. Thus, any PDA enabled set can be controlled by a PDA and the user is not required to be at a specific location before using the PDA to dial a telephone number. The PDA controls the telephone set via telephony applications stored within. Moreover, these applications may be downloaded to the PDA for use with the PDA enabled telephone set.
In order to facilitate the foregoing, a simplified protocol is established for communicating between application platforms and network portals (e.g. a PDA and a telephone set, a telephone set and a PC, a PDA and a laptop computer, etc.) This simplified protocol allows for a more standard inter-compatible information exchange between such devices than is provided for by the prior art.
An advantage of the present invention is that the telephony application resides directly on the PDA. A call command passes from the PDA to the telephone set and vice versa via the aforenoted protocol to control functions of the telephone set and hence the call server. Information such as numbers to be called, numbers to be assigned to softkeys, the directory number (DN) of the set, etc. is received by or already stored in the PDA and is used by the telephony application to generate a call control command which results in the invocation of a telephony function on the set or call server. The PDA telephony application transfers this command to the telephone set to initiate the telephony feature indicated by the command. It should be noted that the data may originate from an external network, such as the Internet, however, processing of the data (e.g. numbers to be called) takes place on the PDA and is subsequently transferred to the set by the telephony application. Similarly, data from the telephone set may be transferred to the PDA to be stored or displayed on the PDA by an application running on the PDA.
In addition, synchronization of PDA databases and applications with a PC or server based database (i.e. Hot Syncing) is accomplished by communications through the telephone, which, as discussed above, functions as a network portal.
BRIEF DESCRIPTION OF THE DETAILED DRAWINGS
Embodiments of the present invention will now be described with reference to the accompanying drawings in which:
FIG. 1 shows a preferred embodiment of a PDA enabled telephone system in accordance with the present invention;
FIG. 2 provides at a top portion thereof a block diagram showing a protocol for communications between the PDA and telephone system of FIG. 1 and at a bottom portion thereof a datagram showing the structure of a packet of information exchanged between the PDA and telephone set of FIG. 1 ;
FIG. 3 is a block diagram of a PDA enabled telephone system in accordance with the present invention implemented within a TDM network configuration; and
FIG. 4 is a block diagram of a PDA enabled telephone system in accordance with the present invention implemented within an IP based network.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention is directed at a personal digital assistant (PDA) enabled telephone system. Turning to FIG. 1 , a schematic illustration is provided of a PDA enabled telephone system in accordance with the present invention.
The PDA enabled telephony system 10 comprises a telephone set 12 and a personal digital assistant (PDA) 14 . The PDA 14 communicates with the telephone set 12 via a bi-directional serial communication link 15 . The communication link may either be a wired connection communication protocol such as USB or RS-232 protocol or a wireless communication protocol such as Bluetooth or IrDA.
The PDA 14 comprises a user interface display 16 as well as a set of buttons 18 for navigation of the PDA 14 by the user. The PDA 14 may also include a writing implement for interacting with the display 16 . The telephone set 12 may be either an analog set (POTS), digital set, or IP-phone, and is shown comprising a keypad 20 , a pair of control buttons 22 and a port 13 for communicating with the PDA 14 . The telephone set 12 , in turn, communicates with a voice/data network (not shown) such as a PBX, LAN, Wan, etc.
As discussed briefly above, a simplified protocol is provided for communications between the PDA 14 and telephone set 12 , without the requirement of an intermediate PC. The details of this protocol are set forth in co-pending U.S. patent application Ser. No. 10/056,404 entitled “TRANSPORT PROTOCOL FOR APPLICATION PLATFORMS COMMUNICATING VIA NETWORK PORTALS”. According to the simplified protocol, a diverse collection of voice and data devices may communicate with each other without complicated protocol conversions as exist in the prior art. More specifically, a protocol mechanism is provided for establishing communications between an application platform and a network portal, on the one hand, and between the network portal and a voice/data network, on the other hand.
An application platform, or AP, is any device that can send and receive voice or data, or a mixture of both, between other AP devices through a network portal within a hybrid voice/data network. In other words, an application platform (AP) is any device used as a terminating device on the hybrid network. Examples of application platforms include the PDA 14 which is the subject of the present invention, as well as telephones, cellular phones, wireless communication devices, computers, terminals, laptops, etc. A network portal, or NP, is a device that acts as a common gateway to the voice/data network for application platforms. Examples of network portals include any AP as set forth above that is configured to act as a NP, as well as wireless receivers/transmitters (base stations), etc. In the context of the present invention, the telephone set 12 functions as an NP. The voice/data network itself is a system of voice or data (or a mixture of both) devices connected together for the purpose of transferring or routing voice/data information to other like devices. Examples of a voice/data network include a LAN, WAN, Internet, Intranet, PBX, Centrex, and Wireless Systems.
Turning now to FIG. 2 , a high level representation is provided of the protocol blocks between the application platform and the network portal, for implementation of the PDA enabled telephone set of the present invention. The lowest layer, or physical layer, is common between both devices and is the mechanism by which information is passed. The physical layer can be a wired interface (serial, parallel, USB, etc . . . ) or a wireless interface (infrared/IrDA, Bluetooth, etc . . . ).
The next layer up, information encapsulation, performs two functions:
1. Takes information from the level above, packaging this information with a header containing necessary source/destination information and hands it over to the physical layer. 2. Takes information from the level below, removing the header containing necessary source/destination information and hands the information up to the higher level.
This level of abstraction allows for a more standard inter-compatible information exchange between devices than is provided for by the prior art.
The top layer is specific to the type of device it resides on. In the situation of an application platform device (e.g. the PDA 14 ), the Application Specific Interface (ASI), controls the formatting of information for use at the destination. The type of formatting is dependent on destination requirements.
On the NP side of the diagram, a Network Portal Control Interface, or NPCI, determines whether or not the information can be processed internally (e.g. within the telephone set 12 or whether the data should be repackaged for use somewhere within the voice/data network. By having this layer, a NP device is able to process any information which is pertinent to itself rather than always re-transmitting and waiting for another device to return it.
Turning to FIG. 3 , a TDM communication network is shown. The TDM communication network 101 comprises a TDM network 100 , a PBX 102 , an application server 104 and the PDA enabled telephony system 10 comprising the telephone set 12 and the PDA 14 . The telephony system 10 is connected to the PBX 102 via copper cabling 105 . It will be understood that although one telephone is shown, any number of telephones may be included within the TDM communication network 101 .
In operation, the user interacts with the PDA 14 to select a telephony function from the display 16 . All of the telephony functions are located in a telephony application stored within the PDA 14 . It will be understood that this telephony application may be pre-stored within the PDA 14 or downloaded from the application server 104 .
An example of a downloadable telephony application is a phone list database which retrieves directory numbers from a corporate database located on the application server 104 . The PDA 14 downloads the phone list database from the application server 104 and displays the retrieved numbers on the display 16 to the user who then selects the desired entry to be dialed. Once the user selection is made, the telephony application determines the call command to be sent to the PBX 102 and transmits the call command to the PBX via the telephone set 12 (i.e. the telephone set 12 functions as a network portal in the above-discussed communications protocol). The call control command is specific to the type of PBX 102 , but can be characterized by the type of information it contains.
Alternatively, as discussed above, in the event that the telephony command issued by PDA 14 is capable of implementation within the telephone set 12 (e.g. redial), then the set 12 , acting as a network portal, recognizes the command and implements it without further transmission.
It will be understood that although any bi-directional serial communication protocol may be used between the PDA 14 and the telephone set 12 , the bandwidth must be matched with the amount of data being transferred from the telephony application to the telephone set 12 and vice-versa. Software executing on the telephone set 12 performs post processing of the call command from the PDA 14 before transferring the command to the PBX 102 , in accordance with the protocol set forth above. By placing the call control command generation function within the telephony application stored in the PDA 14 , upgrades to the user interface, call control functions etc., may be achieved by simply updating the telephony application.
Turning to FIG. 4 , an IP based communication system is shown incorporating a PDA enabled telephone. The IP based communication system 107 comprises an IP network 106 , a call server 108 , an application server 110 as well as the PDA enabled telephony system 10 . The PDA 14 issues a call control command to the telephone set 12 and the call server 108 in a manner similar to that described in FIG. 3 . In addition, the PDA 14 is capable of accessing any node on the IP network 106 directly from the telephony system 10 without having to route data to the call server 108 . Again, the telephony application running on the PDA 14 is responsible for the generation of the call control command transferred to the telephone set 12 . The software on the telephone set 12 determines if the command is destined for the call server 108 or a node on the IP network 106 . The command is then imbedded in an IP packet containing an address for the desired destination, in accordance with the transport protocol set forth in Applicant's co-pending application set forth above.
In addition to transferring call control data, the IP based PDA enabled telephony system 10 may act as a network portal for any application executing on the PDA 14 . Thus, PDA functions such as software downloads and “Hot syncing” of PDA databases to a network database are facilitated by the telephone set 12 . By placing this functionality on the set, the user gains mobility as any PDA enabled telephony system 10 in the network can provide connectivity for the PDA 14 .
For the IP based PDA enabled telephony system 10 , the PDA 14 comprises an IrDA port for communicating with the telephone set 12 . The data transferred to the telephone set 12 by the telephony application is in the form of a MINET call control command. MINET is a proprietary call control protocol developed by Mitel Corporation. The telephone set 12 recognizes that any MINET command, except those beginning with a header byte of value D 2 , are to be sent to the call server 108 . The IP based telephony system 10 then embeds the MINET command in an IP packet with a destination address for the call server 108 . When the call server 108 receives the packet and interprets the MINET command, the call server 108 executes the embedded MINET call command.
A message originating from the PDA 14 and bound for a node in the network 106 is received by the telephone set 12 as a MINET call control command of type D 2 with the specific destination IP address given by the first data bytes of the MINET call control command. As discussed above, the protocol implementing software in the telephone set 12 reads the destination IP address and any other data in the D 2 message and forms an IP packet bound for the specified address.
In either case, the source address of the IP message is generated by the set firmware and is distinct from the address of the telephone set 12 . This distinct source address allows the call server 108 or the addressed node within the IP network 106 to send return packets to the telephone set 12 , or PDA 14 .
It will be appreciated that, although embodiments of the invention have been described and illustrated in detail, various changes and modifications may be made. Firstly, a Bluetooth implementation of the PDA enabled set may include a wireless transceiver to the PDA, IP phone and other devices on the wireless desktop. IP access for the PDA is implemented in a manner similar to the method described above except that the MINET call control commands are embedded in IP packets within the PDA & Bluetooth transceiver combination, instead of in the telephone set. The telephone set then acts as a network portal for all Bluetooth devices on the desktop. Another modification is that the PDA enabled telephone set may utilize the RS-232 communication protocol to support PDA applications such as Hot-Sync. Although this scenario is addressed by the Bluetooth wireless solution between the set and the PDA, the wired solution provides for faster development. Also, although only one call command is discussed, it will be understood that a plurality of call commands may be sent from the telephony application to the telephone set. All such changes and modifications may be made without departing from the sphere and scope of the invention as defined by the claims appended herein.
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A personal digital assistant (PDA) enabled telephony system is provided comprising a telephone set having a communication port and a personal digital assistant. The personal assistant includes a user interface for displaying telephony functions to a user; a detector for detecting a selected telephony function; a telephony application for determining a call command based on the selected telephony function; and a communicator for communicating said call command to the communication port. In response to receiving the call command, the telephone set executes the selected telephony function.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to U.S. Provisional Application No. 61/901,498, filed on Nov. 8, 2013.
FIELD OF THE INVENTION
[0002] In various embodiments, the present invention generally relates to a method and apparatus that use a pivot-normalization to relate spectral reflectances or colorimetric information from spectrophotometric angles and/or incident light sources to identify the proper pigment(s) to match both the texture and/or gonioapparent effect(s) occurring within an unknown target coating.
BACKGROUND OF THE INVENTION
[0003] In a standard portable spectrophotometer, the incident light is generally, set at an angle of forty-five (45) degrees from normal. The resulting spectral reflectances that can be gathered are generally in the same plane as the incident light and are on either side of the specular angle (equal and opposite angle to the incident light) as well as nearer to the incident light source itself
[0004] New portable spectrophotometric devices offer a vast multitude of angular color response (spectral reflectance) data. Besides the addition of several new angles, including azimuthal, or out-of-plane, angles, many instruments also offer additional light sources with different geometries from standard. By way of example, the incident light source of a second illuminator may be located at fifteen (15) degrees from normal. The plurality of combinations of incident light and angular response can be both too little and too much information to be handled at one time.
[0005] Thus, a need exists for systems and methods that may be used to evaluate all of the data and specific combinations of data from a spectrophotometer. There is also a need for systems and methods in which the individual angular spectral reflectance and colorimetric (e.g. XYZ, L*a*b*, L*C*h*, etc.) responses are handled as both independent entities as well as entities dependent upon the other responses (whether all responses or specifically selected responses) received from the device.
SUMMARY OF THE INVENTION
[0006] In a first aspect, embodiments of the invention provide a computer implemented method. The method includes obtaining, using a processor, reflectance data from a target coating and calculating, using the processor, pivot-normalized reflectance data. The method also includes generating, using the processor, a coating formulation that is the same or substantially similar in appearance to the target coating.
[0007] In another aspect, embodiments of the invention are directed to a system. The system includes a database and a processor in communication with the database. The processor is programmed to obtain reflectance data from a target coating, calculate pivot-normalized reflectance data, and generate a coating formulation that is the same or substantially similar in appearance to the target coating.
[0008] In another aspect, embodiments of the invention provide an apparatus. The apparatus includes means for obtaining reflectance data from a target coating and means for calculating pivot-normalized reflectance data. The apparatus also includes means for generating a coating formulation that is the same or substantially similar in appearance to the target coating.
[0009] In a further aspect, embodiments of the invention provide a non-transitory computer readable medium including software for causing a processor to: obtain reflectance data from a target coating; calculate pivot-normalized reflectance data; and generate a coating formulation that is the same or substantially similar in appearance to the target coating.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 illustrates an embodiment of a process that calculates a formula for a target complex coating.
[0011] FIG. 2 illustrates an example of raw spectral reflectance data from an industry-standard six angles.
[0012] FIG. 3 illustrates an example of a “standard” normalization result.
[0013] FIG. 4 illustrates an example of various pivot-normalized curves overlaying each other.
[0014] FIG. 5 illustrates an example of the use of pivot-normalized reflectance data where the mean and standard deviation have been calculated across the first array of associated information and graphed against one another.
[0015] FIG. 6 illustrates an example of the use of a pivot-normalized data set using a specific set of angles to predict whether a target coating will contain a gonioapparent effect.
[0016] FIG. 7 illustrates an embodiment of a system which may be used to identify physical property attributes of a coating mixture of a target sample.
DETAILED DESCRIPTION OF THE INVENTION
[0017] While the description herein generally refers to paint, it should be understood that the devices, systems and methods apply to other types of coatings, including stain and industrial coatings. The described embodiments of the invention should not be considered as limiting. A method consistent with the present invention may be practiced in a variety of fields such as the matching and/or coordination of apparel and fashion products.
[0018] Embodiments of the invention may be used with or incorporated in a computer system that may be a standalone unit or include one or more remote terminals or devices in communication with a central computer via a network such as, for example, the Internet or an intranet. As such, the computer or “processor” and related components described herein may be a portion of a local computer system or a remote computer or an on-line system or combinations thereof. The database and software described herein may be stored in computer internal memory or in a non-transitory computer readable medium.
[0019] Embodiments of the invention are directed generally to spectral analysis of coatings, and more particularly, but not by way of limitation, to devices, methods and systems for predicting and formulating a complex coating mixture containing metallic, pearlescent, and/or special effect pigments.
[0020] In various embodiments, the present invention generally relates to a method and apparatus for identifying physical property attributes of cured complex coating (e.g., paint) mixtures using pivot-normalization data that are calculated, using a processor, based on the spectral reflectance and colorimetric response from a spectrophotometer.
[0021] In various embodiments, the purpose of using pivot-normalization methodology is multi-fold. First, in order to use all available angles within a given system, pivot-normalization may be used to create an alternate bi-directional reflectance distribution function (“BRDF”)-type analysis. This type of analysis does not exclude any angles, but uses all angles to create a hemispherical “map” or “fingerprint” of a particular texture or pigment type, whether gonioapparent or not. Second, pivot-normalization may be used to evaluate only specific combinations of angles in order to achieve purposeful manipulations. Similarly, this includes the specific exclusion or inclusion of specific singular angles or combinations of angles when a particular texture or effect is being sought after as included or not included in a target coating. Third, pivot-normalization may be used to accommodate for and correct the potential assumption that the received spectral reflectance values are incorrect in some way. Some potential reasons for irregularity or abnormality of the spectral reflectance data, even if minor, may include incident light angle location, incident light fluctuation, aperture size, target coating surface non-uniformity, etc.
[0022] FIG. 1 illustrates an embodiment of a process that calculates a formula for a target complex coating. At step 10 , data is gathered from, for example, a spectrophotometer. In various embodiments, the systems and methods of the present invention may be employed in several ways. For example, the systems and methods may be used on raw data, for example spectral reflectance data and/or colorimetric (e.g., XYZ, L*a*b*, L*C*h*, etc.) and data that may have already been treated. The data are treated data that may include, but are not limited to, multi-dimensional geometric data, vector data, unmodified or modified specular spectral reflectance data, etc. In various embodiments, the data that undergoes pivot-normalization may have two or more identified, associated arrays based on the functionality of the original data. For example, spectral reflectance data may be considered to have arrays comprised of angle and wavelength. Another example includes colorimetric data as a function of angle and reference type (i.e., L*, a*, or b*). In situations where more than two arrays exist, various sets of two may be tested independently, or the various arrays may be condensed into only two arrays. In various embodiments, in order to choose the optimal set of arrays within a data set, testing may be required on several scenarios to both the variety of potential resulting pivot-normalized data sets and the optimum based on desired functionality of the algorithm, with respect to color, texture, pigmentation and all variations within complex mixtures.
[0023] FIG. 2 illustrates an example of raw spectral reflectance data from an industry-standard six angles. In a “standard” normalization situation, the goal of the process is to adjust differing scales of data from multiple data sets (i.e. different angles) to one common scale, thus creating a set of shifted or scaled data that allow for relational analysis and understanding between the original data sets. An example of a “standard” normalization result is illustrated in FIG. 3 . In various embodiments, the goal of the pivot-normalization of the present invention is not to align differing scales to a common scale, but to cause further separation in order to gain improved insight as to similarities and differences between the original data sets and their associated arrays of information. FIG. 4 illustrates an example of various pivot-normalized curves overlaying each other. As can be seen, there is a difference between the resultant information from a “standard” normalization method versus a pivot-normalized method. In FIG. 4 the resolution of the graph has been accounted for using an overlay method rather than aligning the y-axes of each curve.
[0024] At step 12 of FIG. 1 , the data are sorted based on a secondary array of associated information. For example, if using raw spectral reflectance data with associated arrays of angle and wavelength, the data may be sorted by wavelength in order to create a commonality between the scales of the angles within the individual wavelengths. This is contrary to a “standard” normalization method, which sorts by angle in to make a common alignment between the scales of the wavelengths within individual angles. In various embodiments, by sorting by the secondary array first (e.g., the wavelength), the angles become the “commonality.” Within each set of the secondary array, the pivot-normalization calculation at step 14 may take on a standard form. In various embodiments, the normalization calculation is:
[0000]
X
-
μ
σ
Equation
(
1
)
[0000] where X is the specific data set value, μ is the sample or population average of the data set values within the sorted secondary array, and σ is the sample or population standard deviation of the data set values within the sorted secondary array.
[0025] Due to the fact that the standard deviation across the first array of data may be much smaller than that across the second array of data, the resultant pivot-normalized set of data may appear to not yield useful information. Thus, if the resolution of the inspection, analysis, graphing, etc. is poor, detailed features may be missed. Therefore, the resolution of the inspection, analysis, graphing, etc. may be optimized so as to ascertain the benefits of the analysis.
[0026] In various embodiments, when using spectral reflectance data, the calculation may occur individually for the first array of data based on each secondary array of data. However, the output remains linked with the original two associated arrays. Statistics, such as for example mean, median, and sum may be used to create a singular array out of multi-array calculated pivot-normalized data. In another embodiment, an individual specific array value or values may be compared between the pivot-normalized analyses. The value of such a situation is to focus on the particular array value or values of maximum or statistical significance, where a majority of color and/or texture information is visibly or numerically perceived.
[0027] At step 16 of FIG. 1 , the calculated pivot-normalized values or statistics from the pivot-normalized data may further be empirically correlated to known characteristics in order to identify textures, primary flake types, or other appearance information in complex coating mixtures. To employ an empirical method, the pivot-normalized data is calculated for an empirical dataset. All desired statistical or mathematical conversions of the data into a single point may be employed, or the data may remain as functions of the first and second arrays of linked information. In various embodiments, the empirical data set is representative of the expected mixtures and colors that will need to be handled in everyday situations. The empirical data set may be used to create a predictive correlation: y=f(x), where y represents the desired characteristic for identification or a qualitative question regarding the target coating, and f(x) is some function of x's, where x is one or multiple variables using the pivot-normalized calculated values or statistics from the pivot-normalized data from a specific set or multiple sets of associated arrays. The resulting function may be linear or non-linear as defined by the empirical data set.
[0028] FIG. 5 illustrates an example of the use of pivot-normalized reflectance data where the mean and standard deviation have been calculated across the first array of associated information and graphed against one another. The resulting correlations show a high probability of the usage of a colored aluminum pigment only in specific situations, whereas the lack of usage of a colored aluminum pigment exemplifies a significantly different graphical display and therefore also associated probabilities.
[0029] FIG. 6 illustrates an example of the use of a pivot-normalized data set using a specific set of angles to predict whether a target coating will contain a gonioapparent effect. In this case, a calculated range value from the pivot-normalized data for the particular angles resulting in 0.5 or above indicates a higher likelihood of not containing a gonioapparent pigment, whereas a calculated range value closer to 0.2 or below has a higher likelihood of containing the gonioapparent pigment in question.
[0030] Once an empirical correlation has been determined, it may be used at step 18 of FIG. 1 to derive the predicted value for the target coating. This may be achieved by using the target coating's values for the x's (pivot-normalized data, etc.) and calculating the answer for y (the texture effect). While examples have been given herein for the content of a gonioapparent pigment, embodiments of the present invention may derive a result as specific as which gonioapparent pigment at which size flake of that pigment by iteratively choosing the most important single angles or combinations of angles for the pivot-normalization calculations and empirical correlations. The choice of angular comparisons and to what level they are combined may be used to create the best possible empirical correlation. In various embodiments, empirical correlations may also be improved by including other non-pivot-normalization information, for example singular angle colorimetric data.
[0031] In various embodiments, the quality of the overall “map,” or “fingerprint,” approach and the quality of the empirical correlation approach may be dependent upon the quality of the input data. The quality of the input data may be dependent upon the quality of the instrumentation and the quality of the data set used to create a set of known for the overall map or the empirical correlation. While any quality of data from an instrument or an empirical data set will result in an answer, the answer may be improved with the use of a high quality instrument and a widely varied, high quality empirical data set.
[0032] The entire set of calculations described herein may be used in conjunction with a processor in order to facilitate the choice of specific associated array combinations as well as accommodate the volume of calculations required in order to derive and then use an empirical correlation using pivot-normalized data.
[0033] FIG. 7 illustrates an embodiment of a system 90 which may be used to identify physical property, attributes of a coating mixture of a target sample. A user 92 may utilize a user interface 94 , such as a graphical user interface, to operate a spectrophotometer 96 to measure the properties of a target sample 98 . The data from the spectrophotometer 96 may be transferred to a computer 100 , such as a personal computer, a mobile device, or any type of processor. The computer 100 may be in communication, via a network 102 , with a server 104 . The network 102 may be any type of network, such as the Internet, a local area network, an intranet, or a wireless network. The server 104 is in communication with a database 106 that may store the data and information that is used by the methods of embodiments of the present invention for comparison purposes. In various embodiments the database 106 may be utilized in, for example, a client server environment or in, for example, a web based environment such as a cloud computing environment. Various steps of the methods of embodiments of the present invention may be performed by the computer 100 and/or the server 106 .
[0034] It will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed in the forgoing description. Such modifications are to be considered as included within the following claims unless the claims, by their language, expressly state otherwise. Accordingly, the particular embodiments described in detail herein are illustrative only and are not limiting to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof.
[0035] In another aspect, the invention may be implemented as a non-transitory computer readable medium containing software for causing a computer or computer system to perform the method described above. The software can include various modules that are used to enable a processor and a user interface to perform the methods described herein.
[0036] It will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed in the forgoing description. Accordingly, the particular embodiments described in detail herein are illustrative only and are not limiting to the scope of the invention.
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A method that includes obtaining, using a processor, reflectance data from a target coating and calculating, using the processor, pivot-normalized reflectance data. The method also includes generating, using the processor, a coating formulation that is the same or substantially similar in appearance to the target coating.
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TECHNICAL FIELD
[0001] The embodiments described herein relate generally to sample preparation and detection methods, and more particularly, to a method for preparing samples for PCR analysis using filtration in the presence of a surfactant.
BACKGROUND
[0002] In recent years, there has been demand for methods and devices for detecting biological agents that may be used in a terrorism attack. The first step of the detection process is to collect samples that may contain a biological agent. The collected samples are then analyzed for the presence of a biological agent or agents. Due to the diverse nature of the sample collection methods, the collected samples often contains a wide variety of “background” materials that must be removed before the analysis step. The process is often referred to as the “sample preparation step.” There is a need for a sample preparation method that is simple and efficient, and is capable of delivering high quality samples for further analysis.
SUMMARY
[0003] A method for detecting a biological agent in a liquid sample is disclosed. The method comprises: passing a liquid sample through a filter in the presence of a surfactant; and subjecting the filtered sample to direct polymerase chain reaction (PCR) analysis for the presence of a biological agent, wherein the filter has a porosity that allows the biological agent to pass through the filter in its intact form.
[0004] Also disclosed is a method for collecting and detecting a biological agent. The method comprises: collecting particles from a fluid sample; suspending the collected particles in a liquid to form a concentrated liquid sample; passing the concentrated liquid sample through a filter in the presence of a surfactant to produce a filtered sample, wherein the filter has a porosity that allows the biological agent to pass through said filter in its intact form; and analyzing the filtered sample for the presence of the biological agent.
DETAILED DESCRIPTION OF DRAWINGS
[0005] FIG. 1 is a flow chart showing an embodiment of a method of sample preparation and analysis.
[0006] FIG. 2 is a diagram showing penetration of polystyrene latex (PSL) particles across a polyproprolene filter.
[0007] FIG. 3 is a diagram showing retention of Visolite® particles on a polyproprolene filter.
[0008] FIG. 4 is a diagram showing filtration efficiency of Visolite® particles in the absence of surfactant.
[0009] FIG. 5 is a diagram showing filtration efficiency of Visolite® particles in the presence of surfactant.
[0010] FIGS. 6A and 6B are electron microscope pictures of the filter material after exposure to Visolite® particles suspended in water with surfactant ( FIG. 6A ) and Visolite® particles suspended in water with surfactant ( FIG. 6B ).
[0011] FIG. 7 is a diagram showing PCR response to Gamma killed Bacillus Anthracis spores filtered in the presence or absence of surfactant.
DETAILED DESCRIPTION
[0012] Described herein is a sample preparation method for the detection of biological agents. The terms and descriptions used herein are set forth by way of illustration only and are not meant as limitations. Those skilled in the art will recognize that many variations are possible within the spirit and scope of the invention as defined in the following claims, and their equivalents, in which all terms are to be understood in their broadest possible sense unless otherwise indicated.
[0013] Referring now to FIG. 1 , an embodiment of the method 100 for collecting and detecting a biological agent includes collecting ( 110 ) particles/aerosols from a fluid sample; suspending ( 130 ) the collected particles/aerosols in a liquid to form a concentrated liquid sample; passing ( 150 ) the concentrated liquid sample through a filter in the presence of a surfactant to produce a filtered sample; analyzing ( 170 ) the filtered sample for the presence of the biological agent, and producing ( 190 ) an alarm when the biological agent is detected.
[0014] The biological agent can be any microorganism of interest. Examples of the microorganisms of interest include, but are not limited to, eukaryotic and prokaryotic cells, parasites, bacteria, virus particles and prions. Examples of eukaryotic cells include all types of animal cells, such as mammal cells, reptile cells, amphibian cells, and avian cells, blood cells, hepatic cells, kidney cells, skin cells, brain cells, bone cells, nerve cells, immune cells, lymphatic cells, brain cells, plant cells, and fungal cells. In another aspect, the biological agent can be a component of a cell including, but not limited to, the nucleus, the nuclear membrane, leucoplasts, the microtrabecular lattice, endoplasmic reticulum, ribosomes, chromosomes, cell membrane, mitochondrion, nucleoli, lysosomes, the Golgi bodies, peroxisomes, or chloroplasts.
[0015] Examples of bacteria include, but are not limited to, Abiotrophia, Achromobacter, Acidaminococcus, Acidovorax, Acinetobacter, Actinobacillus, Actinobaculum, Actinomadura, Actinomyces, Aerococcus, Aeromonas, Afipia, Agrobacterium, Alcaligenes, Alloiococcus, Alteromonas, Amycolata, Amycolatopsis, Anaerobospirillum, Anaerorhabdus, Arachnia, Arcanobacterium, Arcobacter, Arthrobacter, Atopobium, Aureobacterium, Bacteroides, Balneatrix, Bartonella, Bergeyella, Bifidobacterium, Bilophila Branhamella, Borrelia, Bordetella, Brachyspira, Brevibacillus, Brevibacterium, Brevundimonas, Brucella, Burkholderia, Buttiauxella, Butyrivibrio, Calymmatobacterium, Campylobacter, Capnocytophaga, Cardiobacterium, Catonella, Cedecea, Cellulomonas, Centipeda, Chlamydia, Chlamydophila, Chromobacterium, Chyseobacterium, Chryseomonas, Citrobacter, Clostridium, Collinsella, Comamonas, Corynebacterium, Coxiella, Cryptobacterium, Delftia, Dermabacter, Dermatophilus, Desulfomonas, Desulfovibrio, Dialister, Dichelobacter, Dolosicoccus, Dolosigranulum, Edwardsiella, Eggerthella, Ehrlichia, Eikenella, Empedobacter, Enterobacter, Enterococcus, Erwinia, Erysipelothrix, Escherichia, Eubacterium, Ewingella, Exiguobacterium, Facklamia, Filifactor, Flavimonas, Flavobacterium, Francisella, Fusobacterium, Gardnerella, Gemella, Globicatella, Gordona, Haemophilus, Hafnia, Helicobacter, Helococcus, Holdemania Ignavigranum, Johnsonella, Kingella, Klebsiella, Kocuria, Koserella, Kurthia, Kytococcus, Lactobacillus, Lactococcus, Lautropia, Leclercia, Legionella, Leminorella, Leptospira, Leptotrichia, Leuconostoc, Listeria, Listonella, Megasphaera, Methylobacterium, Microbacterium, Micrococcus, Mitsuokella, Mobiluncus, Moellerella, Moraxella, Morganella, Mycobacterium, Mycoplasma, Myroides, Neisseria, Nocardia, Nocardiopsis, Ochrobactrum, Oeskovia, Oligella, Orientia, Paenibacillus, Pantoea, Parachlamydia, Pasteurella, Pediococcus, Peptococcus, Peptostreptococcus, Photobacterium, Photorhabdus, Plesiomonas, Porphyrimonas, Prevotella, Propionibacterium, Proteus, Providencia, Pseudomonas, Pseudonocardia, Pseudoramibacter, Psychrobacter, Rahnella, Ralstonia, Rhodococcus, Rickettsia Rochalimaea Roseomonas, Rothia, Ruminococcus, Salmonella, Selenomonas, Serpulina, Serratia, Shewenella, Shigella, Simkania, Slackia, Sphingobacterium, Sphingomonas, Spirillum, Staphylococcus, Stenotrophomonas, Stomatococcus, Streptobacillus, Streptococcus, Streptomyces, Succinivibrio, Sutterella, Suttonella, Tatumella, Tissierella, Trabulsiella, Treponema, Tropheryma, Tsakamurella, Turicella, Ureaplasma, Vagococcus, Veillonella, Vibrio, Weeksella, Wolinella, Xanthomonas, Xenorhabdus, Yersinia, and Yokenella . Other examples of bacterium include Mycobacterium tuberculosis, M. bovis, M. typhimurium, M. bovis strain BCG, BCG substrains, M. avium, M. intracellulare, M. africanum, M. kansasii, M. marinum, M. ulcerans, M. avium subspecies paratuberculosis, Staphylococcus aureus, Staphylococcus epidermidis, Staphylococcus equi, Streptococcus pyogenes, Streptococcus agalactiae, Listeria monocytogenes, Listeria ivanovii, Bacillus anthracis, B. subtilis, Nocardia asteroides , and other Nocardia species, Streptococcus viridans group, Peptococcus species, Peptostreptococcus species, Actinomyces israelii and other Actinomyces species, and Propionibacterium acnes, Clostridium tetani, Clostridium botulinum , other Clostridium species, Pseudomonas aeruginosa , other Pseudomonas species, Campylobacter species, Vibrio cholerae, Ehrlichia species, Actinobacillus pleuropneumoniae, Pasteurella haemolytica, Pasteurella multocida , other Pasteurella species, Legionella pneumophila , other Legionella species, Salmonella typhi , other Salmonella species, Shigella species Brucella abortus , other Brucella species, Chlamydi trachomatis, Chlamydia psittaci, Coxiella burnetti, Escherichia coli, Neiserria meningitidis, Neiserria gonorrhea, Haemophilus influenzae, Haemophilus ducreyi , other Hemophilus species, Yersinia pestis, Yersinia enterolitica , other Yersinia species, Escherichia coli, E. hirae and other Escherichia species, as well as other Enterobacteria, Brucella abortus and other Brucella species, Burkholderia cepacia, Burkholderia pseudomallei, Francisella tularensis, Bacteroides fragilis, Fudobascterium nucleatum, Provetella species, and Cowdria ruminantium , or any strain or variant thereof.
[0016] Examples of viruses include, but are not limited to, Herpes simplex virus type-1, Herpes simplex virus type-2, Cytomegalovirus, Epstein-Barr virus, Varicella-zoster virus, Human herpesvirus 6, Human herpesvirus 7, Human herpesvirus 8, Variola virus, Vesicular stomatitis virus, Hepatitis A virus, Hepatitis B virus, Hepatitis C virus, Hepatitis D virus, Hepatitis E virus, Rhinovirus, Coronavirus, Influenza virus A, Influenza virus B, Measles virus, Polyomavirus, Human Papilomavirus, Respiratory syncytial virus, Adenovirus, Coxsackie virus, Dengue virus, Mumps virus, Poliovirus, Rabies virus, Rous sarcoma virus, Yellow fever virus, Ebola virus, Marburg virus, Lassa fever virus, Eastern Equine Encephalitis virus, Japanese Encephalitis virus, St. Louis Encephalitis virus, Murray Valley fever virus, West Nile virus, Rift Valley fever virus, Rotavirus A, Rotavirus B, Rotavirus C, Sindbis virus, Simian Immunodeficiency virus, Human T-cell Leukemia virus type-I, Hantavirus, Rubella virus, Simian Immunodeficiency virus, Human Immunodeficiency virus type-1, Vaccinia virus, SARS virus, and Human Immunodeficiency virus type-2, or any strain or variant thereof.
[0017] Examples of parasites include, but are not limited to, Toxoplasma gondii, Plasmodium falciparum, Plasmodium vivax, Plasmodium malariae , other Plasmodium species, Trypanosoma brucei, Trypanosoma cruzi, Leishmania major , other Leishmania species, Schistosoma mansoni , other Schistosoma species, and Entamoeba histolytica , or any strain or variant thereof.
[0018] The fluid sample may be virtually any fluid suspected of containing a biological agent of interest. The term “fluid,” as use in the embodiments described herein, refers to a substance that continually deforms (flows) under an applied shear stress regardless of how small the applied stress. Exemplary fluid samples include air samples and liquid samples. Examples of liquid samples include, but are not limited to, water samples, wash liquids from foods or food processing equipment, milk, fruit and vegetable juices, blood, plasma, urine, and solid materials suspended in a liquid.
[0019] The particles/aerosols in the fluid sample may be collected ( 110 ) using conventional particles collection methods. In one embodiment, the particles/aerosols are collected using a commercial off-the-shelf particle/aerosol collector. Examples of the particle/aerosol collectors include, but are not limited to, electrostatic collectors, virtual impactors, regular plate impactors, cyclone collectors and filter-based collectors. The collection conditions, such as the sample flow rate and collecting temperature, may be optimized for the biological agent of interest.
[0020] In one embodiment, the particles/aerosols are collected ( 110 ) with an electrostatic collector. The electrostatic collector removes particles from an air sample by using electrostatics to direct the particles or aerosols onto a metal grid or into a liquid, creating a highly concentrated particle/aerosol sample.
[0021] In another embodiment, the particles/aerosols are collected ( 110 ) with a virtual impactor with a desired threshold size. Briefly, a jet of particle-laden air is accelerated toward a collection probe positioned downstream so that a small gap exists between the acceleration nozzle and the probe. A vacuum is applied to deflect a major portion of the airstream through the small gap. Particles larger than a preset threshold size, known as the cutpoint, have sufficient momentum so that they cross the deflected streamlines and enter the collection probe, whereas smaller particles follow the deflected airstream. Larger particles are removed from the collection probe by the minor portion of the airstream according to the magnitude of the vacuum applied to the minor portion.
[0022] In another embodiment, the particles/aerosols are collected ( 110 ) with a regular impactor. The particles are accelerated through a nozzle towards an impactor plate maintained at a fixed distance from the nozzle. The plate deflects the flow creating fluid streamlines around itself. Due to inertia, the larger particles are impacted (and collected) on a collector plate while the smaller particles follow the deflected streamlines.
[0023] In another embodiment, the particles/aerosols are collected ( 110 ) with cyclones or centrifugal collectors that create a ‘cyclonic’ or centrifugal force to separate particles/aerosols from a fluid sample stream. The centrifugal force is created when the fluid sample enters the top of the collector at an angle and is spun rapidly downward in a vortex (similar to a whirlpool action). As the fluid sample flow moves in a circular fashion downward, heavier particles are thrown against the walls of the collector, collect, and slide down into a hopper.
[0024] In yet another embodiment, the particles/aerosols are collected ( 110 ) with a filter-based collector that collects particles/aerosols on a filter. The filter can be a porous material that traps particles/aerosols.
[0025] The collected particles/aerosols are then suspended ( 130 ) in a suspension liquid to form a concentrated liquid sample. Typically, the concentrated liquid sample contains particles of various sizes and a wide variety of “background” materials that need to be removed to ensure the reliability of the down-stream analysis. Particles that are larger than the particles of interest are removed by filtration. For example, most viruses and bacteria have a size of less than 10 microns. Therefore, if the particles of interest are such biowarfare agents, it is possible to pass the concentrated liquid sample through a 10 micron filter to remove larger particles that are not of interest.
[0026] However, most biological particles are charged particles that tend to be retained by the filter regardless of their physical size. In addition, the electrical charges on biological particles may change randomly, causing fluctuation in the filtration efficiency and a high degree of variability in the final analysis. In the embodiments described herein, the concentrated liquid sample is filtered ( 150 ) in the presence of a surfactant to produce a filtered sample. The filtrating step isolates the biological particles of interest from larger particles or other objects in the collected sample. As used in the embodiments described herein, “isolating” occurs when one or more of the particles of interest are substantially separated from other larger components of the sample. When the particle is an organism, one or more different types of organisms may be together in the product of the isolation, and the isolated organism may be viable or non-viable.
[0027] As used herein, the term “surfactant” is intended to mean a substance that functions to reduce the surface tension of a liquid in which it is dissolved. Surfactants include, for example, amphipathic organic compounds that exhibit partial solubility in both organic solvents and aqueous solutions. General characteristics of surfactants include their ability to reduce the surface tension of water, reduce the interfacial tension between oil and water and also form micelles. Surfactants of the invention include non-ionic and ionic surfactants. Surfactants are well known in the art and can be found described in, for example, Randolph T. W. and Jones L. S., Surfactant-protein interactions. Pharm Biotechnol. 13:159-75 ( 2002 ).
[0028] Examples of non-ionic surfactants include, but are not limited to, alkyl poly (ethylene oxide), alkyl polyglucosides such as octyl glucoside and decyl maltoside, fatty alcohols such as cetyl alcohol and oleyl alcohol, cocamide MEA, cocamide DEA, and cocamide TEA. Specific examples of non-ionic surfactants include the polysorbates including, for example, polysorbate 20, polysorbate 28, polysorbate 40, polysorbate 60, polysorbate 65, polysorbate 80, polysorbate 81, polysorbate 85 and the like; the poloxamers including, for example, poloxamer 188, also known as poloxalkol or poly(ethylene oxide)-poly(propylene oxide), poloxamer 407 or polyethylene-polypropylene glycol and the like, and polyethylene glycol (PEG).
[0029] Ionic surfactants include anionic, cationic and zwitterionic surfactants. Examples of anionic surfactants include, but are not limited to, sulfonate-based or carboxylate-based surfactants such as soaps, fatty acid salts, sodium dodecyl sulfate (SDS), ammonium lauryl sulfate and other alkyl sulfate salts. Examples of cationic surfactants include, but are not limited to, quaternary ammonium-based surfactants such as cetyl trimethylammonium bromide (CTAB), other alkyltrimethylammonium salts, cetyl pyridinium chloride, polyethoxylated tallow amine (POEA) and benzalkonium chloride. Examples of zwitterionic or amphoteric surfactants include, but are not limited to, dodecyl betaine, dodecyl dimethylamine oxide, cocamidopropyl betaine and coco ampho glycinate.
[0030] The type and amount of surfactant is application-dependent. In one embodiment, the surfactant is a non-ionic surfactant. In another embodiment, the surfactant is an ionic surfactant. In another embodiment, the surfactant is SDS. In another embodiment, the surfactant is Dynasolve™ (Dynaloy Indianapolis, Ind.). In another embodiment, the surfactant is PEG. In another embodiment, the surfactant is used in an amount within the range of 0.01-2% (w/w). In another embodiment, the surfactant is used in an amount within the range of 0.1-1% (w/w).
[0031] In some embodiments, samples are filtered ( 150 ) without the collection step ( 110 ) and the re-suspension step ( 130 ). In one embodiment, a liquid sample is filtered ( 150 ) in the presence of a surfactant to produce a filtered sample, which is then analyzed for the presence of a biological agent by PCR. Samples with a simple makeup, such as a water sample, may be filtered directly. Samples with more complex makeup, such as foods, tissue samples, or other biologically-derived materials, however, may subject to several processing steps to allow adequate recovery of isolated organisms. This is particularly true in instances when the isolated organism is to be detected with equipment that is sensitive to impurities, such as a biochip.
[0032] In one embodiment, a sample is processed to create a bioagent-containing liquid component and this liquid component is then separated from non-liquid material. Processing steps can include dilution, blending, chopping, centrifugation, filtrations such as vacuum filtration through various depth filters and filter aid facilitated filtration, processing through rolled stationary phase, enzyme treatment (e.g., lipases, proteases, amylases), lipid extraction (e.g., with ethanol, methanol, and/or hexane), massaging, and contacting the solution with positively-charged or negatively-charged membrane materials or particles. A single processing step may be used one or more times or two or more processing steps may be used in combination.
[0033] In another embodiment, an additional purification step is performed prior to, or after the filtration ( 150 ). The additional purification step may be performed using purification technologies well known in the art, such as centrifugation or affinity purification. The additional purification step may also be another filtration step.
[0034] Next, the filtered sample is analyzed ( 170 ) for the presence of the biological agent of interest. In one embodiment, the filtered sample is subjected to polymerase chain reaction (PCR) analysis for the presence of the biological agent of interest. In another embodiment, the filtered sample is analyzed with a biochip. The term “biochip” as used herein, refers to a collection of miniaturized test sites (microarrays) arranged on a solid substrate that permits many tests to be performed at the same time in order to achieve higher throughput and speed. Examples of the microarrays include, but are not limited to, nucleotide microarrays, protein microarrays, and antibody microarrays.
EXAMPLES
[0035] The following specific examples are intended to illustrate the collection and detection of representative biological agents using methods described in the embodiments. The examples should not be construed as limiting the scope of the claims.
Example 1
Filtration of Polystyrene Latex (PSL) Particles with Polyproprolene Filters
[0036] Hydrophobic, charge neutral PSL particles in sizes ranging from 1 to 10 μm are suspended in either water or water with a sub-percent level of surfactant, such as sodium dodecyl sulphate (SDS). The particle suspensions are filtered with a polyproprolene filter having a physical 50% cut point of 10 μm. As shown in FIG. 2 , particles suspended in water with surfactant (Surf 1 ) have a much higher penetration rate (i.e., the percentage of particles that pass the filter) than particles suspended in water without surfactant (H 2 O).
Example 2
Filtration of Visolite Particles with Polyproprolene Filters
[0037] Since PSL particles carry only a small negative charge, they are not considered the best simulant material for anthracis spores. Experiment 1 is repeated using Visolite® powders (GE Energy, Kansas City, Mo.) as a simulant to anthracis spores. Visolite® particles are hydrophobic and have a negative charge that is closer to that of the anthracis spores. The particles are polydispersed in sized from 0.6 to 12 μm with a mean diameter of 1.6 μm (the approximate size of anthracis spores). As shown in FIG. 3 , the presence of surfactant significantly reduces the retention rate from 64% to 7%.
[0038] The pre- and post-filtration Visolite® suspensions are also analyzed with a Beckman Coulter Multisizer. As shown in FIG. 4 , in the absence of surfactant, there is a significant drop in Visolite® concentration after filtration, suggesting that a large fraction of the Visolite® particles are retained by the filter material. In contrast, the pre- and post-filtration Visolite® concentration are similar in the presence of surfactant ( FIG. 5 ), indicating a low retention rate by the filter material. Electron microscope analysis further confirmed that the presence of surfactant significantly reduces the retention of Visolite® particles by polyproprolene filters. As shown in FIG. 6A , there is little accumulation of Visolite® particles in the filter after passing a surfactant-containing Visolite® suspension through the filter. FIG. 6B shows the heavy accumulation of Visolite® particles in the filter after passing a Visolite® suspension through the filter in the absence of surfactant.
Example 3
PCR Detection of Filtered Bacillus anthracis Spores
[0039] Gamma killed Bacillus Anthracis spores are suspended in pure water or water containing 0.5% sodium dodecyl sulphate (SDS). The suspensions are filtered with a polyproprolene filter having a physical 50% cut point of 10 μm. The filtered suspensions are then analysis by real-time PCR with primers specific to Bacillus Anthracis . Compared to samples filtered in pure water, samples filtered in the present of SDS showed stronger (about 10×) Ct response and smaller (about ⅕) standard deviation ( FIG. 7 ). These results are consistent with the results in Examples 1 and 2.
[0040] The foregoing discussion discloses and describes many exemplary methods and embodiments of the present invention. As will be understood by those familiar with the art, the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Accordingly, the disclosure of the present invention is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.
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A method for detecting a biological agent in a liquid sample is disclosed. The method comprises: passing a liquid sample through a filter in the presence of a surfactant; and subjecting the filtered sample to direct polymerase chain reaction (PCR) analysis for the presence of a biological agent, wherein the filter has a porosity that allows the biological agent to pass through the filter in its intact form.
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BACKGROUND OF THE INVENTION
The invention concerns a method and a device for the control of dividing-shed formation on a sectional warping machine according to the preamble to claim 1, respectively claim 3. It is already known that the purpose of yarn division on a sectional warping machine is to form yarn crossings that later facilitate further processing of the warp yarns. For sizing of the warp yarns, too, dividing elements require introduction into the warp yarns, so that unravelling of said warp yarns after leaving the size bath is assured.
Devices for semi-automatic or automatic formation of the shed have, in preparation for weaving, already been state of the art and in use for a long time. A principle requirement for correct yarn division is that the divided shed warps are correctly separated, and that one or more yarns are not allocated by the dividing element to the wrong shed warp. This is especially possible if separate yarns adhere to one another when opening the shed and in this way are dragged to the wrong side of the shed against the normal operating yarn tension.
When manually inserting the dividing elements into the shed, such incorrect yarn alignments are as a rule quickly recognised, and can be quickly corrected. In the case of automated yarn division equipment, however, such faults are problematic, as disclosed by EP-A-368 801, for example. Therein, the dividing elements are introduced automatically into the shed from the side by means of an element transporter as soon as said shed is fully open.
With that, incorrectly tensioned yarns in the feed area can rupture, or become allocated to the wrong shed warp after positioning of the dividing element, and this can lead to subsequent faults in the warp.
SUMMARY OF THE INVENTION
It is thus a purpose of the invention to create a method of the type described in the introduction, with the aid of which the correct dividing-shed formation can be controlled in order to prevent incorrect yarn division particularly in automatic shedding devices. On detecting a fault, the working process should be interrupted automatically so that the fault can be eliminated by the operator, and in order to avoid rupture of the separate yarns. According to the present invention, this purpose is fulfilled by a method possessing the features of claim 1. From the point of view of the device, the purpose is fulfilled by a device possessing the features of claim 3.
Sensors in the form of yarn monitors are state of the art and mainly used on the creel of a sectional warping machine. However, stationary sensors are always concerned here. However, the introduction of a mobile sensor into the tensioned shed permits in a particularly simple way the detection of incorrectly tensioned yarns and triggering of the corresponding sequences with the aid of the control signal thereby generated. With that, it is no longer necessary for an operator to monitor the automatic introduction of the dividing elements, which anyway requires a high level of concentration due to the high cycle speed and the sometimes large number of yarns.
The yarn sensor is preferably introduced into the shed together with a motor-driven element transporter, the drive of said element transporter being able to be switched off and/or being reversible by means of the control signal. In this way, no separate transmission and no separate drive device is required for the sensor. By switching off and/or reversing the element transporter drive, rupturing of incorrectly tensioned yarns by a further feed motion is prevented.
The yarn sensor is preferably a contact sensor reacting to contact with the yarns, wherein a predetermined yarn tension and thus a predetermined response resistance or sensitivity can be set. The advantage of the contact sensor is that its susceptibility to detrimental outside influences is low and that fine yarns, too, can be detected without problems. Naturally, a remote sensor would also be conceivable, operating with optical, electromagnetic or other physical effects.
A particularly reliable working method for the yarn sensor can be attained if said sensor possesses a catching fork, the fork limbs of which define a specific catching area in the shed. The catching fork effects clear location of an incorrect yarn at the sensor, and at the same time a catching area can be defined with the fork limbs that is considerably larger that the actual active area of the sensor. With that, the catching fork can be formed to resemble a shovel, and can possess fork limbs formed as a wing extending out from a basis surface, the width of said basis surface being less than the width of the fork opening. On withdrawal of the element transporter, the V-shaped or U-shaped arrangement of the fork limbs also causes reliable repelling of the shed warps after introduction of the dividing element.
The catching fork is preferably mounted in bearings under spring tension on a holder so as to be movable, wherein a switching element is arranged in the holder, said switching element being able to be activated by the catching fork on touching a yarn in the catching area through a relative movement in relation to the holder. The sensitivity of the sensor can be set via spring tension, wherein the switching element only responds if a specific relative movement has been travelled.
The switching element is preferably a proximity switch, since this is less susceptible to contamination in the dusty environment of a sectional warping machine. The switching element could, however, also be a microswitch, an optical or piezoelectric switching element, or similar.
The catching fork is preferably mounted to be able to pivot about an approximately vertical axis, and tensioned by means of a spring acting against the holder, for example a pressure spring. Depending on the design of the catching fork, a lever action can be generated about the vertical axis, and in contrast to a linear guidance of the catching fork, there is no risk of crabbing or jamming.
In order to prevent the catching fork from overcoming the spring resistance due solely to mass inertia during the feed acceleration of the holder, it is preferably provided with a compensating mass. Said compensating mass must be arranged in such a way that a feed acceleration of the holder does not generate a torque at the catching fork that overcomes the spring tension, in other words that inertial balance prevails in relation to a plane running through the vertical pivot axis in the direction of feed. Only additional force effects on contacting an incorrect yarn cause a torque at the catching fork, and thus actuation of the switching element.
Operational security can in addition be increased by arranging two sensors at a distance from each other in an approximately horizontal plane. Since the individual yarns of a shed warp do not run parallel to one another, but diverge towards the creel, incorrect yarns must also be detected that are arranged in all possible inclined positions. With an arrangement of two sensors, at least one of the two sensors will always actuate in accordance with the inclined position of the incorrect yarn. The sensors, with catching forks, are with that preferably mounted on the holder in such a way that they can be pivoted in opposite directions against the tension of their respective spring.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention is more closely described in the following and represented in the drawings: namely,
FIG. 1 a side view of a sectional warping machine in a highly schematic representation;
FIG. 2 a perspective representation of a dividing element on a shed warp;
FIG. 3 a device according to the present invention on introduction into an opened shed;
FIG. 4 a side view onto the device according to FIG. 3, seen in the direction of yarn run;
FIG. 5 a plan view onto the device according to FIG. 3, and
FIG. 6 a plan view onto an individual catching fork.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an in principle state-of-the-art sectional warping machine 1, as described for example in the above-mentioned EP-A-368 801. The operating status of the machine is shown during introduction of a yarn crossing element. With that, a yarn strip 10, withdrawn from a creel which is not shown here, is guided through a rod grid 2. By means of guide rods 3, the yarn strip is assembled in one plane downstream of the rod grid 2. The two lease reeds 4, 4' are pushed towards one another, and thus open the dividing shed 15, which is defined by an upper shed warp 11 and a lower shed warp 12. These shed warps run through the warping reed 5, which has been pushed back with the aid of a laterally arranged dividing device 7, in order to introduce a dividing element.
The warping reed 5 is arranged according to the state of the art on a warping carriage 8, said warping carriage being able to be displaced in the parallel and radial directions in relation to a sectional warping drum 6, and supporting a deflection roller 9. The warping carriage also supports the dividing device 7, which is thus always arranged in the same relative lateral position to the shed warps. In each case, an upper and a lower element transporter 13, 14 can be extended on the dividing device. The lower element transporter 13 always ingresses into the opened shed 15; the upper element transporter can be lowered onto the lower element transporter.
With the aid of element transporters 13, 14, two strips of film are guided laterally beneath, respectively above the upper shed warp 11, as can be seen in FIG. 2. Both film strips are each connected together by means of a lateral weld bead 17, 17' and combine to form the dividing element 16. Naturally, other dividing elements could also be introduced. In the case of division for sizing, the procedure is basically the same, wherein other types of shed warps are formed with the aid of the rod grid 2 only. This method is basically known to the expert in the art, however, and will not be more fully explained here.
FIG. 3 schematically shows the lower element transporter 13 as described above, said element transporter being introduced into the opened shed 15 in the direction of the arrow a. The upper shed warp 11 and the lower shed warp 12 are, again, shown schematically. An incorrect yarn 34 is also shown which, for example, would be allocated to the upper shed warp 11, but which runs through the opened shed 15 due to an operating fault.
The device according to the present invention is arranged at the head of the element transporter 13. Said device comprises a holder 25 on the face of which two yarn sensors 18, 18' are arranged at a distance from each other. The yarn sensors, respectively the catching forks 19 (FIG. 4) allocated to said yarn sensors, define a catching area 20 which has been depicted by means of a dotted line. The incorrect yarns 34 crossing this catching area are thus detected by the sensor 18', which generates a control signal in a way described in the following. This control signal causes immediate switch-off of the feed, and triggers an alarm which attracts the attention of the operator. After elimination of the fault, automatic operation can be continued in the normal way.
Details of the device according to the present invention can further be seen in FIGS. 4 to 6. The holder 25 is formed as an approximately rectangular body screwed to the element transporter 13 by means of two fixing screws 26, 26'. The two sensors, formed as catching forks 19, 19', are each mounted on the holder 25 to be able to pivot about a vertical axis 28, 28' in the direction of arrows b. Each catching fork 19 has two fork limbs 21, 21' which open outwards from a basis surface 22. The fork limbs thus form an inclined wing, which can be seen in particular in FIG. 6. In the plan, the catching fork is formed like a shovel or a plough blade. Screw holes 24 for fixation on a mounting element 27 are arranged on the basis surface 22. A larger opening 23 is also arranged in the basis surface 22, through which the screws 26, 26' can be tightened or slackened.
Both the catching forks are mounted to be able to pivot in opposite directions and each held under tension by a pressure spring 30 arranged at a distance from the pivot axis. The tensioned position is suggested by a dotted line. Each pressure spring is mounted in and acts against a bore in the holder 25.
A proximity switch 29 is mounted on each outer side of the holder 25 so that it lies within the area of action of the outer end 31 of a catching fork. Each proximity switch generates a control signal as soon as a catching fork 19 is pivoted by contact with an incorrect yarn and the outer end 31 approaches said proximity switch.
Each catching fork 19 is connected to a mounting element 27 mounted in a hollow chamber 33 in the holder 25, said hollow chamber being open towards its facing side. The mounting element 27 also serves to compensate for inertia, however, in that it forms a compensation mass 32 which compensates the mass inertia taking effect in the direction of the arrow b. On acceleration of the two sensors, said acceleration taking effect in the direction of arrow a, said sensors thus behave neutrally under the influence of mass inertia, and there is no rotational moment in the direction of arrow b. Without this inertial compensation, the sensors would respond due to the acceleration forces alone.
Naturally, depending on the yarns being worked or according to the specific prevailing operating conditions, other arrangements of sensors would be conceivable. In certain cases, for example sensors could also be arranged on different horizontal planes.
Inasmuch as the invention is subject to modifications and variations, the foregoing description and accompanying drawings should not be regarded as limiting the invention, which is defined by the following claims and various combinations thereof:
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On a sectional warping machine, the dividing-shed formation for introducing a dividing element is controlled in such a way that at least one yarn sensor (18, 18') is introduced transversely to the running direction of the shed warp (11, 12) into the opened dividing shed (15). The yarn sensor generates a control signal on detecting an incorrectly arranged yarn (34) in the feed area. The yarn sensor is preferably introduced into the dividing shed (15) together with a motor-driven element transporter (13), wherein the drive of the element transporter can be switched off and/or reversed by the control signal.
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BACKGROUND OF THE INVENTION
[0001] The field of the invention relates generally to rotary blade systems, and more specifically, to methods and system for wirelessly balancing rotor assemblies.
[0002] Known gas turbine engines include rotor assemblies that are rotatable relative to stationary engine structures. Known rotor assemblies include a number of rotatable components including a central shaft, shaft cones, compressor blades and disks, turbine buckets and wheels, and/or dynamic air seals. Each component is acted upon by static and/or dynamic axial pressure forces. Rotor imbalance may be a common source of vibration in known rotor assemblies. An imbalance in rotary machinery may be evident if the mass axis of a rotating disk or shaft does not substantially coincide with the axis of rotation. In such operating conditions, the rotating shaft or disk rotates about its axis and generates a centrifugal force that is substantially distributed to the bearings and support structure. The centrifugal force may induce a vibrational frequency to the non-rotating structure that is synchronous with rotor speed. The resulting dynamic response of the rotor/stator system may cause amplitudes of motion or may lead to failure of the rotor, bearings, and/or the support structure.
[0003] To reduce the effects of imbalances, at least some known turbofan engines are manually balanced. In such a process, the fan is balances by coupling weights in the fan spinner or an adjacent rotating structure in an attempt to counter the rotor imbalance and to reduce the forced response of the system to acceptable levels. Vibration measurements are taken and used to calculate the distribution (amplitude and phase) of the corrective weights to be installed. The engine is then stopped and the appropriate weight(s) are added to the appropriate rotor assembly component. The engine is then cycled over its full rotor operating range to determine if the corrective weights reduced the vibration levels to acceptable levels. If the vibration levels are not acceptable, the process is repeated until acceptable vibration levels are achieved. Such a balancing procedure may be a time-consuming process that may require cycling the engine through its full rotor operating range several times. Additionally, balancing the fan assembly in this manner requires experienced technicians, expends significant quantities of fuel, and may result in an increase of environmentally undesirable emissions based on the increased engine running time.
BRIEF DESCRIPTION OF THE INVENTION
[0004] In one aspect, a balancing system for reducing imbalance in a rotatable member of a machine is provided. The system includes a plurality of vibration sensors positioned about a stationary portion of the machine, a controller assembly communitively coupled to the plurality of vibration sensors, and a balancing assembly coupled to the rotatable member, said balancing assembly configured to wirelessly communicate with said controller assembly, said balancing assembly configured to modify the weight distribution of the rotatable member in response to a command wirelessly transmitted from the controller assembly. The controller assembly is configured to receive data from the plurality of vibration sensors and determine an imbalance in the rotatable member using the received data.
[0005] In another aspect, a method for balancing a rotor in a gas turbine engine is provided. The method includes coupling a balancing assembly to the rotor, measuring an imbalance of the rotor, determining a force vector that facilitates reducing the determined imbalance, transmitting, wirelessly, a movement command to the balancing assembly, modifying a weight distribution of the balancing assembly using the movement command, and iteratively performing the aforementioned steps until the imbalance is facilitated being minimized.
[0006] In yet another aspect, a balancing assembly rotatably coupled to a gas turbine engine rotor is provided. The assembly includes a first balancing member, a second balancing member, wherein the first balancing member is positioned radially outward from the second balancing member, and at least one bearing configured to support an associated one of said first and second balancing members.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a cross-sectional view of an exemplary turbofan engine assembly including a balancing assembly.
[0008] FIG. 2 is an exemplary cross-sectional schematic view of an exemplary balancing assembly used with the turbofan engine assembly shown in FIG. 1 .
[0009] FIG. 3 is a cross-sectional schematic view of a portion of balancing assembly shown in FIG. 2 .
[0010] FIG. 4 is a cross-sectional end view of the balancing assembly shown in FIG. 3 and taken along line 4 - 4 .
DETAILED DESCRIPTION OF THE INVENTION
[0011] FIG. 1 illustrates an exemplary gas turbine engine 10 having a longitudinal axis 11 . Engine 10 includes a fan assembly 12 , a core gas turbine engine section 14 coupled downstream from fan assembly 12 , and a low-pressure turbine 16 coupled downstream from the core gas turbine engine section 14 . In the exemplary embodiment, core gas turbine engine section 14 includes a multi-stage booster compressor 17 , a high-pressure compressor 18 , a combustor 20 , and a high-pressure turbine 22 . Fan assembly 12 includes a plurality of fan blades 23 that extend radially outward from a rotor disk 24 , a fan shroud 26 , a fan spinner 28 , and a plurality of circumferentially spaced outlet guide vanes 30 that support fan shroud 26 . Fan spinner 28 is coupled to a spinner support bracket 31 . Engine 10 also includes an inlet 32 and an exhaust 34 . In the exemplary embodiment, low-pressure turbine 16 and booster compressor 17 are coupled together via a first drive shaft 36 , and compressor 18 and high-pressure turbine 22 are coupled together via a second drive shaft 38 .
[0012] In operation, air is drawn into engine inlet 32 , and compressed through booster compressor 17 and high pressure compressor 18 . Compressed air is channeled to combustor 20 wherein it is mixed with fuel and ignited to produce air flow through high pressure turbine 22 and low pressure turbine 16 , and exits through exhaust 34 .
[0013] FIG. 2 is an enlarged cross-sectional schematic view of an a balancing system 50 used with engine 10 . In the exemplary embodiment, balancing system 50 includes a balancing assembly 100 that is removably coupled within engine 10 by at least two support members 102 . More specifically, in the exemplary embodiment, support members 102 are coupled at a first end 103 to a balancing assembly flange 104 and at a second end 108 between fan spinner 28 and spinner support bracket 31 . Support members 102 may be coupled to assembly 100 by any coupling method, for example, by welding, or any other method that enables assembly 100 to function as described herein. In another embodiment, balancing assembly 100 may be integrally formed with, or permanently coupled, to fan spinner 28 such that fan spinner 28 and balancing assembly 100 may be removed and/or installed within engine 10 as a single unit.
[0014] In the exemplary embodiment, balancing assembly 100 includes two rotatable balancing members 110 and 112 . Balancing member 110 is rotated by a first motor 114 and balancing member 112 is rotated by a second motor 116 . Both balancing members 110 and 112 are oriented substantially concentrically along a central rotor 118 having a center axis 119 . Balancing assembly 100 also includes an internal control assembly 120 . Control assembly 120 , balancing members 110 and 112 , and motors 114 and 116 are housed a housing 122 . In the exemplary embodiment, motors 114 and 116 are stepper motors. Alternatively, motors 114 and 116 may be any power source that enables balancing assembly 100 to function as described herein. Additionally, internal control assembly 120 includes a receiver 124 , a processor 126 , a power source 128 , and an antenna 129 . During use, and as described in more detail below, control assembly 120 regulates balancing assembly 100 .
[0015] Additionally, balancing system 50 also includes a controller assembly 200 that includes a processor 202 , a transceiver 204 and an antenna 206 . In the exemplary embodiment, controller assembly 200 is coupled in wireless communication with a plurality of vibration sensors 210 (shown in FIG. 1 ) coupled within engine 10 . Controller assembly 200 is also coupled in wireless communication with balancing assembly internal control assembly 120 . In operation, controller assembly 200 issues commands balancing assembly internal control assembly 120 to facilitate rotating balancing members 110 and 112 in the calculation of a balancing solution described in more detail below. In the exemplary embodiment, controller assembly 200 and internal control assembly 120 form a closed loop system, such that upon a command being sent from controller assembly 200 to internal control assembly 120 , internal control assembly 120 transmits a position response back to controller assembly 200 . In the alternative embodiment, controller assembly 200 and internal control assembly 120 form an open loop system, such that controller assembly relies solely on input from vibration sensors 210 positioned about engine 10 and transmits commands to internal control assembly 120 in an iterative fashion.
[0016] FIG. 3 is a cross-sectional view of balancing assembly 100 and illustrates the orientation of balancing members 110 and 112 . In the exemplary embodiment, balancing members 110 and 112 are substantially concentrically aligned and each has a radially eccentric weight distribution, as described below. Members 110 and 112 are oriented such that balancing member 110 is radially outward from balancing member 112 when assembly 100 is coupled within engine 10 . A plurality of bearing assemblies 130 and 132 provide support and stability to members 110 and 112 , respectfully. In the exemplary embodiment, bearing assemblies 130 and 132 also provide radial support to balancing assembly 100 . An internal support 134 extends substantially perpendicularly inward from assembly housing 122 (shown in FIG. 2 ) to facilitate providing additional axial and radial support to assembly 100 . Moreover, in the exemplary embodiment, members 110 and 112 and bearing assemblies 130 and 132 are oriented in the same axial plane such that bearing assembly 130 provides rotational support between internal support 134 and balancing member 112 , and such that bearing assembly 132 provides rotational support between balancing member 110 and balancing member 112 . Alternatively, members 110 and 112 and bearing assemblies 130 and 132 may be oriented in any configuration that enables balancing assembly 100 to function as described herein.
[0017] FIG. 4 illustrates a cross-sectional end view of balancing assembly 100 . In the exemplary embodiment, balancing member 110 has an eccentrically offset center of mass 140 . Similarly, balancing member 112 has an eccentrically offset center of mass 142 . Each member 110 and 112 is rotatably coupled about rotor 118 and center axis 119 such that members 110 and 112 can rotate in a clockwise direction 144 or a counter-clockwise direction 146 . Alternatively, balancing members 110 and 112 and bearing assemblies 130 and 132 may be coupled within balancing assembly 100 in any configuration that enables system 50 to function as described herein.
[0018] During engine operation, system 50 uses wireless communications to automatically determine a balance solution for engine 10 . Balancing assembly 100 is coupled to rotor 118 as described herein, and vibration sensors 210 are positioned about engine 10 . In the exemplary embodiment, sensors 210 include accelerometers, and a key phasor (not shown) used to determine a rotational position of fan assembly 12 . The key phasor is used to establish a phase reference relative to fan spinner 28 and to calibrate the signals from vibration sensors 210 .
[0019] FIGS. 5 and 6 illustrate a cross-sectional end view of balancing assembly 300 and illustrate exemplary force vectors associated with balancing assembly 300 . Balancing assembly 300 is substantially similar to balancing assembly 100 (shown in FIGS. 1-4 ) and components in balancing assembly 300 that are identical to components of balancing assembly 100 are identified in FIGS. 5 and 6 using the same reference numerals used in FIGS. 1-5 . Accordingly, balancing assembly 300 includes balancing members 110 and 112 and respective centers of mass 140 and 142 oriented about a center axis 119 .
[0020] In the exemplary embodiment, centers of mass 140 and 142 of each respective balancing member 110 and 112 are oriented 180° apart at the beginning of the balancing process. Alternatively, centers of mass 140 and 142 of each respective balancing member 110 and 112 may be positioned at any angular location that enables balancing assembly 300 to function as described herein. Balancing assembly 300 has an exemplary force vector 305 , and each balancing member 110 and 112 has a force vector 310 and 320 , respectively. As shown in FIG. 5 , in the exemplary embodiment, an exemplary resultant force vector 330 is determined via known vector summation 340 for balancing assembly 300 .
[0021] Vibration signals sent to the controller assembly 200 are digitally filtered by processor 202 to obtain the rotor-speed frequency. Upon sensing vibration, vibration sensors 210 wirelessly transmit a signal to controller assembly 200 , which is received by transceiver 204 located therein. Controller assembly processor 202 generates a command signal based on vibration data received from sensors 210 , and transmits the command signal to balancing assembly receiver 124 . Activation of motors 114 and 116 is controlled by commands from controller assembly 200 .
[0022] FIG. 6 illustrates a cross-sectional end view of balancing assembly 300 and illustrates exemplary force vectors associated with balancing assembly 300 following a balancing iteration. More specifically and in the exemplary embodiment, motors 114 and 116 rotate balancing members 110 and 112 to cause the center of mass 140 and/or 142 of each respective balancing member 110 and 112 to be oriented at a determined angle with respect to fan spinner's 28 rotational speed. Balancing members 110 and 112 are adjusted to facilitate reducing force vector 305 . Resultant force vector 330 is again determined via known vector summation 340 for balancing assembly 300 following the exemplary balancing process iteration.
[0023] In the exemplary embodiment, the controller assembly 200 uses a least-squares method algorithm for computing a balance solution. To calculate the balance solution the algorithm uses plain least squares to facilitate minimizing residual vibration levels at the vibration sensors, and then iterates, using weighted least squares, to facilitate reducing the maximum residual vibration in light of the vibration response from multiple sensors over a range of operating rotor speeds. Alternatively, the balance solution may be calculated by any method that enables balancing assembly 300 to function as described herein.
[0024] In the exemplary embodiment, following an iteration that produces an acceptable vibration level, the controller assembly processor 202 outputs a final balance solution that includes a quantity of balancing weight to be installed and a relative angular position for the installation of the balancing weight relative to the fan spinner, or any rotating engine structure that facilitates reducing the vibration level. At this time, balancing assembly is removed from engine 10 and the appropriate balancing weight is positioned within engine 10 at the determined relative angular position.
[0025] The above-described systems and methods facilitate automatic balancing of rotor blades in a gas turbine engine using an autobalancer that provides an automated means to quickly determine the balance solution for the fan without user intervention and without having to stop and start the engine for multiple vibration measurement and balance shot iterations. Furthermore, this automatic balancing system provides an opportunity to achieve significant fuel and labor cost savings and to significantly reduce CO 2 emissions based on decreased engine running time. As a result, the above-mentioned balancing system facilitates providing
[0026] Although the systems and methods described herein are described in the context of a balancing assembly for gas turbine engine rotors, it is understood that the systems and methods are not limited to such balancing assemblies. Likewise, the system components illustrated are not limited to the specific embodiments described herein, but rather, system components can be utilized independently and separately from other components described herein.
[0027] As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural said elements or steps, unless such exclusion is explicitly recited. Furthermore, references to “one embodiment” of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.
[0028] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
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A balancing system and method for reducing imbalance in a rotatable member of a machine is provided. The system includes a plurality of vibration sensors positioned about a stationary portion of the machine, a controller assembly communitively coupled to the plurality of vibration sensors, and a balancing assembly coupled to the rotatable member, said balancing assembly configured to wirelessly communicate with said controller assembly, said balancing assembly configured to modify the weight distribution of the rotatable member in response to a command wirelessly transmitted from the controller assembly. The controller assembly is configured to receive data from the plurality of vibration sensors and determine an imbalance in the rotatable member using the received data.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to container for flowable food packaging. Specifically, the present invention relates to tetrahedral top cartons and carton blanks therefor.
2. Description of the Related Art
Gable top cartons have been known for the better part of the twentieth century. Their characteristic simplicity and resealability have helped to sustain their popularity as containers for traditional liquid food products such as milk and juice, but in recent years they have been used for products ranging from ammunition to Epsom salts. Gable top cartons typically begin as generally rectangular carton blanks made of a laminated paperboard or similar material. The carton blanks are provided with a number of creases to facilitate folding and forming the blank into a rectangular carton having the characteristic gabled top.
When fully folded, filled, and sealed, the gable top cartons included a gabled top structure that engages four side-panels. Traditionally, each side panel is generally perpendicular to each adjacent side panel. The panels are each divided from one another by a single vertical score line extending the entire height of the sidewall. These side panels form the characteristic hollow rectangular body of the container and define the volume of product that a carton may hold.
In accordance with accepted design approaches, the design of a traditional gable top carton to accommodate a specified volume involves adjusting the dimensions of the four sidewalls defining the rectangular body that is to contain the specified volume. Very often, these product volume requirements are specified by the packager and selected from standard volumes that have been deemed accepted in the consumer market for the product (i.e., pint, quart, half gallon, gallon, half liter, liter, etc.). When this design approach is utilized, there exists a generally established relationship between the surface area of the carton blank and the carton volume. The surface area of the carton, and particularly the area of the four sidewalls constituting the bulk of the surface area, is thus generally fixed for a given container volume.
Additional end panel extensions and end panel shapes are often employed to assist in folding and sealing the traditional gable top cartons. These added extensions and shapes result in added carton surface area per unit volume of product. One departure from the typical gable top carton is Sisco, U.S. Pat. No. 2,980,304, for a Paperboard Fluid Container which issued on Apr. 18, 1961. Sisco discloses a pyramid top carton which is adapted to substitute for glass bottles of the 1960s. The pyramid top carton of Sisco is reinforced with added layers to lessen the need for a separate nesting member. It is readily apparent that the Sisco carton does not seek to reduce the material content of a carton. The traditional approaches to gable top carton design have heretofore devoted little effort to optimizing the carton surface area per unit volume of product.
BRIEF SUMMARY OF THE INVENTION
The present invention is able to reduce the material content of a carton as compared to a similar gable top carton. The present invention is able to accomplish this by providing a tetrahedral top carton which utilizes less material than a standard gable top carton. The tetrahedral top carton has a tetrahedral top structure composed of four top panels intersecting and sealed to each adjacent top panel. The tetrahedral top carton may have a fitment disposed thereon for accessing the contents. Alternatively, a pouring spout may be integrated into one of the top panels of the tetrahedral top structure. The tetrahedral top carton of the present invention has at least a eight percent reduction in material as compared to a traditional gable top carton where four full top panels are folded in a manner to have two top panels folded on top of two other top panels and forming a top central fin.
Another aspect of the present invention is a blank for forming the tetrahedral top carton. The blank has a plurality of vertical score lines and a plurality of diagonal score lines which define the side panels and top and bottom panels, and the top and bototm fins of the carton. The carton and blank may also have bottom fins providing for an overfolded bottom structure.
It is a primary object of the present invention to provide a tetrahedral top carton.
It is a further object of the present invention to provided a carton with a material reduction over a standard gable top carton.
It is a further object of the present invention to provide a blank for a tetrahedral top carton.
Having briefly described this invention, the above and further objects, features and advantages thereof will be recognized by those skilled in the pertinent art from the following detailed description of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Several features of the present invention are further described in connection with the accompanying drawings in which:
There is illustrated in FIG. 1 a perspective view of a preferred embodiment of a folded and sealed carton of the present invention;
There is illustrated in FIG. 2 a front elevational view of the carton of FIG. 1;
There is illustrated in FIG. 3 a top plan view of the carton of FIG. 1;
There is illustrated in FIG. 4 a perspective view of an alternative embodiment of a folded and sealed carton of the present invention;
There is illustrated in FIG. 5 a front elevational view of the carton of FIG. 4;
There is illustrated in FIG. 6 a side elevational view of the carton of FIG. 4;
There is illustrated in FIG. 7 a top plan view of th e carton of FIG. 4;
There is illustrated in FIG. 8 a perspective view of an alternative embodiment of a folded and sealed carton of the present invention;
There is illustrated in FIG. 9 a perspective view of an alternative embodiment of a folded and sealed carton of the present invention;
There is illustrated in FIG. 10 a plan view of a preferred embodiment of a carton blank constructed in accordance with the teachings of the present invention;
There is illustrated in FIG. 11 a plan view of an altern ative embodiment of a carton blank constructed in accordance with the teachings of the present invention;
There is illustrated in FIG. 12 a plan view of an alternative embodiment of a carton blank constructed in accordance with the teachings of the present invention;
There is illustrated in FIG. 13 a plan view of an alternative embodiment of a carton blank constructed in accordance with the teachings of the present invention;
There is illustrated in FIG. 14 a plan view of an alternative embodiment of a carton blank constructed in accordance with the teachings of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The novel tetrahedral top carton of the present invention is an unique improvement over the traditional gable top cartons of the prior art. The drawings and description are in reference to a one liter carton. However, those skilled in the pertinent art will readily recognize that cartons having capacities either greater or lesser than one liter may be utilized without departing from the scope and content of the present invention. When measured for material savings against a standard gable top one liter carton, the tetrahedral top carton of the present invention has a savings of at least 8.6 percent compared for the standard gable top carton. From a diferrent perspective based on usage of material, with a standard one liter gable-top carton being set at 100 on an index, the tetrahedral top carton of the present invention has a measurement of at least 91.4 on the same index. Thus, the novel tetrahedral top carton of the present invention uses less material to package the same amount of product as a traditional gable top carton.
A preferred embodiment of the present invention is shown in FIGS. 1-3. In this preferred embodiment, the carton is generally designated 20, and includes a tetrahedral top 22 with a fitment 24 disposed in the center of the tetrahedral top 22. The fitment 24 has a reclosable cap which allows for access to the contents of the carton 20. The carton 20 is usually composed of a fiberboard material coated with polyethylene. The carton has four side panels 26-32, extending from the bottom of the carton 20 to the tetrahedral top 22. The four side panels 26-32 are generally perpendicular to each adjacent side panel with side panel 26 opposite side panel 30, and side panel 28 opposite side panel 32.
The tetrahedral top structure 22 is formed from a plurality of top panels 34-40 with the respective top fins 158-172, not shown in FIGS. 1-3, folded inward to form top diagonal edges 52-58. Each of the top diagonal edges 52-58 extend from a corresponding edge 42-48, to a cut-out 50, not shown, wherein the fitment 24 is disposed therein. The top diagonal edges 52-58 along with the respective upper horizontal score lines 120-126, define each of the four pseudo-triangle shaped top panels 34-40 which form the tetrahedral top 22.
To access the contents of the carton 20, the fitment 24, also referred to as an integrated resealable spout/cap, is provided to the consumer. Although the fitment 24 is a screw and thread type fitment, other fitments may be utilized in practicing the present invention without departing from the scope and spirit of the present invention. For example, a flip-cap may substituted for the fitment 24 shown in FIGS. 1-3. The fitment 24 may be applied to the carton 20 by any number of common methods such as ultrasonic welding, hot melt, or the like. The fitment 24 may be applied through the inside of the carton as described in copending U.S. patent application Ser. No. 08/710,619. Alternatively, the fitment 24 may be applied to the outside of the carton, either before or after filling and sealing, as described in U.S. Pat. No. 5,473,857. However, the present invention is not to be limited by application of the fitment 24, or of the necessity of a fitment 24 as described below.
There is illustrated in FIGS. 4-7 an alternative embodiment of the carton of the present invention. The carton 20A illustrated in FIGS. 4-7 is very similar to the carton 20 illustrated in FIGS. 1-3, and the similar parts have a corresponding designation except that an "A" is added to the end. For example, the side panels of FIGS. 4-7 are designated 26A-32A while the side panels of FIGS. 1-3 are designated 26-32. Thus, the description provided for FIGS. 1-3 is applicable to FIGS. 4-7 for similar designations.
The unique features of FIGS. 4-7 include the placement of the fitment 24 within a cut-out 50A, not shown, on a single top panel 34A, and the apex 60 where all four top panels 34A-40A meet and form the tetrahedral top 22A. The placement of the fitment 24 on the single top panel 34A provides an integrated angled spout component allowing for facilitated pouring of the product. Milk or juice are common products, however, other flowable food products are well within the broad intentions of the present invention.
There is illustrated in FIG. 8 yet another embodiment of the carton of the present invention. As mentioned above for FIGS. 4-7, the carton 20B illustrated in FIG. 8 is very similar to the carton 20 illustrated in FIGS. 1-3, and the similar parts have a corresponding designation except that a "B" is added to the end. The unique variation in FIG. 8 from the carton 20 of FIG. 1 is outward folded top fins 62-68. The top fins 62-68 projected upward creating an almost ornamental design to the carton 20B. However, the outward folded top fins 62-68 are a result of carton fabrication on a form, fill and seal machine. Instead of folding the fins inward to create the top diagonal edges 52-58 as shown in FIG. 1, some packaging machines may fold the fins outward to create the carton 20B of FIG. 8. The top fins 62-68 are each composed of fins from adjacent panels 34B-40B sealed together to form a single top fin 62-68 between two adjacent top panels 34B-40B. The two parts of each of the top fms 62-68 are described below in reference to the blanks illustrated in FIGS. 10-14. Fin sealing edges 70 tightly seal each of the top panels 34B-40B to each adjacent top panel 34B-40B. The fin sealing edges 70 also create a tight seal to prevent leakage of the product from the carton 20B. Similar fin sealing edges 70 are made on the cartons 20 and 20A of FIGS. 1-7, however, since the fins are folded inward, the fin sealing edges are not viewable. By forming a tight seal, the fin sealing edges 70 prevent splitting of the top fins 62-68 through moisture absorption.
There is illustrated in FIG. 9 yet another alternative embodiment of a tetrahedral top carton of the present invention. As mentioned above for FIGS. 4-8, the carton 20C illustrated in FIG. 9 is very similar to the carton 20 illustrated in FIG. 1, and the similar parts have a corresponding designation except that a "C" is added to the end. The unique variation in FIG. 9 from the cartons 20, 20A or 20B of FIGS. 1, 4 and 8 respectively is the absence of a fitment 24 from the carton 20C. In this embodiment, the product inside the carton 20C is accessed through tearing open one of the top panels 34C-40C to form an integrated pouring spout. It is obvious that the non-fitment embodiment of FIG. 9 presents an even greater savings per carton due to the dual savings of material and lack of a fitment. However, the embodiment of FIG. 9 still has a tetrahedral top 22C.
Preferably, the top panels 34-40 (or any other series A-C) are equal in shape and area with adjacent panels 34-40 intersecting at a forty-five degree angle to a plane formed by corresponding adjacent side panels 26-32. However, other embodiments may have the top panels 34-40 of unequal area and shape. For example, if the carton 20 had a rectangular cross-section instead of the square cross-section of the 70 mm×70 mm carton 20, then top panels 34 and 38 would be of equal shape and area, and top panels 36 and 40 of equal shape and area. Thus, it is apparent that for purposes of the present invention, a tetrahedral top is defined as possibly having four top panels 34-40 unequal in shape and area.
There is illustrated in FIG. 10 a plan view of a preferred embodiment of a carton blank constructed in accordance with the teachings of the present invention. The carton blank 100 is fabricated into the carton 20 illustrated in FIG. 1. The blank 100 may be formed, filled and sealed on a packaging machine such as available from TETRA PAK, INCORPORATED of Chicago, Ill. The blank 100 is defined by a plurality of score lines which allow the blank 100 to be folded into the tetrahedral top carton 20 as illustrated in FIG. 1. A plurality of vertical score lines 102-108 will form edges 42-48 of the carton 20. The plurality of vertical score lines 102-108 will define the side panels 26-32 of the carton 20. The vertical score line 102 separates side panel 32 from a sealing panel 118. The sealing panel 118 is folded under side panel 30 during the initial forming of the carton 20.
The plurality of upper horizontal score lines 120-126 defines the plurality of top panels 34-40 from the plurality of side panels 26-32. An upper sealing horizontal score line 128 defines a top sealing panel 138 from the sealing panel 118. The plurality of lower horizontal score lines 174-180 defines the plurality of bottom panels 184-190 from the plurality of side panels 26-32. A lower sealing horizontal score line 182 defines a bottom sealing panel 192 from the sealing panel 1118. A bottom fin horizontal score line 194 defines the bottom fm 196. A plurality of lower diagonal score lines 198-204 assist in the folding of the bottom of the carton 20.
A plurality of upper diagonal score lines 140-154 define a plurality of top fins 158-172 from their respective top panels 34-40. In the carton 20 of FIG. 1, the top fins are folded inward and sealed to form the respective top diagonal edges 52-58. Each of the top panels 34-40 of the blank 100 have an arcuate edge 212-218 which form the cut-out 50 for placement of the fitment 24 therein for carton 20. Also on the edge of the blank 100, between adjacent top panels 34-40, a plurality of cut-outs 206-210 are each defined by a straight parallel edge transforming into angled edges on each end of the straight edge. Blank 100 is also utilized to form carton 20B of FIG. 8 with the outward folded fins 62-68. As described above, the fins 158-172 are folded outward and sealed together to form outward folded top fins 62-68
As set forth for the various embodiment of the cartons 20 and 20A-C, the various embodiments of blanks in FIGS. 11-13 are very similar to the blank 100 illustrated in FIG. 10, and the similar parts have a corresponding designation except that an "A", "B" or "C" respectively, is added to the end. In FIG. 11, which is the blank 100A for the carton 20A of FIGS. 4-7, the unique variations are the cut-out 50A for placement of the fitmnent 24 on a single top panel 34A, and the straight parallel edges 220-226 at the very top of the top panels 34A-40A. Each pair of the plurality of upper diagonal score lines 140A-154A on each of the top panels 34A-40A meet to form an apex at the center of each of the straight parallel edges 220-226. When the plurality of fins 158A-172A are folded inward, the apex 60 for carton 20A is formed from each of these apices.
Blank 100B of FIG. 12 has the straight parallel edges 220A-226A similar to FIG.11, however, the fitment 24 is disposed within the center as with the blank 100 of FIG. 10. This blank 100B has a square cut-out 50B, not shown, for placement of the fitment 24 therein.
FIG. 13 illustrates a blank 100C which may be utilized to form the carton 100C of FIG. 9. The Each pair of the plurality of upper diagonal score lines 140C-154C on each of the top panels 34C-40C meet to form an apex at the center of top perimeter of each of the top panels 34C-40C. When the plurality of fins 158C-172C are folded inward, the apex 60C for carton 20C is formed from each of these apices.
There is illustrated in FIG. 14 a blank 100D for formation of a tetrahedral top carton of the present invention on a mandrel where the tetrahedral top is the bottom of 39 the blank 100D. In this embodiment, the tetrahedral top is formed on a mandrel where the bottom of a typical gable top carton is formed. The blank 100D of this embodiment will have similar designations for similar parts except that a "D" is added to the end. However, the top panels 234-240 and bottom panels 284-290 of the blank 100D are different than the other blanks 100, 10A-C. The blank 100D when constructed would be similar to the carton 20 of FIGS. 1-3.
The tetrahedral top 22 is formed from top panels 234-240 on a mandrel similar to the forming of a bottom of a standard gable top carton. In this manner, a carton 20 20 formed from a blank 100D would be filled from the tetrahedral top and sealed on the bottom last. This reverse filling is accomplished on a slightly modified form, fill and seal packaging machine. The bottom of the carton 20 formed from blank 100D has an overfolded bottom which allows the tetrahedral top 22 to be sealed with a fitment 24 attached prior to filling. The overfolding improves the carton 20 durability and resistance to leaking. The plurality of bottom panels 284-290 are defined from the side panels 26D-32D by a plurality of lower horizontal score lines 174D-180D. A plurality of bottom fins 292-304 are defined from the plurality of bottom panels 284-290 by a plurality of lower fin horizontal score lines 306-318. The plurality of bottom fins provide for the overfolding bottom of a carton 20 constructed from blank 100D.
From the foregoing it is believed that those skilled in the pertinent art will recognize the meritorious advancement of this invention and will readily understand that while the present invention has been described in association with a preferred embodiment thereof, and other embodiments illustrated in the accompanying drawings, numerous changes, modifications and substitutions of equivalents may be made therein without departing from the spirit and scope of this invention which is intended to be unlimited by the foregoing except as may appear in the following appended claims. Therefore, the embodiments of the invention in which an exclusive property or privilege is claimed are defined in the following appended claims:
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The present invention is tetrahedral top carton and a blank therefor. The carton has at least a nine percent material savings over a traditional gable top carton containing an equal volume of product. The carton has a tetrahedral top structure formed from four top panels intersecting and sealed adjacently. The carton may have a fitment thereon for accessing the contents. The fitment may be placed on the pinnacle of the tetrahedral top structure or on a single top panel. The carton may have outward folded fins projecting from the intersection of the top panels, or the fins may be folded inward to create a diagonal crease/edge in the intersection between adjacent top panels. The carton may also have an overfolded bottom for reverse filling on a form, fill and seal packaging machine.
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BACKGROUND OF THE INVENTION
This invention relates to a pipe connector system that is particularly adapted for the field connection of pipe, particularly thermo plastic pipe. The pipe connector system includes an engagement ring for a stub-end pipe and the alternate use of a removable convoluted flange assembly or a removable shell-type, coupling for interconnecting pipe segments. The interchangeable flange assembly or coupling allows the pipe connector system of this invention to be used in conventional piping systems. The adaptability and flexibility provided by the interchangeable flange system or coupling system makes the combined system ideally suited where alterations in the piping system are inevitable, or where alternatives are required for different situations.
For example, in the mining industry, thermal plastic pipe is used to convey particulate matter pneumatically or in a liquid slurry. In addition to frequent rerouting of the transport system, the piping is subject to wear from the abrasive material transported. To maximize usage of the thermal plastic pipe, segments of the pipe might be removed and replaced. A system that allows flexibility in the field replacement of pipe has great advantages in returning the system to operation.
As a further example, certain situations may require the use of a shell-type coupling, where the connecting bolts of a flange assembly are not accessible. Additionally, a flange connector may be required to connect a pipe segment to a flanged fitting such as a value. A system having readily available alternatives is therefore desired, particularly in pipe systems that are temporary or subject to alteration.
The pipe connectors of this invention include an engagement ring that engages the stub-end of a pipe to seat the alternate interconnectors. The engagement ring is designed to restrain cold flow of material in the end stub to insure a seal is maintained. The common configuration of the engagement ring enables either the coupling or the flange assembly to interconnect the piping. Additionally, the engagement ring is formed as either a full-ring or a split-ring depending on the connector used and the requirements of the interconnection process.
For example, where a pipe segment has a stub end pre-installed, a split ring is required for utilization of the interconnectors. However, where a stub end is being installed, a full ring can be slipped over the pipe end, with a flange if desired, before installation of the stub end. In thermoplastic pipe, a stub end can be thermally coupled to the pipe end by thermocoupling equipment. This procedure can easily be performed in the field and is one of the factors that makes thermoplastic piping desirable for many industrial, agricultural and material moving processes.
The use of light-weight, convoluted flange assemblies which can be cast from aluminum or ductile iron, is advantageous for savings in transport, storage and installation costs. Similarly, the cast aluminum or ductile iron coupling assemblies are designed and configured to minimize weight for the design strength of the coupling. The flange assemblies and coupling assemblies can be fabricated from other materials such as stainless steel or polymer encapsulated steel for specialty situations.
SUMMARY OF THE INVENTION
The pipe connector system of this invention includes an interchangeable flange assembly or coupling for interconnecting pipe having a stub end. The pipe connector system is particularly adapted for the interconnection of HDPE (thermo plastic) pipe. The flange connector and coupling connector each use a common engagement ring. The engagement ring may be a full or split ring that forms a contact collar between the connector and the stub. The use of the split ring is particularly advantageous when the thermo plastic pipe is fitted with a stub end at the time of installing the flange connectors. Although the flange connectors can be utilized with a full engagement ring, once installed, the stub end must be cut to allow removal of the engagement ring and flange connectors. By use of the split ring, the flange connectors and the split ring can be removed from the thermo plastic pipe without removing the stub end. When either a full ring or split ring is used with the coupling connectors, the coupling connectors can be removed without removal of the stub end of the pipe.
The flange connectors in the flange assembly comprise convoluted flange members that are designed to transmit coupling forces through the engagement ring to the gasket face of the stub at the end of the thermal plastic piping. Similarly, the coupling connectors are designed to interconnect in clamshell fashion and transmit the coupling forces through the engagement ring to the gasket face of the end stub. This is accomplished by the chamfered contact faces of the connectors and the engagement rings, which develop vectors of the force of interconnection developed by the coupling bolts that include opposed forces longitudinal to the pipe and normal to the gasket face, and inwardly radial forces that oppose fluid developed forces within the piping at the stub end.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a prospective view of a flange connector system installed on a segment of thermal plastic piping.
FIG. 2 is a prospective view of a coupling connector system on a segment of thermal plastic piping.
FIG. 3 is a back elevational view of one of the flange connectors in the coupling connector system.
FIG. 4 is a side elevational view of the coupling connectors in the coupling connector system.
FIG. 5 is a side elevational view of a full engagement ring that forms part of the pipe connector system of this invention.
FIG. 6 is a side elevational view of a split engagement ring that forms part of the pipe connector system of this invention.
FIG. 7 is an enlarged partial cross sectional view of a segment of pipe with the flange connectors and split rings installed.
FIG. 8 is an enlarged partial cross sectional view of a segment of pipe and the coupling connectors and full rings installed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the pipe connector system of this invention designated generally by the reference numeral 10 is shown with a flange connector system 12 installed on a thermo plastic pipe 14 . The flange connector system 12 includes a flange assembly 15 with first and second flange members 16 interconnected by bolts 18 . The flange members 16 engage engagement rings 17 , that in this embodiment is in the form of a split ring unit 22 . The split ring unit 22 includes a pair of semi-circular ring segments 24 for each flange member 16 to effect the connection of two segments 26 of the thermal plastic pipe 14 . Each pipe segment 26 includes a stub end 28 that is thermo-coupled to the pipe segment 26 .
Referring to the pipe connector system 10 of FIG. 2, a coupling connector system 32 is shown. The coupling connector system 32 includes a coupling assembly 33 comprising a pair of coupling members 34 that are semi-circular or crescent-shaped in configuration. The coupling members 34 have projecting bolt carriages 36 through which are installed connecting bolts 38 for clamping the two coupling members 34 together around engagement rings 17 , here a full ring unit 35 . The full ring unit 35 comprises a pair of engagement rings 40 (one shown), which seat the coupling members 34 when interconnecting the pipe segments 41 . The coupling connector system 32 engages the stub ends 42 at the end of pipe segments 41 in a manner similar to the split rings 22 of FIG. 1, as described in greater detail hereinafter.
Referring to FIG. 3, the elevational view of the backside of one of the flange members 16 is shown. The flange member 16 is of a convoluted type having an outer ring portion 44 an inner ring portion 46 and an intermediate web portion 48 interconnecting the inner ring portion 46 and the outer ring portion 44 . The web portion 48 has a series of bolt holes 50 evenly spaced around the flange member. Adjacent each bolt hole 50 are rib members 52 which provide added strength to the light weight flange member in the larger sizes. The inner ring portion 46 has an incline or chamfered contact surface 54 that engages a complimentary incline or chamfered contact surface 56 on the engagement rings 17 as shown in FIGS. 5 and 6.
Referring to FIG. 4 an elevational view of the coupling assembly 33 of the coupling connector system is shown. The coupling assembly 33 has the two crescent-shaped coupling members 34 interconnected by carriage bolts 38 that are seated in projecting bolt carriages 36 . The coupling members 34 have a shell-like housing 58 with a central perimeter ridge 60 , spaced inner rims 62 and a series of ribs 64 between the perimeter ridge 60 and the inner rims 62 . The ridge 60 and ribs 64 provide structural rigidity to the housing 58 to uniformly transmit the clamping forces of the bolts 38 to the engagement rings 17 .
The engagement rings 17 as noted are of two types that are interchangeable. The split ring unit 22 is shown in FIG. 6 and includes two identical semi-circular ring segments 24 . The ring segments 24 have a generally “z” cross section with an incline or chamfered contact surface 56 that contacts a complimentary contact surface 54 on the inner ring portion 46 of the flange members 16 , or a similar complimentary contact surface 66 on the inside of the inner rim 62 of the coupling members 34 as shown in FIGS. 7 and 8. The split ring unit 22 is typically used in pairs with a pair of flange members 16 . A single unit 22 is used with a flange member 16 , for example, when a stub end pipe segment is connected to a flanged fitting.
Alternately, the engagement rings 17 may comprise the full ring unit 35 shown in FIG. 5 . The full ring unit 35 has a pair of rings 40 each with the same “z” cross section with the incline or chamfered contact surface 56 . The ring unit 35 is ordinarily used in pairs with the flange assembly 15 or coupling assembly 33 . The coupling assembly 33 requires the use of a pair of engagement rings 17 , unless a fitting includes specially prepared coupler stub with an incline or chamfered contact surface matching the contact surface of the coupling members 34 .
Referring to the flange connector system 12 of FIG. 7, the pipe segment 26 is shown thermally fused to a stub end 28 . The stub end 28 has an enlarged end stub 68 with a gasket face 70 . A gasket 72 is interposed between the opposed stub ends 28 to seal the interconnection of the pipe segments 26 . The end stub 68 has a shoulder 74 against which a complimentary contact face 76 on the engagement ring 17 is seated. The engagement ring 17 and flange member 16 are slipped over the pipe segment 26 before the stub end 28 is joined when the ring 17 is a full ring unit 35 . A split ring unit 22 can be installed after the stub end 28 is attached and is the usual ring unit used with the flange members 16 . The engagement ring 17 has a first inner cylindrical contact surface 78 sized to slip over the outside of the pipe segment 26 and neck 82 of the stub end 28 , and a second inner contact surface 84 sized to engage the outer perimeter 86 of the stub 68 .
When the flange members 16 engage the engagement rings 17 by the incline contact surfaces 54 seating on the incline contact surfaces 56 of the engagement rings 17 , the coupling forces developed by the bolts 18 on tightening are transmitted to the stub end 28 as shown in the superimposed vector diagram in FIG. 7 .
In a similar manner, the engagement rings 17 in the coupling connector system 32 of FIG. 8 encompass the stub ends 42 of the segments 41 . The contact face 76 on the engagement rings 17 contacts the shoulder 74 of the stubs 68 to transmit the coupling forces of the coupling members 34 (one shown). The coupling member 34 shown, has opposed inclined contact surfaces 66 in the housing 58 , which seat on the inclined contact surface 56 of the rings 17 . The superimposed vector diagram in FIG. 8 illustrates the manner in which the clamping forces of the connecting bolts 38 are transmitted to the opposed gasket faces 70 through the stub end 42 on tightening the bolt nut 88 . The engagement rings 17 described with reference to FIGS. 7 and 8 may be either split ring units 24 as shown in FIG. 6, full ring units 35 as shown in FIG. 5 or a mix of the two units depending on the circumstances involved in the installation.
The operability of either connector system on the common ring design provides a degree of flexibility that is particularly useful in systems subject to modification.
While, in the foregoing, embodiments of the present invention have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, it may be apparent to those of skill in the art that numerous changes may be made in such detail without departing from the spirit and principles of the invention.
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A pipe connector system for connecting stub end pipe particularly thermoplastic pipe, the pipe connector system using a common engagement ring and either a flange connector system or a shell-type coupling connector system to interconnect two segments of stub end pipe or to connect stub end pipe to a pipe fitting, the alternate connector systems allowing flexibility and versatility depending on the situation, the common engagement ring being formed as either a full ring or split ring, the split ring permitting the connector system to be utilized when the pipe has a stub end pre-installed.
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This application claims priority from both GB0711428.3 and GB0617394.2, the whole contents of which are incorporated herein by way of reference for supporting the disclosure of this application.
BACKGROUND OF THE INVENTION
1. Technical Field
In brief, however, the present invention relates couplers for attaching an accessory, such as an excavator bucket, to an excavator arm of an excavator. Generally a coupler will comprise one or two jaws (or grooves, hooks or slots) and one or two latches for selectively securing (or releasing) one or two attachment pins of the accessory in the or each jaw (or groove, hook or slot).
2. Description of Related Art
Many couplers have been developed in the art. Some are fully automatic, i.e. fully operable from within the cab of the excavator for both coupling and decoupling an accessory to or from the coupler and some are part automatic/part manual, requiring many or most operations for coupling and decoupling of an accessory to or from the coupler to be carried out from within the cab, but with one or more operations needing to be done instead at the coupler itself.
A part automatic and part manual coupler is disclosed in GB2359062. The coupler is attached remotely to the accessory, i.e. from within the cab of the excavator. However, that attachment is made more secure by an additional manual step—the insertion of a safety pin into a position behind a pivoting latching hook of the coupler.
A fully automatic coupler is disclosed in GB2330570. It has a gravity operated blocking bar that is designed to fall behind the rear latching hook during normal use, whereby when the coupler is in use, and therefore in a normal, in-use or upright, orientation, the latching hook is prevented from being retracted by the presence of the blocking bar behind the latching hook. To release the accessory, however, that blocking bar is lifted from that blocking position either by a second hydraulic ram (i.e. one that is not connected to the latching hook) or simply by inverting the coupler, i.e. by moving the excavator arm and coupler into either the crowd position or to a position curled above the excavator arm (an unconventional position for an excavator arm to assume). In that inverted orientation, the blocking bar will fall away from its blocking position to allow the latching hook for the rear attachment pin then to be retracted by the latching hook's own hydraulic ram.
There are also many other couplers, either fully automatic or part automatic and part manual. See, for example, the couplers disclosed in the following publications: Australian Patent AU557890, German Utility Model DE20119092U, European Patent Applications EP0405811 and EP1318242, GB Patent Application GB2332417, U.S. Pat. Nos. 5,692,325 and 6,132,131, and PCT Publication WO99/42670.
The majority of prior art couplers have a first (or top) half that is for attaching the coupler to the excavator, and that attachment is generally to an excavator arm of the excavator. The coupler of EP0405813, however, is instead for attaching a digger bucket to the front end loader of the excavator. The couplers then have on the other or opposite side of the coupler two attachment pin engaging jaws, grooves, hooks or slots, whereby an accessory having a pair of attachment pins (such as an excavator bucket) can be attached to that coupler via the pair of attachment pins: one of the jaws, grooves, hooks or slots is for engaging a first or front attachment pin of the accessory and the other jaw, groove, hook or slot is for engaging the second or rear attachment pin of the accessory.
Couplers are also known for attaching accessories that have only one attachment pin. Those couplers have just one jaw, groove, hook or slot. Typically, however, the accessory then has the other jaw, groove, hook or slot for engaging a second attachment pin, which is instead positioned on the coupler.
Despite the existence of numerous designs of coupler, there is still an ever increasing demand upon the industry for the provision of even more security for fully automatic couplers, and for which couplers no manual steps need to be carried out by the user on the coupler for completing the securement or detachment of an accessory. A purpose for this drive is that it allows the user to remain within the safe environment of the cab of the excavator. This is important since accessories and couplers are typically quite large and heavy pieces of equipment, and thus they are potentially dangerous when being manipulated by an excavator.
For couplers having a pair of jaws, one of the jaws usually faces downwards, i.e. away from the first half of the coupler, and that jaw is usually referred to as the rear jaw—it is normally located, in use, the furthest away from the cab, and excavator arms usually extend from a rear of the excavator. Due to its position, and the way it faces in use, often that jaw is not visible from the cab. The other jaw, however, usually faces away from that rear jaw and towards the cab. It generally is also rotated by approximately 90° relative to the rear jaw, i.e. instead of pointing downwards, it usually points forwards. It is usually, in use, nearer to the cab than the rear jaw and thus it is usually referred to as the front jaw.
In many such prior art couplers a pivoting or sliding latching hook or latching plate is provided for the rear jaw for locking an attachment pin within that jaw. Thus, to couple the accessory to the coupler, a first or front attachment pin is first engaged into an open front jaw of the coupler, and the coupler is then rotated or manipulated relative to the accessory to position the second attachment pin into the coupler's open rear jaw. Then the latching hook or latching plate is driven rearwardly, for example by a hydraulic piston or a screwthread, to close the rear jaw to lock the rear attachment pin within the rear jaw. That in turn locks the front attachment pin in the front jaw.
Such a securement of the accessory to the coupler is entirely secure, subject to there being no failure of the respective components of the coupler. However, users of such couplers additionally demand back-up safety mechanisms to be incorporated into those couplers to provide assurances that an accessory cannot accidentally be decoupled from a coupler, even if the drive mechanism for the latching hook or the latching plate is accidentally retracted or in the event of a mis-use of the coupler, or even in the event of a failure of a component of the coupler or the accessory. Further, there is a drive towards making the back-up safety features both automatic to implement and visible from within the cab. By being automatic, they cannot be omitted or forgotten by the user, and by being visible from the cab it is possible to assess their status from the cab, i.e. to carry out a remote visual check as to whether the safety features have adopted their correct back-up safety position for ensuring a backed-up securement between the coupler and the accessory. Further, the demand is for such couplers that still allow fully automatic coupling and decoupling of the accessory from the coupler.
It should also be observed that many prior art couplers have the provision for accommodating different accessories, i.e. ones having different distances between their respective attachment pins. That allows accessories from different manufacturers, or from different product ranges, to be accommodated by the coupler (it is commonplace for different buckets and other accessories from different manufacturers to have different distances between their pairs of attachment pins, i.e. different pin spacings). Prior art couplers generally achieve that by the provision of either a screwthread drive system or a hydraulic ram mounted between the two jaws, grooves, hooks or slots. The screwthread or a hydraulic ram can then move one or both of the jaws, grooves, hooks or slots relative to a frame of the coupler to accommodate the different pin spacings. Generally speaking, however, just one of the jaws, grooves, hooks or slots is moved by the screwthread or hydraulic ram, and that one is most frequently the rear one (or the latch associated therewith).
The securement of the two attachment pins within the two jaws is generally by a relative separation of the two pin-engaging components. That securement of the two fixed attachment pins of the accessory within the two jaws of the coupler can be referred to as a primary securement since it alone provides a securement of the accessory to the coupler. Such primary securement mechanisms are strong and thus are generally reliable since it is most unlikely that a component of it, such as either the screwthread or the hydraulic ram, or the hook or jaw themselves, will fail. That is because these items are all designed to meet the demands of the usual environment of use for the coupler. Indeed, these items are often “over-engineered” to provide a significant overload buffer). Despite that, however, it is usual to provide the above mentioned back-up safety (or failsafe) mechanisms to prevent the accessory from decoupling from the coupler in the unlikely event of such a failure.
Such safety back-up mechanisms, as known in the art, include at a most simple level, just a cover for the actuation circuit (usually in the cab of the excavator). That prevents accidental access to the actuation switches during use of the accessory. However, there is a demand for additional security. As such, failsafe mechanisms are provided in or on the coupler itself. See, for example, the coupler of EP1318242. It has a spring driven hook for the front jaw, which hook defaults to a closed state for securing a front attachment pin within the front jaw of the coupler. Therefore, even if the rear hook fails, the accessory is secured within the coupler. A problem with that coupler, however, is that if the decoupling command is given accidentally, the spring driven hook will automatically be retracted by the hydraulic ram as the sliding rear jaw reaches a fully retracted position. U.S. Pat. No. 6,132,131 and U.S. Pat. No. 5,692,325 similarly provide a latching hook for the front jaw that is driven by the rear jaw's hydraulic ram, and as such they also have that same problem. In GB2332417, however, a toggling dual-hook arrangement is provided—there are two moving hooks that are interconnected by a toggling arrangement to ensure that as one hook opens the other hook closes, and vice versa. This prevents both hooks from opening simultaneously. However, if either the link or one of the hooks fails, the coupling between the accessory and the coupler becomes vulnerable.
SUMMARY OF THE INVENTION
The present invention, therefore, seeks to provide coupler designs that are both fully controllable from within the cab, and that will allow improved security in the securement of the accessory to the coupler, i.e. preventing accidental decouplings, but while still allowing intentional decoupling operations to be carried out without undue burden.
According to a first aspect of the present invention there is provided a coupler for coupling an accessory to an excavator arm of an excavator, the coupler comprising a first portion for attaching the coupler to an excavator arm of an excavator and the coupler having a second portion adapted to receive an accessory with two attachment pins, wherein:
the second portion has two jaws, one for receiving a first attachment pin of an accessory and the other for receiving a second attachment pin of the accessory; a first latch is associated with the first jaw for securing the first attachment pin within the first jaw when the first latch is in a latching position; a second latch is associated with the second jaw for securing the second attachment pin within the second jaw when the second latch is in a latching position; a third latch is provided that extends between the first and second latches, the third latch, when in a latching position, being adapted to resist movement of the first latch from a latching position into a non-latching position; and when the third latch is in a non-latching position, the first latch is not resisted from moving between a latching position and a non-latching position by the third latch.
Preferably the second latch is linked or connected to the third latch.
Preferably the second latch is pivotally linked to the third latch. They may, however, be an integrally formed member.
In another arrangement, the second and third latches are separate components that are selectively engageable with each other by movements of one or both of those latches, and wherein the third latch also resists movement of the second latch from a latching position into a non-latching position when it is itself in a latching position but wherein it will not resist movement of the second latch from a latching position into a non-latching position when it is in some other predetermined position. Preferably that predetermined position cannot be assumed by the third latch while a first attachment pin is secured within the first jaw by the first latch. Preferably that is achieved by the provision of a flange on the first latch that restricts movement of the third latch while a first attachment pin is secured within the first jaw by the first latch.
Preferably the latching position of the third latch is its default position, i.e. the position it assumes during normal use of the coupler (i.e. non-inverted and with an attachment attached thereto).
Preferably the third latch is moveable from a latching position into a non-latching position by means of gravity by at least partially inverting the coupler. Alternatively, or additionally, a mechanical actuator may be provided for moving the third latch.
A biasing member may be provided to bias the third latch towards a latching position.
Preferably the third latch, in a latching position bears against the first latch.
One or more of the latches may comprise a solid bar and/or a hook.
One or more of the latches may comprise a pair of solid bars and/or hooks.
One or more of the latches may comprise a bifurcated bar or hook.
Preferably the first latch is moveable from a latching position into a non-latching position by a mechanical actuator, such as a hydraulic ram.
Preferably the second latch is moveable from a latching position for the second jaw into a non-latching position for the second jaw by means of gravity by at least partially inverting the coupler. Alternatively, or additionally, a mechanical actuator may be provided for moving the second latch.
A biasing member may be provided to bias the second latch towards a latching position.
The same biasing member and/or mechanical actuator may control the movements of both the second latch and the third latch since those latches are linked or connected together.
Preferably the second jaw has a recessed groove in its lower half.
Preferably the coupler can accommodate a range of pin spacings between the two attachment pins of the accessory by making the rear jaw significantly wider in side view than the front jaw (or wider than the diameter of a typical rear attachment pin for that size of coupler). In this manner, accessories from different manufacturers, with different pin spacings, can be attached to the coupler without modification of either the coupler or the accessory.
For adjusting the first latch, the mechanical actuator is preferably a hydraulic ram. It might, however, be a pneumatic ram or a screwthread drive mechanism.
Preferably the mechanical actuator is mounted within the confines of the coupler, generally between and slightly above the two jaws.
Preferably the first latch is a pivoting latching hook, or a pair of pivoting latching hooks.
Preferably the first latch pivots to move through an arc between a latching position and a non-latching position. In other embodiments it might be a plate that slides such that it moves linearly between a latching position and a non latching position.
Each jaw may be bifurcated. It is preferred, however, that the first jaw is a pair of jaws formed in the two sidewalls of the coupler. It is also preferred that the second jaw is a single piece jaw, for example a moulded jaw or a welded multi-part fabrication.
It should be noted that the term “jaw” should be interpreted to encompass similar attachment pin receiving members such as grooves, hooks or slots, or other similar terms that are to be found in the art. For example, a hook, a groove or a slot in the main body of a coupler can form a jaw.
Preferably the first latch has a latching face facing in a first direction for bearing against the first attachment pin and a second face facing away from that latching face. Preferably one or more flange is formed on that second face. Then, in its latching position, the third latch preferably rests on one or more of those flanges. Preferably the predetermined position lies beyond the position that the third latch assumes when resting upon that flange.
The end of the third latch adapted to rest on those flanges may have one or more stepped surfaces. It would be one or more of those stepped surfaces that would preferably rest on that or those flange(s).
The first latch is adapted to be moveable into a non-latching position from a latching position by retracting it generally in the direction that its second face faces. However, when a pin is not within the first jaw, the first latch is also able to move in the opposite direction beyond the position in which its latching face would have engaged an attachment pin had one been in the first jaw. By that additional range of motion, the flange or flanges on the first latch can be moved clear of the reach of the third latch. As a result the range of available motion for the third latch is also extended. That enables the third latch to be extended into the predetermined position, if desired.
The present invention also provides a method of attaching an accessory to a coupler on an excavator arm of an excavator, the method comprising:
a) providing an excavator with a powered excavator arm having a coupler on an end thereof, the coupler comprising two jaws and a latch for each jaw, one of the latches being powered for movement between a latching position and a non-latching position, and the other being moveable from a latching position into a non-latching position by fully extending the powered latch beyond a latching position, i.e. while there is no pin within that jaw, into a fully extended position while the coupler is in a normal, in use, orientation; b) providing an accessory with two accessory pins thereon sized and spaced to fit into the two jaws of the coupler; c) powering the powered latch to extend it into the fully extended position to move the other latch into a non-latching position; d) manipulating the coupler to locate a first attachment pin of the accessory into the jaw associated with that other latch; e) curling the accessory and coupler, using the excavator arm, so as to invert the coupler, thereby placing the accessory roughly above the coupler; f) reverse powering the powered latch to retract the powered latch for opening its associated jaw, whereupon the second attachment pin locates into that jaw under the weight of the accessory; g) powering the powered latch to extend it to a latching position for securing the second attachment pin in its jaw; and h) uncurling the coupler, using the excavator arm. The attachment is now attached securely to the coupler.
In an alternative arrangement, the present invention provides a method of attaching an accessory to a coupler on an excavator arm of an excavator, the method comprising:
a) providing an excavator with a powered excavator arm having a coupler on an end thereof, the coupler comprising two jaws and a latch for each jaw, each latch being selectively moveable between a latching position and a non-latching position, wherein one of the latches is powered for movement between a latching position and a non-latching position, and the other is selectively resisted from movement from a latching position into a non-latching position by a third latch, wherein that third latch can be moved into a predetermined, non-latch-resisting position upon extending the powered latch beyond a latching position, i.e. while there is no pin within that jaw, into a fully extended position while the coupler is in a normal, in use, orientation, b) providing an accessory with two accessory pins thereon sized and spaced to fit into the two jaws of the coupler; c) powering the powered latch to extend it into the fully extended position for moving the third latch into its predetermined, non-latch-resisting position; d) manipulating the coupler to locate a first attachment pin of the accessory into the jaw associated with the other latch; e) curling the accessory and coupler, using the excavator arm, so as to invert the coupler, thereby placing the accessory roughly above the coupler; f) reverse powering the powered latch to retract the powered latch for opening its associated jaw, whereupon the second attachment pin locates into that jaw under the weight of the accessory; g) powering the powered latch to extend it to a latching position for securing the second attachment pin in its jaw; and h) uncurling the coupler, using the excavator arm. The attachment is now attached securely to the coupler.
The present invention also provides a method of detaching an accessory from a coupler on an excavator arm of an excavator, the method comprising:
a) providing an excavator with a powered excavator arm having a coupler on an end thereof and with an accessory coupled thereto, the accessory having two accessory pins thereon located within two jaws of the coupler, and secured into those jaws by respective latches associated with each jaw, wherein one of the latches is powered for movement between a latching position and a non-latching position, and the other latch is moveable from a latching position into a non-latching position, when an attachment pin is not located within the other jaw, by fully extending the powered latch beyond a latching position into a fully extended position while the coupler is in a normal, in use, orientation; b) curling the accessory and coupler, using the excavator arm, so as to invert the coupler, thereby placing the accessory roughly above the coupler; c) reverse powering the powered latch to retract the latch for opening its associated jaw; d) uncurling the coupler and attachment, using the excavator arm, to position the accessory below the coupler whereupon the attachment pin within the opened jaw exits the opened jaw under the weight of the accessory; e) powering the powered latch to extend it into the fully extended position to move the other latch into a non-latching position to open the other jaw; and f) manipulating the coupler relative to the attachment to remove the other attachment pin of the accessory from that other jaw.
Preferably the act of inverting the coupler and accessory to place the accessory roughly above the coupler serves to move a mechanical stop away from a latching position behind the powered latch.
Preferably the mechanical stop is linked to the other latch.
Preferably the movement of that powered latch into the fully extended position allows the mechanical stop to move beyond its own latching position into a final release position, or the above mentioned predetermined position, whereupon the other latch is released to be free to move into a non-latching position.
In an alternative arrangement, the present invention provides a method of detaching an accessory from a coupler on an excavator arm of an excavator, the method comprising:
a) providing an excavator with a powered excavator arm having a coupler on an end thereof and with an accessory coupled thereto, the accessory having two accessory pins thereon located within two jaws of the coupler, and secured into those jaws by respective latches associated with each jaw, each latch being selectively moveable between a latching position and a non-latching position, wherein one of the latches is powered for movement between a latching position and a non-latching position, and the other latch is selectively resisted from movement from a latching position into a non-latching position by a third latch, wherein that third latch can be moved into a predetermined, non-latch-resisting position upon extending the powered latch beyond a latching position, i.e. while there is no pin within that jaw, into a fully extended position while the coupler is in a normal, in use, orientation; b) curling the accessory and coupler, using the excavator arm, so as to invert the coupler, thereby placing the accessory roughly above the coupler; c) reverse powering the powered latch to retract the latch for opening its associated jaw; d) uncurling the coupler and attachment, using the excavator arm, to position the accessory below the coupler whereupon the attachment pin within the opened jaw exits the opened jaw under the weight of the accessory; e) powering the powered latch to extend it into the fully extended position to move the third latch into its predetermined, non-latch-resisting position; f) moving the other latch into a non-latching position; and g) manipulating the coupler relative to the attachment to remove the other attachment pin of the accessory from that other jaw.
Preferably step f) is achieved by recurling the accessory and coupler, using the excavator arm, so as partially to invert the coupler, thereby placing the accessory in a position that is substantially level with the coupler. That then allows the other latch to fall into a non-latching position under the influence of gravity if it is free to do so. It should be appreciated, however, that that other latch might instead be power operated, e.g. it may have its own actuator, such as a hydraulic ram.
It would also be desirable to provide just a simple supplementary failsafe or securement mechanism for couplers. Preferably the supplementary failsafe or securement mechanism will be able to ensure that an accessory will still be retained upon the coupler until that supplementary failsafe or securement mechanism is released even in the event of a catastrophic failure of the primary securement mechanism, e.g. the hydraulic ram or the screwthread, or even a moveable jaw, groove, hook or slot, or even in the event of an accidental or inadvertent release of that primary securement mechanism by the operator.
According to a further aspect of the present invention, therefore, there is provided a coupler for coupling an accessory to an excavator arm of an excavator, the accessory comprising at least one attachment pin for use in the coupling, the coupler comprising a first side for attaching the coupler to an excavator arm of an excavator and the coupler having a second side onto which the accessory will be coupled, the second side comprising a jaw for receiving the attachment pin of the accessory for connecting the accessory to the coupler by the engagement of the jaw with the attachment pin, wherein the jaw comprises a gravity-operated member having a first state—the jaw-open or jaw-unlocked state, and a second state—the jaw-closed or jaw-locked state, the gravity-operated member at least partially closing the jaw of the coupler when it is in its first state, said first state being achieved by the gravity-operated member when the coupler (and, when connected, the accessory) is in a normal, in-use orientation due to the influence of gravity on the gravity-operated member.
Preferably the two different states of the gravity-operated member are two different positions of the gravity-operated member. However, the gravity-operated member might instead simply remain in a constant normal position, instead switching between a rotatable or free state and a non-rotatable or more restricted state depending upon the orientation of the coupler.
The present invention, with its gravity-operated member, therefore has a jaw that can be selectively opened or closed (or unlocked and locked) dependent upon the orientation of the coupler since gravity will open or unlock the member in one orientation and will close or lock the member (with the jaw at least partially closed by the member) in other orientations.
It should be noted that the terms “jaw” should be interpreted to encompass similar pin receiving members such as grooves, hooks or slots, or other similar terms that are to be found in the art. For example, a hook can form a jaw, a groove or a slot, and similarly a groove is in essence just a slot. In view of that, and also for the sake of convenience, the single term “jaw” is used hereinafter.
Preferably, in a first orientation (e.g. the normal, in-use orientation) the member will fall under the influence of gravity into its closed position. However, upon reorienting the coupler, for example to an inverted position, the member will fall under the influence of gravity from that closed position into its open position. Instead of simply falling between two positions, however, the member may roll, slide or pivot between those positions. Alternatively, it might remain stationary, instead either being locked or unlocked from a particular closed position dependent upon the orientation (or path of motion between orientations) of the coupler.
When open (or unlocked), an attachment pin within the jaw, when not otherwise restrained, can be removed from the jaw. Similarly, an attachment pin can be inserted into the jaw. However, when closed, be that either completely or partially, or when locked, an attachment pin within the jaw cannot be removed from the jaw since the locked or closed member will block its path out of the jaw. It might be possible, however, dependent upon the chosen configuration of the locking/closing mechanism, to insert an attachment pin into the jaw even when the gravity-operated member is either closing the jaw or locking the jaw closed, e.g. by sliding it sideways into the jaw, rather than from the front of the jaw.
Preferably, the gravity-operated member is mounted onto the second side of the coupler either directly to the jaw, or onto a frame of the coupler, which frame carries the jaw.
Preferably the gravity-operated member is a pivotal member, mounted to the coupler about a pivot axis, the pivoting of the member moving it between its open and closed (or locked and unlocked) positions.
Preferably the first side is a top side of the coupler, the second side is a bottom side of the coupler, and the coupler also comprises a frame having two sideplates extending generally between the top and bottom sides of the coupler. Preferably the pivot axis runs perpendicular to those sideplates, i.e. in a transverse direction of the coupler. The axis might, however, extend in a longitudinal direction of the coupler (the above-mentioned pin-spacing is measured in the longitudinal direction of the coupler, whereas the attachment pins of an accessory extend in the transverse direction of the coupler).
The gravity operated member might comprise two pivoting axes, the first running in the transverse direction of the coupler and the second running in the longitudinal direction of the coupler. This allows the member to pivot in more than one direction. Even more pivoting directions can be achieved with a ball and socket joint.
Instead of pivoting, the member may slide or roll between its open and closed/locked and unlocked positions.
Preferably an accessory for coupling to the coupler comprises two attachment pins, the coupler thereby needing two jaws. One or more gravity-operated member as defined above may be provided for each or either jaw. However, preferably only one jaw has a gravity-operated member for closing the jaw, and most preferably it will just be the front jaw—usually the jaw without a hydraulically or mechanically driven latching hook or latching plate.
Preferably the other jaw (the rear jaw) points downwards and has a hydraulically or mechanically driven latching hook or latching plate, which, together with the first jaw, (which usually points forwards) provides a primary coupling mechanism for coupling the accessory to the coupler in a fixed orientation relative to the coupler. The gravity-operated member is then preferably a secondary securing mechanism (as a secondary securing mechanism, the gravity-operated member does not serve to couple the accessory to the coupler in a fixed orientation relative to the coupler, but instead merely serves to attach or tether the accessory to the coupler simply by retaining the attachment pin within the first jaw when the member is in its closed or locked position).
The coupler with two jaws may be in accordance with any of the other aspects of the invention described above.
Preferably, the gravity-operated member is not hook-shaped. The member instead is preferably a blocking bar, a blocking toggle or a blocking wedge.
By the term “gravity-operated”, it is intended that no spring or hydraulic member, or any other mechanical, hydraulic, magnetic or electrical biasing influence, is to be used, in normal use, to move the member from its closed or locked position into its open or unlocked position. Instead, simply gravity is to be relied upon for that purpose, whereby the coupler has to be at least partially inverted in order to release the gravity-operated member. Such an inversion of the coupler, sufficient for decoupling the accessory from the coupler, should not occur during the normal use of the coupler with an accessory attached thereto since it is unusual to operate an excavator arm and accessory in a manner that places the accessory suitably above the end of the excavator arm.
Similarly it is desired just to rely upon gravity to return the member to its closed or locked position. However, it is possible to provide a gravity-operated member that has a biasing member, such a spring, for assisting in ensuring that the gravity-operated member will fall, move into or assume its closed or locked state when the coupler is in its normal, in-use orientation. In such an embodiment, gravity would still be relied upon to overcome that biasing force in order for the member to assume its open or unlocked state.
Preferably, when the coupler comprises two jaws, the second or rear jaw is associated with a moveable latch and a mechanical stop for selectively locating behind that moveable latch for selectively restricting the movement of that moveable latch.
Preferably the mechanical stop is also operable under the influence of gravity.
Preferably, when the coupler is in a normal, in use, level orientation, i.e. with the two jaws approximately level with each other, with an accessory arranged below the coupler, and with an attachment pin of the accessory retained within the second jaw by the moveable latch, the mechanical stop tends, under the influence of gravity, to fall into a position resting against the moveable latch for restricting the movement of that moveable latch from that pin latching position.
Preferably, when the coupler is in an inverted position, the mechanical stop instead falls away from the moveable latch, into a non-latching position. That position allows the second latch to be retracted from its latching position for releasing the pin retained by it within the second jaw.
Preferably the mechanical stop, when it is resting against the moveable latch provided for the rear jaw, also provides a movement-restricting function for the gravity operated member, whereby the gravity operated member cannot be moved into a jaw-open position.
Preferably the mechanical stop, when the coupler is inverted, also provides against the gravity operated member a bias towards a front-jaw-closing position for that gravity operated member.
Preferably the mechanical stop has a third position that is only achievable by the mechanical stop while an attachment pin is not retained within the second jaw. Preferably that position is a position beyond the position assumed by the mechanical stop as it rests against the moveable latch for the rear jaw. Preferably that third position disengages the movement-restricting function of the mechanical stop in relation to the gravity operated member. Thus, while an attachment pin is secured within the rear jaw by the moveable latch associated therewith, the front jaw cannot be opened by movement of the gravity operated member. However, upon disengagement of the attachment pin from the rear jaw, the third position for the mechanical stop can be achieved, and thus the front jaw can also be opened.
Preferably the mechanical stop has a pivot axis and a first arm pointing from that pivot axis generally towards the gravity operated member for the front jaw, and a second arm pointing from that pivot axis generally towards the moveable latch for the rear jaw.
Preferably the two arms extend away from each other at an angle of greater than 90° (and less than 270°).
Preferably the arm that points generally towards the gravity operated member has a flange on it that is adapted to bear against a corresponding flange of the gravity operated member. The interaction between those flanges restrict the motion of the gravity operated member. Thus, when the mechanical stop is in its third position, the two flanges are separated with respect to each other such that they cannot bear against each other through the range of motion required by the gravity operated member for opening the front jaw.
Preferably the two flanges have opposing angled faces that bear against each other when the coupler is inverted for biasing the gravity operated member into or towards a locked or closed position.
For a pivoting mechanical stop that operates under the influence of gravity, the moment of inertia for the mechanical stop needs to be such that arm of the blocking bar extending towards the moveable latch for the rear jaw will tend to overbalance the other arm. For example, the arm of the blocking bar extending towards the moveable latch will tend to be significantly heavier or longer than the other arm.
Preferably the gravity operated member has a stop-surface adapted to bear against a corresponding surface of the coupler's frame when the gravity operated member is in a front-jaw-locking or closing position for preventing movement of the gravity operated member beyond that front-jaw-locking or closing position. Two such stop surfaces that are spaced apart may be provided to spread the loading across a larger area of the frame in the event of the accessory's weight being carried by that gravity operated member, e.g. if the accessory is incorrectly mounted onto the coupler.
Preferably the two stop surfaces are planar. More preferably they are not co-planar.
Preferably one of the stop surfaces is a forward facing surface, with the corresponding surface of the coupler's frame lying as a rearward facing surface of the frame, for example on a forwardly extending integral rail of the frame.
Preferably the second stop surface is provided on an underside of a third flange of the gravity operated member.
Preferably, the gravity-operated member is arranged such that it will be in its locked or closed state for most normal, in-use orientations and rotations of the coupler. Those normal, in-use orientations will usually range from a level orientation (i.e. where the two attachment pins are level) to perhaps at least 45° from that level orientation in a first or digging curl direction (i.e. moving towards the crowd position) and from the level orientation to perhaps at least 135° from that level orientation in an opposite curl direction—the emptying curl direction (i.e. up and over the excavator arm). Therefore the preferred embodiment of the present invention will keep its gravity-operated member in a locked or closed position through a range of angles of curl perhaps in excess of 180°.
In a more preferred embodiment, the member will only move to its open position in response to specific re-orientations of the coupler, such as a full inversion of the coupler (i.e. into a position curled up and above the excavator arm, which may be a rotation of more than 170° in the emptying curl direction from the level orientation), or in response to lesser rotation, e.g. 60° or more in the digging curl direction (i.e. into or towards the crowd position). Adjusting the position of the pivot point of the member relative to the centre of gravity of the member provides for different angle ranges in that regard where the pivot axis runs transverse across the coupler, e.g. between sideplates of the coupler. Further, undesired rotations for the member can be avoided, or rotation limits can be provided, by pivot stops.
It should also be noted that the former of the two decoupling positions (i.e. a position curled up and above the excavator arm) is the less desirable position for the coupler during a decoupling of the accessory from the coupler. That is because it positions the coupler at a significantly more elevated position than that achieved in the crowd position. As a result, such a position would never be used in practice. It should also be noted that such a position serves no useful purpose, and thus is an unlikely position for an operator to put the coupler into.
It is also preferred that a decoupling of the accessory from the coupler is not an automatic result of a single act of (at least partially) inverting the coupler. With the preferred embodiment of the present invention, there is also a primary coupling mechanism, with the gravity operated member providing just a secondary securement function, for example of being an automatic tether. As a result, the mere reorientation of the coupler into a position that moves the gravity-operated member into an open or unlocked position will not actually decouple the accessory from the coupler. The primary coupling mechanism would also need to be disengaged or retracted before that could happen.
It should also be noted that when a coupler is in a fully inverted orientation (i.e. up above the excavator arm, and rotated by more than 170° from the level orientation), the weight of the accessory will be bearing directly down onto the coupler. The weight of the accessory, therefore, should keep the accessory on the coupler.
The accessory also cannot be released while the weight of the accessory is forcing the attachment pin to press into the back of the jaw. That, therefore, is a preferred state for the coupler at the time of decoupling. That state is achieved for example by reorienting the coupler into the crowd position. Then, to withdraw the attachment pin from the jaw in that orientation, the weight of the accessory will be rested on the floor or the like, preferably in a stable manner (e.g. on a flat bottom surface of the accessory or on a stand for the accessory), and then the weight of the accessory on the ground is used to keep the accessory stationary while the jaw is disengaged from the attachment pin of the accessory by manipulation of the excavator arm and the coupler relative to that accessory in an appropriate manner (after disengagement of any primary coupling mechanism).
The present invention therefore allows the decoupling of an accessory from the coupler by the use of specific and deliberate reorientations and manipulations, which acts would not be carried out during normal excavation operations. As a result, the accessory cannot be decoupled from the coupler accidentally. Thus the present invention will provide remarkable reassurances to an excavator operator.
The present invention also provides various methods of coupling an accessory onto a coupler that is attached to an excavator arm of an excavator.
The present invention also provides various methods of uncoupling an accessory from a coupler that is attached to an excavator arm of an excavator.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
These and other preferred features and embodiments of the present invention will now be described purely by way of example with reference to the accompanying drawings in which:
FIG. 1 is a cut-away side elevation of a preferred embodiment of the present invention;
FIG. 2 is a schematic cut-away perspective of a preferred embodiment of the invention with two attachment pins of a bucket (part illustrated) secured within the two jaws of the coupler;
FIGS. 3 to 8 are schematic cut-away perspectives of the embodiment of FIG. 2 illustrating the preferred sequence of operations for firstly attaching an attachment to the coupler ( FIGS. 3 to 5 ) and then for disengaging the attachment from the coupler ( FIGS. 6 to 8 );
FIG. 9 is a top perspective view of the preferred coupler, with an attached bucket (in part) illustrating the preferred elements of the coupler roughly in plan.
FIG. 10 shows a part sectional side elevation view of a coupler illustrating a further embodiment of the present invention;
FIG. 11 shows the same part sectional/side elevation view of the coupler of FIG. 10 , but in which the member is in its second, jaw-closed position;
FIG. 12 shows a front elevation view of the coupler of FIGS. 10 and 11 with the member in its jaw-closed position;
FIG. 13 is a detail side view of the gravity-operated member of FIGS. 10 , 11 and 12 ;
FIG. 14 is a front perspective view of a further embodiment of the present invention;
FIG. 15 is a schematic view of the embodiment of FIG. 14 showing an attachment pin of an accessory passing the member;
FIG. 16 is a front elevation view of the embodiment of FIG. 14 with the member in its jaw-closed position;
FIG. 17 is a side elevational view of a further coupler in accordance with the present invention;
FIG. 18 shows the internal working mechanisms of the coupler of FIG. 17 ;
FIG. 19 is a schematic view of the coupler of FIG. 17 with two attachment pins of an accessory secured thereto;
FIGS. 20 to 23 schematically illustrate the operational steps involved for attaching an accessory to the coupler of FIG. 17 ;
FIGS. 24 and 25 show the coupler of FIG. 17 , rotated by 45° from horizontal, for illustrating the movement restricting function of the mechanical stop for the gravity operated member;
FIGS. 26 to 30 schematically illustrate the operational steps involved for disengagement of an accessory from the coupler of FIG. 17 ; and
FIGS. 31 , 32 and 33 show details of the interactions between the gravity operated member and the frame of the coupler.
DETAILED DESCRIPTION OF THE INVENTION
Referring first of all to FIG. 1 , a cut-away side elevation of a preferred coupler 10 , showing the preferred internal working mechanisms for the coupler 10 of the present invention, is shown. The coupler 10 has a first, or upper, portion 12 and a second, or lower, portion 14 . The coupler also has a front 16 and a rear 18 . In normal use the front 16 points towards the cab of an excavator (not shown), whereas the rear 18 points away from the cab.
The upper portion 12 is adapted for connecting the coupler 10 onto the excavator arm of the excavator and it is displaced slightly forwardly relative to the lower portion 14 , as is conventional. In this illustrated embodiment, however, it is displaced further forward than would be conventional. That, however, is optional.
In the upper portion 12 , two pairs of holes 20 are provided, although only one of each pair is shown. Those holes 20 are for attachment of the coupler 10 to the excavator arm of the excavator by using a pair of attachment pins. That attachment is conventional in the art, and thus needs no further discussion.
The lower portion 14 , which is instead for coupling onto an accessory, such as an excavator bucket, instead uses a pair of jaws for that attachment. The first jaw, or the rear jaw 22 , and the second jaw, or the front jaw 24 , conventional as well for that purpose, and thus are sized to receive a further pair of attachment pins, this time fitted to the accessory.
As is conventional now, the rear jaw 22 is a downwardly facing jaw whereas the front jaw 24 is a forward facing jaw. Thus, with this arrangement, the basic principle behind coupling an accessory to the coupler is first to locate a front attachment pin of the accessory within the front jaw 24 and then to swing a rear attachment pin of the accessory into the rear jaw from below. Next, to prevent that second pin from just swinging out of the rear jaw, a pivoting latching hook, or first latch 26 , is associated with that rear jaw 22 such that it can be swung about a pivot 28 into a latching position across the rear jaw 22 to secure the second attachment pin within the rear jaw 22 . That then secures the accessory firmly onto the coupler 10 .
As is also conventional, in this preferred embodiment the pivoting latching hook 26 is driven into that latching position by a mechanical actuator such as a hydraulic ram 32 .
However, instead of a hydraulic ram, a pneumatic ram or a screwthread drive, or some other drive device, might be provided.
Further, instead of a pivoting latching hook, a sliding mechanism for that latch might instead be provided.
The present invention is distinguished over prior art couplers, however, by the provision of a unique second latch 34 , and an attached third latch, or mechanical stop 36 . They are provided to interfere with the above basic principle of operation of the coupler so as to prevent inadvertent, or non-deliberate, disengagement of the accessory from the coupler 10 , while still allowing deliberate disengagement of the accessory from the coupler.
The second latch 34 is associated with the front jaw 24 and it is adapted selectively to close the front jaw 24 for securing an attachment pin within the front jaw 24 . Because of that latch 34 , before the accessory can be decoupled from the coupler 10 , steps have to be taken to cause that latch to retract for opening the front jaw 24 . Further details of those steps, and the more specific details of that second latch, will now be described in further detail with reference to FIGS. 2 to 8 .
As can be seen in FIG. 2 , which shows only one half of the second latch 34 , the second latch 34 is a pivotal plate connected via a hinge to a third element 36 . The plate is generally rectangular with a solid section and is preferably made from steel. Its hinge has a central axis 42 .
The second latch 34 can drop in and out of a latching position within the front jaw 24 by sliding generally linearly through a slot defined by two plates 48 , 50 . It can keeps a generally linear line of movement since it can pivot about its own pivot axis 42 , i.e. relative to the third element 36 . Further, its interaction with the two plates 48 , 50 within that slot defined therebetween, prevents rotation of the second latch 34 relative to main body of the coupler 10 , and relative to the front jaw 24 .
In an alternative construction, however, the second latch 34 and the mechanical stop 36 may be a single unitary element, thus not needing at least the front plate 48 of the two plates 48 , 50 .
The third element 36 is a mechanical stop 36 . As more clearly shown in FIG. 3 , in which the hydraulic ram 32 has been removed for clarity, the mechanical stop 36 is itself also a pivotal member—it is pivotally mounted relative to the main body 38 of the coupler 10 about a pivot pin (not shown) via a bearing hole 40 in the mechanical stop 36 . Thus the mechanical stop 36 can pivot relative to the main body 38 of the coupler 10 .
The mechanical stop 36 has a first arm with an end 56 that extends away from the bearing hole 40 away from the second latch 34 . It also has a second arm extending away from the bearing hole 40 , but instead towards the second latch 34 . That second arm carries the pivot axis 42 for the second latch 34 near its end and that axis is located directly above, or in line with, the slot defined between the two plates 48 , 50 of the front jaw.
As a result of that geometry (of the mechanical stop relative to the axes and the slot of the front jaw), it is through the pivoting motion of the mechanical stop 36 about the central axis of its bearing hole 40 , i.e. relative to the main body of the coupler, that the second latch 34 can be lifted or lowered generally linearly through the slot between the two plates 48 , 50 .
The pivotal movement of the mechanical stop 36 is illustrated by the arrows 44 in FIG. 3 .
The generally linear motion of the second latch 34 relative to the front jaw 24 is illustrated by the double headed arrow 46 also in FIG. 3 .
It is preferred that the first arm of the mechanical stop, i.e. the arm extending from the bearing hole 40 to the end 56 , is at least twice as long as the second arm of the mechanical stop 36 , i.e. the arm extending from the bearing hole 40 towards the second latch 34 . Similarly it is preferred that that first arm of the mechanical stop is at least twice as long as the second latch 34 . Those arrangements together should allow the second arm to have a greater moment of inertia about the bearing hole 40 than the second arm combined with the second latch 34 . Similarly, or alternatively, the first arm may simply be sufficiently heavier than the second arm and second latch combined to provide the desired greater moment of inertia for that first arm about the bearing hole 40 than the second arm and second latch 34 combined. This moment of inertia arrangement is desired so that gravity can always cause the first arm to drop and the second arm to lift, whenever the orientation of front and rear of the coupler is altered with respect to one another. This is the desired arrangement despite the fact that that arrangement tends to cause the second latch 34 to be permanently biased towards a non-latching position when the coupler 10 is in a normal use orientation, i.e. with the attachment being located underneath the coupler. That is because in normal use the second latch 34 will not be able to lift fully up into the roof of the front jaw 24 for opening the front jaw 24 due to the first latch 26 interfering with the range of motion available to the mechanical stop 36 . Instead, the second latch's normal position during use is as shown in FIG. 2 —it extends partially across the opening of the front jaw 24 . That is sufficient for “closing” the second jaw for locking an attachment pin within the second jaw. This feature is further explained below with regard to attaching and detaching an accessory to and from the coupler.
Returning, however, to the design of the second latch 34 , in preferred embodiments the second latch 34 is painted in a high visibility colour such as orange or red. That is preferred since the second latch is one of the safety features of the coupler that will nearly always be visible from the cab of the excavator—it at least partially extends across the opening of the front jaw 24 , and that opening generally faces towards the cab during normal use of accessories. The high visibility second latch 34 , therefore, acts as a visible marker for confirming the correct or secure attachment of an accessory to the coupler 10 , and that visual aid can be seen by the excavator operator from the within his cab.
For securing the rear attachment pin 54 within the rear jaw 22 , however, this preferred embodiment has a first latch 26 in the form of a pivoting latching hook. That pivoting latching hook is mounted for rotation about a pivot pin 28 and is moveable between a latching position and a non-latching position by a hydraulic ram 32 . That hydraulic ram 32 is the primary mechanism for holding that first latch 26 in its latching position. To assist with that and to add to the security of that, it is preferred that the hydraulic ram is provided with a check valve to prevent a release of the hydraulic pressure on the ram in the event of a hydraulic failure such as a cut in the hydraulic piping leading to it.
The mechanical stop 36 , however, provides a further backup to prevent the inadvertent or non-deliberate release or retraction of the first latch 26 into a non-latching position. To that end the mechanical stop 36 provides an interference function against that first latch 26 , as most clearly illustrated in FIG. 5 .
For providing that interference function, the first arm of the mechanical stop 36 extends away from the bearing hole 40 , and away from the second latch 34 , towards the first latch 26 . Further its length is long enough to bear against the first latch 26 when the first latch is in a latching position against an attachment pin. However, the first arm is not too long—it needs to be able to swing past the first latch 26 when the first latch 26 is fully extended, i.e. when there isn't an attachment pin within the rear jaw.
Because of the mechanical stop 36 , i.e. when the first latch is in a latching position against an attachment pin, the first latch 26 cannot be retracted even by the hydraulic ram 32 until that mechanical stop 36 has been moved from that interference position.
The movement of that mechanical stop 36 is achieved by inverting the coupler 10 , as shown in FIG. 4 , by fully curling the bucket and coupler under the excavator arm using the hydraulics of the excavator arm of the excavator. In that inverted position, due to the moments about the bearing hole 40 , the mechanical stop 36 will rotate under the influence of gravity so as to move its end 56 that was in engagement with the first latch 26 away from the first latch 26 . That rotational movement is in the direction shown by the downwardly pointing arrow 58 in FIG. 4 .
It should also be observed that that rotation of the mechanical stop 36 does not open the front jaw 24 since the second latch 34 is still extending partially across the opening of the jaw 24 —it actually closes it further, as shown by the upwards arrow 60 in FIG. 4 . Upon that rotation of the mechanical stop, the first latch 26 is free to be retracted from its latching position into a non-latching position by the hydraulic ram 32 (not shown in FIG. 4 either, again for clarity). Thus, the rear jaw 22 can be opened (as shown in FIG. 4 .
Although the basic operations of the three latches have been described above, the preferred method for attaching an accessory, such as a bucket 62 , to the coupler 10 will now be described with reference to FIGS. 3 , 4 and 5 .
Referring first to FIG. 3 , the first step in the attachment procedure is the engagement of the front jaw 24 of the coupler onto the front attachment pin 52 of the bucket 62 . That is usually done while the bucket 62 sits on the ground and is achieved by manipulation of the coupler 10 relative to the bucket 62 , while the coupler is in its normal upright orientation. However, before that can be done, the front jaw 24 needs to be open, i.e. the second latch 34 needs to have been lifted into or above the roof of the front jaw 24 .
The front jaw is likely to be open if the last operation with the coupler was the disengagement of the coupler from an accessory. However, if it is not open, to open it the second latch 34 must be lifted. That, however, can only be done while the rear jaw 22 is not accommodating an attachment pin, and only when the first latch has been driven rearwardly to a fully extended position. That can usually be done by using the hydraulic ram 32 , as shown in FIG. 3 .
Once the first latch 26 is fully extended, or while it is being fully extended, the mechanical stop 36 falls clear of the first latch 26 once it is no longer able to reach the first latch 26 to bear against it. That additional rotation of the mechanical stop is then enough to lift the attached second latch 34 clear of the front jaw 24 , i.e. fully into or above the roof of the front jaw 24 , to open that jaw 24 .
Once the front attachment pin 52 of the bucket 62 has then been engaged into the front jaw 24 of the coupler 10 , the hydraulics of the excavator arm are then powered up to curl the bucket 62 and the coupler 10 under the excavator, i.e. towards the cab, so as to invert the coupler 10 . That positions the bucket 62 roughly above the coupler 10 , as shown in FIG. 4 . During that rotation of the coupler, the mechanical stop 36 will again fall under the influence of gravity to rotate it in the direction shown by the single downward arrow 58 in FIG. 4 . Thus the end 56 of the mechanical stop passes the first latch 26 again.
Further, as that happens the weight of the bucket will keep the front attachment pin securely in the cradle of the front jaw. Thus the second latch will be able to slide back partially across the opening of the front jaw 24 to close the front jaw 24 for securing the front attachment pin 52 within that front jaw 24 .
While the above is happening, the first latch 26 remains fully extended. Thus it prevents the passage of the rear attachment pin 54 of the bucket 62 into the rear jaw 22 of the coupler 10 . However, once the above has happened, the first latch 26 can then be retracted by the hydraulic ram 32 to open the rear jaw 22 —the mechanical stop 36 is moved clear of the fist latch so it will not prevent that from happening.
Next, as the first latch 26 is retracted, the rear jaw opens and eventually the rear attachment pin 54 will fall into that jaw 22 under the weight of the bucket. Then the first latch 26 can be powered back to a latching position by the hydraulic ram. The bucket 62 and coupler 10 can then be reinverted to the position or orientation of FIG. 5 —the normal working orientation—by uncurling the arrangement with the excavator arm.
During that uncurling operation the final part of the coupling procedure occurs—the mechanical stop falls back down into an interference position, i.e. with its end 56 bearing against the first latch 26 .
From the above it will be appreciated that it is important that the front jaw is openable sufficiently by the movement/rotation of the mechanical stop to allow an attachment pin to be engaged into the front jaw, and also for it to remain sufficiently closed during normal use, i.e. while the mechanical stop is in a latching position, to prevent removal of the attachment pin from the front jaw. That balance is more readily achieved if the latch only extends partially across the front jaw when the mechanical stop is in its latched position. Thus the length of the second latch 34 is preferably chosen such that with the mechanical stop in a latching position, the second latch extends only approximately half way across the opening for the front jaw 24 . However, adjusting the relative the lengths of the arms of the mechanical stop 36 will adjust the amount of lift/movement available for the second latch 34 by the rotation of the mechanical stop 36 into its fully dropped position from its latching position. Similarly, adjusting the location of any lower rotation stop for the mechanical stop can adjust the amount of lift/movement available for the second latch 34 by the rotation of the mechanical stop 36 into its fully dropped position from its latching position.
In this preferred embodiment the first latch 26 is a hook having an attachment pin facing surface 64 and a back surface 66 . The end 56 of the mechanical stop 36 can bear against that back surface 66 when the mechanical stop 36 is in a latching position. However, to provide a more precise latching position for the mechanical stop 36 , The back surface 66 of the first latch 26 is provided with a flange 68 having at least one step. This stepped flange 68 provides a seat onto which the mechanical stop's end 56 can sit when it is in its latching position behind the first latch 26 . Further, if more than one step is provided, each step provides an alternative seat for the mechanical stop's end 56 , whereby attachments with different pin spacings can be accommodated more readily by the coupler 10 —as shown in FIG. 3 , two or even three steps are preferably provided on the flange 68 , with each step providing a corresponding latching position for the mechanical stop 36 , depending upon the amount of extension needed by the first latch 26 for its attachment pin facing surface 64 to engage the attachment pin of the respective accessory.
Instead of multiple steps on the flange, the end 56 of the mechanical stop could instead be stepped.
In the illustrated embodiment, the rear jaw is relatively narrow. Thus only a narrow range of accessory pin spacings can be accommodated by that coupler 10 . However, that rear jaw 22 could be widened slightly to widen the range of accessory pin spacings accommodatable by the coupler.
The flange 68 also serves a second purpose. It provides more control for the operation of the mechanical stop both in its latching position and between its latching position and it fully dropped position (i.e. for opening the front jaw). By having the flange with the step, the exact state of rotation of the first latch will not define whether the mechanical stop is in a latching position. That is because it is in a latching position whenever it bears onto the step. Thus the mechanical stop will only fall past that latching position when the operator wants it to do so, i.e. by fully powering forward the fist latch 26 when there isn't an attachment pin in the rear jaw 22 .
Next, with reference to FIGS. 6 , 7 and 8 , the removal of a bucket 62 from the coupler 10 will now be described.
Referring first to FIG. 6 , the first step in decoupling a bucket 62 from the coupler 10 is to invert the bucket 62 and coupler 10 so as to place the bucket 62 roughly above the coupler 10 . That in turn causes the mechanical stop 36 to rotate clear of its latching position behind the first latch 26 , as shown by arrow 58 . The hydraulic ram 32 can then be powered to retract the first latch 26 for opening the rear jaw 22 .
Once that has been done, the bucket 62 and coupler 10 are then reinverted to the normal orientation of FIG. 7 . That in turn allows the rear attachment pin 54 to swing free from the open rear jaw 22 , as shown. The front attachment pin 52 , however, is still secured within the front jaw 24 by the second latch 34 . Thus even if free swinging, the bucket 62 still will not detach from the coupler 10 . Before that can happen it is necessary to release the front attachment pin 52 from that front jaw 24 .
To release the front attachment pin 52 from the front jaw 24 , the bucket 10 would first normally be seated onto the ground to make it safe. Then the hydraulic ram 32 is again powered, but this time to drive the first latch 26 into its fully extended position, as in FIG. 3 above, but as now shown in FIG. 8 . That in turn allows the mechanical stop 36 to fully drop into the final bucket release position (as shown by arrow 72 ) in which it lifts the second latch 34 clear up into the roof of the front jaw 24 (as shown by arrow 74 ). Only then is the front attachment pin 52 also then free to be removed from the front jaw 24 .
One final safety feature is incorporated into this coupler. That is the provision of a recess 70 in the floor of the front jaw 24 (see FIG. 1 ). That recess, in this illustrated embodiment has a width of approximately the same length as the height of the jaw's opening. An attachment pin can thus locate into it. That recess 70 makes it even more unlikely that the front attachment pin will disengage from the front jaw unintentionally. That is because even if the rear attachment pin is already free and the front jaw is open, a free swinging bucket in that open front jaw will still not tend to fall out of the jaw. Instead the pin will tend to locate into the recess within that front jaw. Further, one in the recess, it will not readily come out of it due to the weight of the bucket. Thus, only when the bucket is on the ground, or shaken vigorously, will the removal of the bucket from that jaw be facilitated. That is because only then will the weight of the bucket 62 be taken off the jaw 24 of the coupler 10 . That in turn allows the coupler 10 to be more readily manipulated in a suitable manner relative to the jaw to free the front attachment pin 52 from the front jaw 24 .
Referring finally to FIG. 9 , a top plan view of the working elements of the preferred coupler is provided. From that view it is clearly visible that the second latch 34 lies between a pair of mechanical stops 36 . However, other configurations within the scope of the claims as appended hereto would be acceptable as well. The pair of mechanical stops 36 , the hydraulic ram 32 , the first latch 26 and the second latch 34 have each been shaded with different hash lines to help identify them in the figure.
It can also be noted from FIG. 9 that in this preferred embodiment has the hydraulic ram 32 sitting generally between the two mechanical stops 36 . That provides a more compact arrangement of the coupler 10 in its height dimension, whereby the bucket's digging capacity will be less compromised by the use of a coupler between the excavator arm and the bucket.
Referring next to FIG. 10 , a further embodiment of the present invention is shown. The coupler 110 comprises a top side 112 , a bottom side 114 , a front 116 and a rear 118 . The coupler also comprises sideplates 120 (see FIG. 12 ).
In the top side 112 , two holes 122 are provided for attachment of the coupler 110 to an excavator arm of an excavator in a conventional manner, i.e. with two attachment pins (not shown).
In the bottom side 114 , a front jaw 124 and a rear jaw 126 are provided for receiving two further attachment pins (not shown), this time of an accessory (also not shown) for attachment of the accessory to the coupler 110 again in a generally conventional manner. Indeed, for this embodiment, a primary coupling mechanism (not shown) for that purpose can consist of a pivoting latching hook and hydraulic cylinder as disclosed in GB2359062. However, for simplicity, those features have not been shown in the drawings. For completeness, however, the disclosures of GB2359062 are incorporated herein by way of reference, and as such, a full discussion of the primary coupling mechanism is not required herein. The drawings do, however, show three apertures 28 that pass through both of the sideplates 120 of the coupler 110 which are for receiving a locking pin (through just one pair of them) for locking the latching hook in its latched position, as disclosed in GB2359062.
The present invention, however, has an additional feature that is not disclosed in GB2359062. That is the gravity-operated member 130 , as most clearly shown in FIG. 13 . That gravity-operated member 130 is a toggle in an upper wall 132 of the front jaw 124 . The jaw is otherwise of a generally conventional configuration, having a moulded lower wall (of a pointed type, with a pointed front 133 ) and the upper wall, with the opening 131 for the jaw 124 being defined therebetween.
The toggle is mounted within a hole 134 in the upper wall 132 and is mounted for rotation about a pivot axis, as defined by a peg or bolt 136 that passes through the hole 134 in a transverse direction (i.e. transverse to the sideplates 120 of the coupler 110 ). The head 135 and nut 137 of the bolt are shown in FIG. 12 .
The toggle may pivot about the bolt 136 between an open position, as shown in FIG. 10 , in which the toggle sits fully within the hole 134 , and a closed position, as shown in FIGS. 11 to 13 , in which part of the toggle still sits within the hole 134 , but in which a second end or nose 138 of the toggle extends out of the hole 134 to partially close the opening 131 of the jaw 124 .
That toggle is mounted off-centre relative to the bolt 136 , whereby it is balanced so that in a normal orientation of the coupler 110 , i.e. in an in-use orientation in which the front and rear jaws 124 , 126 (and therefore also any attachment pins held therein) are generally level to each other, the toggle's centre of gravity will cause it to rotate under the influence of gravity into that latter closed position in which the nose 138 descends into the front jaw so as to partially close the opening 131 of the front jaw 124 .
By having this arrangement, in normal use an attachment pin 140 within that front jaw 124 will only be able to be removed from the front jaw 124 through the opening 131 of the jaw 124 if the toggle was to rotate out of its way. That is because attachment pins 140 have a size corresponding generally to the height of the front jaw 124 . However, further rotation of that toggle is not possible due to the configuration of the toggle, the bolt 136 and the hole 134 . The toggle in its closed position has a wall 148 that bears against a front wall member 142 of the hole 134 (see FIG. 13 ). Further, preferably that front wall member 142 , the bolt 136 and the toggle are all reinforced, toughened or hardened as well, whereby they should be able to resist even a significant attempt to force an attachment pin 140 out of the jaw.
Referring now to FIG. 13 , specific details of the preferred arrangement for the toggle, the hole 134 , the bolt 136 and the front wall member 142 will now be described.
The toggle preferably comprises at its first end two perpendicular walls 144 , 148 that tangentially extend from a curved section 146 . There is also a third wall 149 that extends parallel to and perpendicular to the two other walls 144 , 148 , respectively. Further, that first end has an aperture therein through which the bolt 136 passes for pivotally mounting the toggle within the hole 134 of the front jaw 124 . The aperture is between the two parallel walls 148 , 149 and runs parallel to all three walls 144 , 148 , 149 .
The hole 134 in the upper wall 132 of the front jaw 124 has a flat bottom 151 and the inside surface of the front wall member 142 extends perpendicular to that flat bottom 151 . That inside surface also is flat.
The bolt 136 is arranged through the hole 134 of the first jaw 124 in a position that is spaced from, yet parallel to, both the flat bottom 151 and the inside surface of the front wall member 142 . The distance of the bolt 136 from the inside surface is slightly greater than the radius of the curved section 146 of the toggle. The distance of the bolt 136 from the flat bottom is greater than its distance from the inside surface.
The aperture in the toggle is arranged concentrically to the curved section 146 of the toggle. As a result, the toggle will be free to rotate within the hole 134 through a full 90° range of angles, i.e. between its open and closed positions. In the open position, the first of the two perpendicular walls 144 , 148 will bear against the front wall 142 to provide a first rotation limitation for the toggle. In the closed position, the second of the two perpendicular walls 144 , 148 will bear against the front wall 142 to provide a second rotation limitation for the toggle. Changing the angle between these two perpendicular walls 144 , 148 will therefore change the available range of angles of rotation for the toggle.
In addition, the toggle comprises a second end 138 —the end that extends out of the hole 134 when the gravity-operated member 130 is in its closed position. That end 138 comprises a curved wall 150 that will face towards an attachment pin 140 within the front jaw 124 when the member 130 is in its closed position. That curved surface, although optional, provides an increased area of surface contact between the attachment pin 140 and the toggle in the event of an attempt to remove the attachment pin 140 from the front jaw 124 through the opening of the jaw 124 when the member 130 is in its closed position. As a result, forces are less concentrated on the toggle.
No biasing member is provided for the toggle, whereby it relies purely upon gravity for its orientation. However, as a result it is free to rotate within that 90° range if it is acted upon by an external force. Accordingly, although the toggle will prevent the withdrawal of an attachment pin 140 from the front jaw 124 , the toggle will rotate to allow an attachment pin 140 to be inserted into the jaw 124 (as shown in FIG. 10 ).
By positioning the aperture for the bolt 136 in the first end of the toggle, the centre of gravity of the toggle is arranged towards the second end of the toggle relative to its pivot axis. Thus the gravity-operated member 130 , which is mounted in the upper wall 132 of the front jaw 124 (which upper wall 132 extends generally parallel to the longitudinal axis of the coupler 110 ) will default to a closed position whenever the coupler is level (e.g. as shown in FIG. 11 ). However, the toggle can be opened by rotating the coupler clockwise (as seen in the drawings) through an angle of about 90°, i.e. into the crowd position.
Referring now to FIGS. 14 , 15 and 16 , an alternative embodiment of the present invention is disclosed in which an alternative gravity-operated member 130 is provided.
Instead of the coupler having a primary coupling mechanism in accordance with GB2359062, the coupler of this embodiment features a primary coupling mechanism involving a latching hook 154 and a blocking bar 152 for that latching hook 154 , similar to that disclosed in GB2330570, the disclosures of which are incorporated herein by way of reference. Yet further, the front jaw is formed from two sideplates 153 , rather than having the moulded, pointed, configuration of the first embodiment. Both configurations, however, are generally conventional and interchangeable.
In accordance with this alternative embodiment, the gravity-operated member 130 features a flap member that has a first pivot axis 136 that extends in a generally longitudinal direction of the coupler 110 . Therefore, to allow it to rotate out of the opening of the jaw 124 from its locked position (as shown in FIG. 14 ), the coupler 110 needs to be inverted to a greater degree than the first embodiment—it must be almost completely inverted in order for gravity to cause it to rotate about its pivot axis into its open position. Additionally, however, the flap member has a second pivot axis 156 —a hinge axis. That second pivot axis 156 can be free swinging between a straight and folded position or it may be spring biased to keep it closed even when the coupler is inverted. The hinge, however, will have a rotation stop (not shown) as known in the art of hinges, to prevent it from swinging in the opposite direction to that shown in FIG. 15 , whereby an attachment pin can be inserted into the jaw, but by means of which the attachment pin cannot be removed from the jaw without inverting the coupler. Thus the hinged flap can also provide a similar function to the toggle of the first embodiment.
Referring now to FIGS. 17 to 32 , another embodiment of the present invention is shown. In many ways this is similar to the embodiment disclosed in FIGS. 1 to 9 . Thus similar or corresponding features of this embodiment to that earlier embodiment have been given the same reference signs.
This further coupler design also has a pivoting latching hook 26 that is adapted for rotation about a pivot 28 for locking an attachment pin 54 in a rear jaw 22 of the coupler 10 . That pivoting latching hook 26 is also power operated under the control of a hydraulic ram 32 .
The hydraulic ram 32 is attached at the free end of its piston to the latching hook 26 at a first pivot axis 29 . The free end of the cylinder of that hydraulic ram 32 is attached to the frame 38 of the coupler 10 at a second pivot axis. That second pivot axis is centered on the bearing hole 40 of the mechanical stop 36 . Thus a single axle 41 can be provided for both the cylinder of the hydraulic ram 32 and the mechanical stop 36 .
As shown in FIG. 17 , that axle 41 extends through both sidewalls of the frame 38 of the coupler 10 .
The pivoting latching hook 26 has also again got an attachment pin facing surface 64 which engages against a rear attachment pin 54 when an accessory is coupled to the coupler 10 .
The pivoting latching hook 26 also again has a back surface 66 against which an end 56 of the mechanical stop 36 bears when it is in a latching position behind (or “in front of” when referring to its relative position in relation to the coupler as a whole) that hook 26 . That is clearly shown in FIG. 18 .
The back surface 66 of the pivoting latching hook 26 also again features a flange 68 that also serves to support the mechanical stop 36 for preventing the mechanical stop 36 from swinging into a front-jaw opening position while an attachment pin is retained within the rear jaw 22 by the latching hook 26 .
As for the second latch 34 , however, although it is similarly positioned for at least partially closing the mouth of the front jaw 24 , its interaction with the mechanical stop 36 is different—in this embodiment, the second latch 34 is not connected to the mechanical stop 36 , although the two elements can selectively engage each other under certain conditions. Instead it is mounted for pivotal movement about its own separate pivot axle 243 , much like the gravity operated member of FIGS. 10 to 16 .
The interaction between the pivoting latching hook 26 , the mechanical stop 36 and the second latch 34 will be further described below.
With reference to FIGS. 19 to 23 , a preferred method of coupling an accessory to the coupler 10 will now be described.
As can be seen, the aim is to achieve the completed attachment as shown in FIG. 19 , i.e. with the two attachment pins 52 , 54 of an accessory (not shown) safely secured within the two jaws 22 , 24 of the coupler 10 —the rear attachment pin 54 is held by the pivoting latching hook 26 in the rear jaw 22 , thus also preventing movement of the front attachment pin 52 within the front jaw 24 , but with the front jaw 24 also at least partially closed by the second latch 34 so that the front attachment pin 52 would not be free to exit the front jaw 24 in the event of an incorrect mounting of the rear attachment pin 54 within the rear jaw 22 by the pivoting latching hook 26 .
To achieve that completed attachment, the first step, with an uncoupled coupler 10 , is to power the hydraulic ram 32 to a fully extended state, for fully extending the pivoting latching hook 26 rearwardly across the rear jaw for closing that rear jaw. See FIG. 20 . By powering that latching hook 26 rearward, the flange 68 extending from the back surface 66 of the latching hook 26 clears away from of the end 56 of the mechanical stop 36 . Then, with the coupler in a normal, non-inverted orientation, i.e. preferably with the two jaws at approximately the same height with respect to each other, the mechanical stop 36 will fall past that flange into a fully rotated position—the third or predetermined non-latching position, whereat further rotation is prevented by a stop 245 provided on the frame or main body 38 of the coupler 10 . This stop 245 is illustrated schematically in FIG. 20 and is likely to be some integral component of the base of the frame 38 of the coupler 10 .
With the mechanical stop 36 in that predetermined non-latching position, the opposite end 247 of it—extending away from the pivot axle 41 in a different direction—will have lifted to move a flange 249 of it clear of a corresponding flange 251 on the second latch 34 . The second latch is therefore then free to rotate between a closed or locked condition into a non-closed position.
The interrelation between those flanges, and the rotation of the second latch 34 between a closed or locked condition and the non-closed position will be described in greater detail below.
Since the second latch 34 is now free to rotate through its full range of motion within the frame 38 of the coupler 10 , a front attachment pin 52 can be slotted through the mouth of the front jaw 24 as shown in FIG. 20 . During that process, the front attachment pin 52 will rotate the second latch 34 up into the roof of the jaw 24 so that it can pass that second latch 34 for locating into the rear of that jaw 24 . The second latch will then fall again under the influence of gravity into a closed position, thereby locking that attachment pin within that jaw 24 . That therefore is a first safety feature of the present invention—the accessory cannot now accidentally decouple itself from that front jaw 24 .
The accessory, however, is only presently half coupled to the coupler 10 . Thus it is now necessary to have the rear attachment pin 54 secured into the rear jaw. For that, as shown in FIG. 21 , and by the arrow 253 in FIG. 20 , the coupler 10 and accessory, with it two attachment pins 52 , 54 , is rotated by crowding the excavator arm so as to place the accessory generally above the coupler 10 .
During that rotation, if the front attachment pin 52 was not already fully engaged into the rear of the front jaw 22 , the weight of the accessory will pull the front attachment pin 52 tightly into the rear of the front jaw 22 . Further, the weight of the accessory will causes the rear pin 54 of the accessory to bear against the underside (or now top side since the coupler is inverted) of the pivoting latching hook 26 . Yet further, due to the inversion of the coupler, and the arrangement of the moment of inertia of the mechanical stop 36 , that mechanical stop 36 will also rotate under the influence of gravity (in a counter-rotation direction relative to the rotation of the coupler) so as to fall into a non-latching position away from the back surface 66 of the pivoting latching hook 26 .
As the mechanical stop rotates in that manner relative to the coupler, a bearing surface 255 on its flange 249 (at its opposite end of the mechanical stop) then engages a bearing surface 257 on the adjacent flange 251 of the second latch 34 for biasing that second latch 34 into its jaw-closing position, thus again ensuring a secure initial coupling of the first attachment pin 52 to the coupler 10 . Thus, even though still only one attachment pin is within a jaw of the coupler 10 (the front jaw 24 ), the accessory would still not fall out of the front jaw 22 even if the coupler was to be further rotated, despite it being inverted, due to the second latch now being biased into its closed position.
Whilst in that inverted condition, the next step is to power the hydraulic ram to draw back the pivoting latching hook 26 into a retracted, jaw-open position, as shown in FIG. 22 . This has to be done while the coupler 10 is inverted in order not to have the mechanical stop 36 blocking its path.
As a result of the retraction of the pivoting latching hook 26 , the rear attachment pin 54 will fall into the rear jaw 22 under the weight of the accessory.
Once the rear attachment pin is located in that rear jaw 22 , the hydraulic ram 32 is again powered to extend the pivoting latching hook 26 back across the rear jaw 22 for securing the pin 54 within the rear jaw 22 .
The coupler 10 can then be rotated back to a non inverted condition by uncrowding the excavator arm, as shown by arrow 259 in FIG. 22 .
Once normally oriented, the mechanical stop 36 falls back into a latching position on the flange 68 (or on one of the stepped surfaces provided on the back surface of the hook 26 if a narrower pin spacing is provided for the accessory), as shown in FIG. 23 . The accessory is thus now correctly coupled to the coupler 10 .
Referring next to FIGS. 24 and 25 , further details of the second latch, and its interaction with the mechanical stop 36 , will be described.
As shown in FIG. 24 , the coupler 10 , with an attached accessory, has been rotated to an angle of approximately 45° relative to the level orientation. The mechanical stop 36 is still in its blocking position behind the latching hook 26 . Further, the two attachment pins 52 , 54 are securely locked within the jaws 22 , 24 of the coupler 10 . Yet further, due to the orientation of the coupler, the second latch 34 has rotated under its own weight into a non fully closed position.
Referring then to FIG. 25 , which is an enlarged view of the second latch 34 and the mechanical stop 36 , while the coupler 10 is still rotated to an angle of approximately 45° relative to the level orientation, it can be seen that the second latch 34 has a pivot axle 243 , about which it rotated into the illustrated non fully closed position. Further it has a first flange 261 extending in a first direction away from that axle 243 . That flange 261 serves to at least partially close the front jaw 24 when the second latch 34 is in a closed position (such as this non fully closed position, or the fully closed position of FIG. 23 ). Yet further the second latch 34 has a second flange 251 . That flange 251 is the flange mentioned above that has the bearing surface 257 that engages with the bearing surface 255 of the mechanical stop when the coupler 10 has been inverted into a crowd position. There is also a third flange 285 which will be described in greater detail below with reference to FIGS. 31 to 33 .
It should be appreciated that the mechanical stop 36 is in a blocking position. Thus its end 56 bears down on the flange 68 of the pivoting latching hook 26 (not shown in FIG. 25 —see instead FIG. 24 ). As a result, rotation of the mechanical stop 36 in a further anti-clockwise direction (as viewed in FIG. 25 ) is not possible. As a result of that, the mechanical stop, in this blocking position serves two purposes. Firstly it serves to prevent retraction of the pivoting latching hook 26 from its latched position, as per the prior art. Secondly, however, it serves to prevent rotation of the second latch into a non jaw closing position in the roof of the front jaw 24 . That is achieved s follows:
The bearing surface 257 on the second flange 251 of the second latch 34 bears against the point 263 of the flange 249 on the mechanical stop 36 prior to the second latch 34 achieving a position in which the front attachment pin 52 can exit the front jaw 24 . Attempts to further rotate the second latch will also be in vain due to the inability for the mechanical stop to rotate further anti-clockwise due to it already bearing against the flange 68 of the pivoting latching hook (as discussed above). Thus this arrangement provides a highly secure coupling of an accessory onto the coupler in that neither jaw can be opened while the coupler is in a normal orientation.
It should also be appreciated that with narrower pin spacings, the mechanical stop would be rotated even less anti-clockwise due to it sitting on one of the stepped surfaces on the back surface 66 of the hook 26 . Thus the degree of available rotation for the second latch 34 from a fully closed condition would be even more restricted.
In view of the above arrangement, a special procedure needs to be followed for decoupling an accessory from the coupler 10 of this embodiment. This procedure will now be described with reference to FIGS. 26 to 30 .
The first action to taken is to rotate the coupler, and the accessory, into the crowd position, as shown in FIG. 26 for inverting the coupler. The mechanical stop 36 will then falls away from behind the back surface 66 of the hook 26 (and the second latch 34 will also be biased into the fully closed position as discussed above). This position is shown in FIG. 26 .
Once in that position, the rear jaw 22 can then be opened by powering the pivoting latching hook 26 into a retracted position as shown in FIG. 27 . That then unlocks the rear attachment pin 54 from its containment within the rear jaw 22 .
To then remove the rear attachment pin 54 from the now open rear jaw 22 , the coupler 10 and accessory are once again rotated from the crowd position and the accessory is then rested on the floor so as to allow the coupler 10 and the accessory to be rotate relative to one another about the front attachment pin 52 within the front jaw 24 as the excavator arm is further operated.
That relative rotation (see the arrow 265 in FIG. 28 ) then draws the rear attachment pin 54 clear of the rear jaw 22 , as shown in FIG. 28 .
Once the rear attachment pin 54 is clear of the rear jaw 22 , and while the accessory is resting on the floor (in the case of a bucket, in a tipped condition), the pivoting latching hook 26 can then again be powered into a fully extended condition across the mouth of the rear jaw 22 , as shown in FIG. 29 , for moving the flange 68 clear of the mechanical stop. The mechanical stop is then free to assume the third or predetermined position for releasing the second latch 34 —in that third or predetermined position, the point 263 of the flange 249 of the mechanical stop 36 is displaced sufficiently far away from the flange 251 of the second latch 34 that they won't engage one another. Thus the coupler can then be further manipulated by the excavator arm to orient the coupler nearly on end so as to fully open the front jaw 24 —see FIG. 30 . The accessory can then be released from the coupler 10 by lowering the coupler with respect to the front attachment pin of the accessory. The accessory will then fall to its rest position on the ground, decoupled from the coupler 10 .
To facilitate that final decoupling, the first flange 261 of the second latch 34 has a ramped nib 267 on its end, whereby even if the first flange 261 of the second latch 34 is not fully oriented into the roof of the front jaw 24 by the rotation of the coupler 10 , the passing of the attachment pin 52 out of the front jaw 24 against the nib 267 will push the second latch into that fully open position.
A beneficial result of this decoupling procedure can also be seen in that the coupler 10 is immediately ready for coupling to another accessory—the pivoting latching hook is already in its fully extended condition.
Referring finally to FIGS. 31 to 33 , further details of the second latch 34 and its interaction with the frame 38 of the coupler 10 will be described in further detail.
As previously described, the second latch 34 is mounted onto the frame via a pivot axle 243 . For that purpose, the frame 38 has two coaxial through-holes 269 in side walls 275 of a rail 277 . Further, those holes can be aligned with a through-hole 271 in the second latch 34 , and the axle 243 is then threaded through those three holes. The holes are shown in FIGS. 32 and 33 .
Once the axle 243 has been threaded through those through-holes 269 , 271 , one or more cotter pin 273 , or the like, is used to retain that pivot axle 243 within the frame 38 and the second latch 38 .
The second latch 34 is thus pivotally mounted to the frame 38 via a rail 277 that is integrally formed on the front 16 of the frame 38 of the coupler 10 .
The rail 277 has an inside surface that is adapted to be born against by the front of the first flange 261 of the second latch 34 . Preferably that front is a front-most surface 279 on the leading face of the first flange 261 when the second latch is in a fully closed condition.
The front 279 is preferably planar but may instead be curved. Preferably the inside surface 281 of the rail 277 has a corresponding shape to provide a large surface area of contact between the second latch 34 and that rail 277 when the second latch is in its fully forward or fully closed position.
As also shown in FIG. 33 (in which the second latch 34 and the pivot axle 243 have been removed for clarity), a further load bearing surface 283 is formed on the frame 38 of the coupler 10 . This additional load bearing surface 283 is spaced from the inside surface 281 of the rail 277 but is again integrally formed with the frame 38 .
It should be noted that the rail and the load bearing surface may be welded to, or otherwise connected to, the frame 38 .
The additional load bearing surface 283 is also for bearing any load carried by the frame when the second latch 34 is in a fully closed condition, further to spread the load. For that purpose, the third flange 285 (mentioned above) is provided on the second latch 34 .
That third flange is clearly shown in FIG. 32 , in which the frame has instead been removed for clarity.
That third flange 285 has a bearing surface 287 on its underside. It is positioned so that it bears against the additional load bearing surface 283 whenever the front of the second latch is bearing against the inside surface of the rail. It this provides the additional surface area against which the second latch can bear when it is in its fully closed position.
The additional area is particularly beneficial since it spreads the loading on the frame in the event of the second latch being tasked to carry the weight of an accessory on it, such as due to a failure of some other component of the coupler (such failure releasing the attachment pin in the rear jaw 22 ), or in the event of an improper mounting state for the accessory. Simply loading such a potential force onto the rail might overload the rail.
Preferably the two bearing surfaces 287 (on the first and third flanges 285 of the second latch 34 are planar and substantially perpendicular to one another.
In this embodiment it is also shown that the third flange 285 extends only part way across the width of the second latch (i.e. in the axle direction). It stops clear of the arm of the mechanical stop. Further, where it ends, the second flange 251 starts. In this manner, the mechanical stop will not interfere with the operation of the third flange.
The third flange is in a different plane to the second flange of the second latch 34 .
It is also observed that the front of the second latch 34 has two additional surfaces—the ramped nib 267 described above and an intermediate ramp 289 . Those two additional surfaces may be blended to form a curve, which curve may be blended with the front planar surface 279 . Those surfaces allow or assist the above described camming of the second latch 34 into the roof of the jaw 24 as the front attachment pin 52 exits the jaw 24 during the last stage of the decoupling procedure.
Various aspects of the present invention have been described above purely by way of example. It should be noted, however, that modifications in detail can been made within the scope of the invention as defined in the claims appended hereto, and elements of one aspect might be combined with elements of the other aspects, as would be appreciated by a skilled person.
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Couplers for attaching an accessory to an excavator arm of an excavator. Couplers having a first side for attaching the coupler to the excavator arm and a second side onto which the accessory will be coupled. The coupler includes a latch for selectively securing and releasing an attachment pin of the accessory in a jaw, groove, hook or slot in the second side of the coupler. The coupler is fully controllable from within the cab of the excavator and it allows improved security in the securement of the accessory to the coupler, i.e. preventing accidental decouplings, but while still allowing intentional decoupling operations to be carried out without undue burden.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2004-339344, filed on Nov. 24, 2004 the entire contents of which are incorporated herein by reference.
BACKGROUND
[0002] The present disclosure relates to an embroidery frame that holds a workpiece cloth to be sewn between an outer frame and an inner frame.
TECHNICAL FIELD
[0003] Conventional embroidery frames have generally been constructed by an outer frame and an inner frame. Tension is applied to workpiece cloth placed on the outer frame by pressing the inner frame into the outer frame. A fastening screw is provided on the outer frame, and the fastening screw is tightened so that the workpiece cloth is clamped between the outer and inner frames.
[0004] The embroidery frame having the above construction is disclosed, for example, in JP-U-7-15793. The outer frame of the embroidery frame is provided with a scale corresponding to a thickness of the workpiece cloth. An end of the fastening screw is aligned with the applicable scale in tightening the fastening screw.
[0005] The embroidery frame is attached to an embroidery frame driving mechanism of a sewing machine, which is capable of embroidery sewing with the workpiece cloth clamped between the outer and inner frames. By moving the embroidery frame independently in two mutually perpendicular directions by the embroidery frame driving mechanism, embroidery is formed on the workpiece cloth.
[0006] The above-described embroidery frame includes embroidery frames in an oblong form having a pair of circular-arc ends which are connected by a pair of substantially straight portions or substantially rectangular forms having a pair of long sides and a pair of short sides. For example, FIG. 12 is a longitudinal side section of a substantially rectangular embroidery frame 100 . As shown in FIG. 12 , the embroidery frame 100 is constructed by an inner frame 101 and an outer frame 102 that clamp a workpiece cloth 103 therebetween. A cloth-clamping surface 101 a of the inner frame 101 and a cloth-clamping surface 102 a of the outer frame 102 are arranged so as to be perpendicular to the upper or the lower surface of the inner frame and the outer frame respectively.
[0007] However, in the embroidery frame 100 having the above described construction, there are cases where long sides 101 b of the inner frame 101 are deformed so as to be bent in the upward direction by the tension of the workpiece cloth 103 . When the long sides 101 b of the inner frame 101 are thus deformed so as to be bent upwards, the workpiece cloth 103 cannot securely be clamped by the inner and outer frames 101 and 102 , and the embroidery area of the workpiece cloth 103 cannot be retained in a flat state. Hence, embroidery sewing performed under such a condition results in a shrinking of the workpiece cloth, thereby deforming the embroidery pattern and reducing the sewing quality.
[0008] Furthermore, in the above embroidery frame 100 , as shown in FIG. 13 , when a fastening screw 104 is loosened and the outer frame 102 is spread, the shape of the inner periphery of the outer frame 102 and the shape of the outer periphery of the inner frame 101 are not similar. Therefore, it is difficult to accurately determine the location in which the inner frame 101 is to be fitted with the outer frame 102 , which is located below the workpiece cloth 103 ; and in some cases, the workpiece cloth 103 is clamped with the inner frame 101 misplaced with respect to the outer frame 102 . In such a case, since the workpiece cloth 103 is not evenly held between the cloth-clamping surfaces 101 a and 102 a of the inner and outer frames 101 and 102 , embroidery sewing performed under such a condition again results in the shrinking of the workpiece cloth, consequently deforming the embroidery pattern and impairing the sewing quality.
[0009] The above described problem occurs also in substantially elliptic embroidery frames or in oval-form embroidery frames.
SUMMARY
[0010] Therefore the object of the present disclosure is to provide an embroidery frame that prevents the upward-bending deformation which is caused by the tension of the workpiece cloth.
[0011] An embroidery frame of the present disclosure is detachably attached to an embroidery unit and is provided with an outer frame and an inner frame that clamp embroidery cloth. The embroidery frame comprises a first inclined surface which is provided at least on a part of a cloth-clamping surface of the outer frame that holds the cloth between the inner and outer frames, and which is upwardly inclined toward an inside of the outer frame; and a second inclined surface which is provided in a portion of the cloth-clamping surface of the inner frame corresponding to the first inclined surface, the inner frame holding the cloth between the outer and inner frames, and which is upwardly inclined toward an inside of the inner frame.
[0012] According to the above-described construction, when the cloth to be embroidered is clamped between the outer and inner frames, the first inclined surface of the outer frame contacts the second inclined surface of the inner frame from the obliquely upward direction. Therefore, even if a force to transform the inner frame in the upward direction is operated on the inner frame by the cloth tension, the outer frame does not allow the upward transformation of the inner frame, and the cloth can be securely clamped between the outer frame and the inner frame. Also, since the embroidery area portion of the cloth can be retained as a flat surface, the quality of the embroidery pattern formed on the embroidery area portion can be improved.
[0013] In this case, when the outer and inner frames are each formed in a substantially elliptic or oval form that has a circular-arc portion and a substantially straight portion, the first and second inclined surfaces are desirably provided on the cloth-clamping surface of the substantially straight portion of the outer frame and the cloth-clamping surface of the substantially straight portion of the inner frame respectively.
[0014] Also, in case the outer and inner frames are each formed in a substantially rectangular form having a long side and a short side, the first and second inclined surfaces are desirably provided on the cloth-clamping surfaces of the long sides of the outer and inner frames respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Other objects, features and advantages of the present disclosure will become clear upon reviewing the following description of the illustrative aspects with reference to the accompanying drawings, in which,
[0016] FIG. 1 shows a plan view of an embroidery frame according to a first illustrative aspect of the present disclosure;
[0017] FIG. 2 shows a plan view of an outer frame;
[0018] FIG. 3 shows a plan view of an inner frame;
[0019] FIG. 4 shows a longitudinal sectional side view of the embroidery frame;
[0020] FIG. 5 shows an enlarged sectional view taken along line 5 - 5 of FIG. 1 ;
[0021] FIG. 6 shows an enlarged sectional view taken along line 6 - 6 of FIG. 1 ;
[0022] FIG. 7 shows an enlarged sectional view taken along line 7 - 7 of FIG. 1 ;
[0023] FIG. 8 shows an enlarged sectional view taken along line 8 - 8 of FIG. 1 ;
[0024] FIG. 9 shows an enlarged sectional view taken along line 9 - 9 of FIG. 1 ;
[0025] FIG. 10 shows an enlarged sectional view taken along line 10 - 10 of FIG. 1 ;
[0026] FIG. 11 shows a plan view of an embroidery frame according to a second illustrative aspect of the present disclosure;
[0027] FIG. 12 shows a longitudinal sectional side view of a conventional embroidery frame attached with a workpiece cloth; and
[0028] FIG. 13 shows a plan view of a conventional embroidery frame attached with a workpiece cloth,
DETAILED DESCRIPTION OF THE INVENTION
[0029] A first embodiment of the present invention will be described with reference to FIGS. 1 to 10 . In the embodiment, the invention is applied to an embroidery frame attached to an embroidery unit of a sewing machine capable of embroidery sewing. Referring to FIG. 1 , an embroidery frame 1 according to the present invention is formed in an elongated substantially elliptic form or an oval form; and is constructed by an outer frame 2 and an inner frame 3 , which is attached to the inner side of the outer frame 2 so as to clamp the workpiece cloth. Therefore, an inner peripheral surface of the outer frame 2 is defined as a cloth-clamping surface 2 a and an outer peripheral surface of the inner frame 3 is defined as a cloth-clamping surface 3 a.
[0030] The outer frame 2 is formed by a synthetic resin, and as shown in FIG. 2 , is constructed in an elongate substantially elliptic form having a pair of substantially straight portions 2 A and a pair of circular-arc portions 2 B. In FIG. 2 , symbol A indicates a range of each substantially straight portion 2 A.
[0031] The outer frame 2 is provided with a link portion 21 , a fastening screw mechanism 22 , an engagement recess 23 functioning as a locating portions and a plurality of inner frame receiving portions 24 a formed in a tongue-like form. The link portion 21 is detachably linked to a carriage of an embroidery frame driving mechanism of the embroidery unit.
[0032] The fastening screw mechanism 22 increases and decreases the width of a splitting portion located near the center of one of the circular-arc portions 2 B of the outer frame 2 , and is provided with an operator 22 a . Before attaching the inner frame 3 to the outer frame 2 , the width of the splitting portion of the outer frame 2 is to be increased by rotating the operator 22 a . Then, after arranging the workpiece cloth 4 in a tensed state by pressing the inner frame 3 into the outer frame 2 along with a workpiece cloth 4 , the operator 22 a is rotated, and the width of the splitting portion of the outer frame 2 is narrowed. Thus, the workpiece cloth 4 is firmly clamped between the outer and inner frames 2 and 3 .
[0033] An engagement recess 23 is formed on the inner surface (cloth-clamping surface 2 a ) in the center of the other circular-arc portion 2 B of the outer frame 2 . The engagement recess 23 is provided for locating the inner frame 3 with respect to the outer frame 2 in the predetermined location.
[0034] The inner frame receiving portions 24 a are provided on the inner periphery of the outer frame 2 ; specifically near the center of the substantially straight portions 2 A and in the lower portion near the border of the substantially straight portions 2 A and the circular-arc portions 2 B (refer to FIGS. 7, 9 and 19 ). When the inner frame 3 is attached to the outer frame 2 , the inner frame receiving portions 24 a contact a lower end of the inner frame 3 from the underside and receive the inner frame 3 . Thus, the inner frame 3 is attached to the outer frame 2 in a predetermined vertical location.
[0035] On the other hand, the inner frame 3 is formed by a synthetic resin. As shown in FIG. 3 , the inner frame 3 is constructed in an elongated substantially elliptic form having a pair of substantially straight portions 3 A corresponding to the substantially straight portions 2 A of the outer frame 2 and a pair of circular-arcs 3 B corresponding to the circular-arcs 2 B of the outer frame 2 . Symbol A in FIG. 3 indicates a range of the substantially straight portions 3 A of the inner frame 3 . That is, the range of the substantially straight portions 2 A and the substantially straight portions 3 A are the same.
[0036] A substantially oblong opening is formed in the inner side of the inner frame 3 , and embroidery can be formed on the portion of the workpiece cloth 4 that corresponds to the opening when the workpiece cloth 4 is clamped between the outer and inner frames 2 and 3 .
[0037] The substantially straight portions 3 A of the inner frame 3 are formed so that the widths gradually increase toward the center thereof from the lengthwise ends for securement of rigidity. Also, the circular-arcs 3 B of the inner frame 3 are formed so that the widths rapidly increase toward the center from both ends of the circular-arc portion for securement of rigidity.
[0038] One of the circular-arc portions 3 B corresponding to the circular-arc 2 B of the outer frame 2 is formed with a centrally located protrusion 31 functioning as a locating portion to be engaged to the engagement recess 23 . The protrusion 31 is formed across the entire vertical direction of the cloth-clamping surface 3 a of the inner frame 3 .
[0039] As shown in FIGS. 5 to 8 , the cloth-clamping surfaces 2 a and 3 a of the substantially straight portions 2 A and 3 A of the outer frame 2 and the inner frame 3 are constructed as an inclined surface upwardly inclined, for example, 10 to 20 degrees toward the inner side of the embroidery frame 1 . That is, the cloth-clamping surfaces 2 a and 3 a correspond to the first and the second inclined surface of the present invention respectively. As opposed to this, as shown in FIG. 4 , the outer and inner frames 2 and 3 include portions other than the substantially straight portions 2 A and 3 A, that is, the cloth-clamping surfaces of the circular-arc portions 2 B and 3 B formed on surfaces perpendicular to the upper or lower surface of the outer and inner frames 2 and 3 respectively.
[0040] Therefore, when the workpiece cloth 4 is clamped between the outer and inner frames 2 and 3 , the cloth-clamping surface 2 a of the straight portion 2 A of the outer frame 2 contacts the cloth-clamping surface 3 a of the straight portion 3 A of the inner frame 3 from the obliquely upward direction via the workpiece cloth 4 . Hence, even if the tension of the workpiece cloth 4 operates, upward-bending deformation of the straight portion 3 A of the inner frame 3 is restrained by the outer frame 2 , and both the outer frame 2 and the inner frame 3 can be kept in a horizontal state as shown in FIG. 4 . Also, upward movement of the inner frame 3 by the tension of the workpiece cloth 4 is also restrained by the outer frame 2 .
[0041] Furthermore, upon attachment of the inner frame 3 to the outer frame 2 , the protrusion 31 is arranged to be engaged to the engagement recess 23 of the outer frame 2 . Thus, the inner frame 3 can be attached to the outer frame 2 in a predetermined location. Moreover, since the inner frame 3 is arranged to be received by the inner frame receiving portion 24 a provided on the outer frame 2 , the attachment can be made such that the inner frame 3 has a predetermined relation of vertical location with respect to the outer frame 2 .
[0042] FIG. 11 indicates a second embodiment of the present invention. Only the difference of the second embodiment from the first embodiment will be described. In the second embodiment, an embroidery frame 10 is formed in a substantially oblong form. That is, the outer and inner frames 12 and 13 of the embroidery frame 10 are provided with a pair of long sides 12 A and 13 A and a pair of short sides 12 B and 13 B respectively.
[0043] Though, not shown, a whole or a part of the cloth-clamping surface of the long sides 12 A and 13 A are arranged in an upward inclined surface inclined inward to the embroidery frame 10 . Also, an engagement recess 23 A is formed in the substantial lengthwise center of the short side 12 B of the outer frame 12 , and a protrusion 31 A is formed in the substantial lengthwise center of the short side 13 B. Furthermore, though not shown, a plurality of inner frame receiving portions similar to the inner frame receiving portions 24 a are formed on the long side 12 A of the outer frame 12 .
[0044] The same operational effect obtained in the first embodiment can be achieved in the above construction as well.
[0045] The present invention is not limited to the above described embodiments but can be transformed, for example, as follows.
[0046] A plurality of inner frame receiving portions may be provided on the entire range of the inner periphery of the outer frame spaced apart in predetermined intervals.
[0047] The present invention is not limited to a substantially elliptic form and a substantially oblong embroidery frame but can also be applied to a circular embroidery frame. In such a case, it is preferable to arrange each of the cloth-clamping surfaces of the outer and inner frames entirely as a inclined surface, however, only a part of the cloth-clamping surface may be arranged as a inclined surface.
[0048] The engagement recess functioning as a locating portion can be provided on the inner frame and the protrusion can be provided on the outer frame.
[0049] The foregoing description and drawings are merely illustrative of the principles of the present disclosure and are not to be construed in a limited sense. Various changes and modifications will become apparent to those of ordinary skill in the art. All such changes and modifications are seen to fall within the scope of the disclosure as defined by the appended claims.
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An embroidery frame is disclosed which is detachably attached to an embroidery unit and provided with outer and inner frames clamping embroidery cloth. The embroidery frame includes a first inclined surface which is provided at least on a part of a cloth-clamping surface of the outer frame that holds the cloth between the inner and outer frames, and which is upwardly inclined toward an inside of the outer frame. The embroidery frame further includes a second inclined surface which is provided in a portion of the cloth-clamping surface of the inner frame corresponding to the first inclined surface, the inner frame holding the cloth between the outer and inner frames, and which is upwardly inclined toward an inside of the inner frame.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of making a printing hammer unit having a plurality of printing hammers secured together, and, more particularly, to a printing hammer unit having a plurality of printing hammers held by resilient members.
2. Description of Prior Arts
There has been widely known a printer of a type, in which a character wheel or belt having characters arranged therearound or thereon is rotated or moved, and the characters on the character wheel or belt are impacted by printing hammers on recording paper interposed between the character holding member and the printing hammers to thereby record the characters on the recording paper.
Further, a printer having such hammers held by springs studded on a base has already been proposed by the applicant in U.S. application Ser. No. 565,225.
In these printers, a plurality of printing hammers must be disposed in juxtaposed relationship when printing is to be effected in a plurality of columns. The plurality of printing hammers so used must have a uniform hammer movement characteristic (or stroke) so as to secure uniform concentration and fixed position of the printed characters from line to line. It is also desirable that such a group of hammers be easily and accurately set. Particularly, in the printers of the above-described type, wherein the printing hammers are held by springs, it is preferable that the spring to drive each printing hammer has a uniform resiliency to secure uniform printing strokes.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method of making a hammer unit, in which a plurality of printing hammers are secured in a uniform condition.
It is another object of the present invention to provide a method of making a hammer unit, in which the printing hammers are secured with high precision.
It is still another object of the present invention to provide a method of making a hammer unit in which the printing hammers can be secured at low cost.
It is yet another object of the present invention to provide a method of making a hammer unit, in which the plurality of printing hammers have a uniform movement characteristic.
Other objects and features of the present invention will become more fully apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a printer, to which the hammer unit fabricated according to the present invention is applied;
FIG. 2A is a perspective view of the hammer unit having an electromagnet secured to each of the hammers, and permanent magnets, as shown in FIG. 1;
FIG. 2B is a perspective view of a character wheel;
FIG. 2C is a perspective view of an ink roller;
FIG. 3 is a perspective view of the hammer unit;
FIG. 4 is a perspective view for illustrating how the permanent magnet is secured to the corresponding hammer portion;
FIG. 5 is a front view of a spring base plate;
FIG. 6 is a cross-sectional view showing the spring base plate fixed in a metal mold;
FIG. 7 is a front view of the hammer portions and base portion secured to the spring base plate;
FIG. 8 is a front view of the hammer unit as completed;
FIG. 9 is a front view of another spring base plate for illustrating the manufacturing process thereof;
FIG. 10 is a front view of still another spring base plate for illustrating the manufacturing process thereof;
FIGS. 11A, 11B and 11C show general arrangement of the spring base plates for illustrating the method of making the hammer unit according to another embodiment of the present invention, wherein FIG. 11A is a front view, FIG. 11B is an exploded perspective view, and FIG. 11C is a front view of a spring base plate S having the hammer portions and the base portion secured thereto;
FIGS. 12A and 12B are for illustrating the method of making the hammer unit according to still another embodiment of the present invention, wherein FIG. 12A is a front view of the spring base plate S, and FIG. 12B is a front view of the spring base plate S having the hammer portions and the base portion secured thereto;
FIGS. 13A through 13E are for illustrating the method of making a hammer unit according to yet another embodiment of the present invention, wherein FIG. 13A is a front view of the spring base plate, FIG. 13B is a front view of the spring base plate having the hammer portions secured thereto, FIG. 13C is a front view of the spring base plate S having the hammer portions and the base portion secured thereto, FIG. 13D is a cross-sectional view showing the spring base plate fixed within a metal mold for forming the hammer portions, and FIG. 13E is a cross-sectional view showing the spring base plate fixed within a metal mold for forming the base; and
FIGS. 14A and 14B are, respectively, a front view and a partly enlarged side elevational view of the spring base plate, wherein weakening grooves, along which connecting portions may be removed, are shown to be formed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before the invention is described, a printer with which the printing hammer unit produced according to the present invention is suitable for use will first be described.
Referring to FIGS. 1 and 2, a base 11 formed of an insulative material such as plastics or the like has a plurality of leaf springs 12a and 12b disposed alternately and studded at predetermined intervals therein. The portions of the leaf springs 12b which are projected downwardly of the base 11 are electrically connected together and further connected to a hammer driving circuit 13, while the portions of the leaf springs 12a which are projected downwardly of the base 11 are individually connected to the hammer driving circuit 13. Thus, such hammer driving circuit 13 is provided in correspondence to each of the hammers which will later be described, and the leaf springs 12a are connected to the terminals 14a of the respective hammer driving circuits 13, while the leaf springs 12b are commonly connected to the terminals 14b of the respective hammer driving circuits 13.
Secured to the portions of the leaf springs 12a and 12b which are projected upwardly of the base 11 is a hammer portion 15 of plastic material for each set of adjacent leaf springs 12a and 12b. Each of such hammer portions 15 comprises an impacting section 15a for impacting a character wheel 16 to be described and a holding section 15b for holding an electromagnet 17 to be also described.
These hammer portions 15, leaf springs 12a, 12b and base 11 together constitute a hammer unit 10 (see FIG. 3), and a further base 18 is secured to the base 11 of the hammer unit 10 by means of a screw 19. A base portion 21 having a pair of permanent magnets 20a and 20b secured thereto is secured to the base 18 by means of a screw 22.
The permanent magnets 20a and 20b are made larger than the length of each hammer portion 15 and are disposed substantially parallel on the base portion 21. These permanent magnets 20a and 20b are magnetized with mutually opposite polarities as shown by the letters U and S in FIGS. 1 and 2.
An electromagnet 17, which may be securely inserted in the holding section 15b of each hammer portion, as seen in FIG. 4, comprises a metal core 17a and a coil 17b wound thereon. After the electromagnet 17 is inserted in and secured to the holding section 15b, the leads 17c and 17d of the coil 17b are electrically connected to the leaf springs 12a and 12b, respectively.
It should be noted that the permanent magnets 20a, 20b and the hammer portions 15 are positioned relative to each other so that, when no hammer driving signal is applied to the hammer driving circuit 13, the core 17a is attracted to the permanent magnets 20a and 20b against the spring forces of the leaf springs 12a and 12b, as indicated by solid lines in FIG. 1. In other words, when the permanent magnets 20a and 20b are inactive, the leaf springs 12a and 12b maintain their upright positions as indicated by dotted lines in FIG. 1.
A character wheel 16 is arranged in correspondence to such hammer portions 15, as shown in FIG. 1. Provided on the character wheel 16 (a perspective view of which is shown in FIG. 2B) are character rings 23 corresponding to the respective hammer portions 15 and each having a ring of characters thereon, and an ink roller 16a (the perspective view of which is shown in FIG. 2c) impregnated with ink and arranged in contact with the character wheel 16. The ink roller is best seen in the perspective view of FIG. 2C.
In the so constructed printer, application of a pulse signal to a terminal 13a of the hammer driving circuit 13 turns on a transistor 13b to permit a current to flow from a terminal 13c to ground through the coil 17b and the transistor 13b.
Since the coil 17b of the electromagnet 17 is so wound that when a current flows as described above, the upper portion of the core 17a in FIG. 1 may be magnetized in the north pole while the lower portion be magnetized in the south pole (in other words, the same polarities as those of the permanent magents 20a and 20b which are opposed to the core 17a), application of a pulse signal as described above causes the magnetic flux from the permanent magnets 20a and 20b to be offset by the electromagnet 17 so that the hammer portion 15 is moved leftward to a dotted-line position as shown in FIG. 1 by the force of the leaf springs 12a and 12b, and hits the character wheel 16 through a recording paper 24 interposed between the character wheel and the hammer portion.
The pulse width of the aforesaid pulse signal is selected such that application of the current to the coil 17b is discontinued at the end of the impact by the hammer portion. Therefore, as soon as the impact is completed, the hammer portion 15 is again attracted by the permanent magnets 20a and 20b to return to its initial position.
Thus, by rotatively driving the character wheel 16 at a predetermined speed, and by causing the current as described above to flow through the coil 17b of the hammer portion 15 when a desired numeric character has come to face the hammer portion, it is possible to cause the impacting section 15a of the hammer portion 15 to impact the character wheel 16 through the recording paper 24 interposed therebetween.
In the above-described printer, it is preferable that the hammer portions be secured to a group of leaf springs 12a and 12b in an identical manner, that some of the leaf springs 12a and 12b be secured to the base in an identical manner, and that the securing be accomplished easily. In other words, it is preferable that the hammer unit comprising the hammer portions 15, leaf springs 12a, 12b and base 11 be accurately and easily formed and that the individual hammer portions have a uniform movement characteristic.
The present invention is concerned with a method of making such a hammer unit and will now be described in detail by reference to the drawings. FIG. 5 shows a leaf spring base plate 25 comprising a multiplicity of leaf springs connected together. This leaf spring base plate 25 may be provided by forming slits 26 of a predetermined length at predetermined intervals in a metal plate to thereby form a plurality of leaf springs 12a and 12b having their upper and lower ends respectively connected together at end edge portions 27a and 27b (connecting portions). Such a leaf spring base plate 25, as is shown in FIG. 6, is fixedly disposed between the upper metallic mold half 28a and the lower metallic mold half 28b of a plastics molding machine. The metallic mold 28 shown in FIG. 6 is provided with a plastics casting cavity 29 for forming the hammer portion secured to a pair of leaf springs 12a and 12b (FIG. 6 shows only one such cavity, but actually a number of such cavities corresponding in number to the hammer portions shown in FIG. 7 are arranged in a direction perpendicular to the plane of the drawing sheet), and a plastics casting cavity 30 for forming the base 11. The cavities 29 and 30 are respectively provided with inlet channels 32 and 33 through which the plastic material may be poured from a plastics inlet port 31 to flow to the mold cavities. Such inlet channels 32 are also provided for the other cavities 29 not shown in FIG. 6.
Thus, a charge of plastic material may be poured through the inlet port 31 and after it is solidified, the material may be removed from the metallic mold halves 28a and 28b and separated from the portion of the solidified plastic material which clogs the inlet channels 32 and 33, whereby a leaf spring base plate 25 of plastic material including the base and hammer portions 15 formed integrally together, as shown in FIG. 7, can be obtained.
The leaf springs 12a and 12b shown in FIG. 5 have notched portions or cutaways 34a and 34b at the locations corresponding to the aforementioned hammer portions 15 and base 11, respectively, in order that the hammer portions 15 and base 11 may not move on the leaf springs 12a and 12b once they have been shaped in the mold. These cutaways are not restrictive forms but protrusions may be formed instead.
After the hammer portions 15 and base 11 have thus been fixed on the leaf spring base plate 25, the base plate is cut along a dotted line 35-35' to remove the edge portion or lug 27a, in the manner as shown in FIG. 8. By the edge portion or lug 27 being so removed, each of the hammer portions 15 is now individually held by a pair of leaf springs 12a and 12b and free to swing about the point at which each hammer portion is secured to the base 11, as the fulcrum. Also, by disconnecting and removing the leaf springs 12a from the end edge portion or lug 27b, at the position shown in FIG. 8, the leaf springs 12b are now electrically connected together, while the leaf springs 12a become electrically independent, and each hammer portion 15 is swingable about the point at which it is secured to the base 11 as the center of oscillation.
Although in FIG. 8, only a portion of each leaf spring 12a is removed at the lower portion of the base 11 so as to keep the leaf springs 12b connected to the edge portion 27b, this edge portion 27b need not always be left as such but may be entirely cut off along dotted line 37-37'. In the latter case, however, the leaf springs 12b must be electrically connected together by a separate process.
In case the hammer unit is formed by cutting off the edge portions of the leaf springs after the molding of the plastic material in the above described manner, the positions of the leaf springs 12a and 12b are accurately maintained by the edge portions 27a and 27b, if the mutual distance between the leaf springs is secured at high precision during manufacturing of the leaf base plate, the hammer unit having such positional precision can be obtained.
Further, the presence of such edge portions 27a and 27b requires a single leaf spring base plate 25 to be placed within the metallic mold only once, which also facilitates the ease with which the leaf springs are placed within the mold.
The formation of the leaf spring base plate 25 as shown in FIG. 5 may be accomplished by immersing in etching liquid a flat plate with anti-corrosion paint being applied to the areas thereof which do not correspond to the slits 26 thereby to remove only the portions which correspond to the slits, and thereafter removing the applied anti-corrosion paint. Preferably, the application of the anti-corrosion paint as well as the etching liquid may be done on both sides of the flat plate.
An alternative method of making the leaf spring base plate 25 as shown in FIG. 5 is to mechanically punch a flat blank plate. However, because of the fact that the pattern (slits) to be punched out in the leaf spring base plate 25 is fine and complicated throughout the base plate and that the spring plate providing the raw material for the base plate is generally so hard as to make it difficult to machine the punching of a required punching pattern by a single press tends to damage the press tool and, even if the punching operation itself were successful at all, the spring plate would tend to be deformed or broken due to the high shearing stress of the spring plate material. In this consequence, it is difficult to obtain a punched product of good dimensional accuracy which maintains an overall surface flatness. In such a case, therefore, it would be preferably to repeat partial punching in sequence, instead of using a single punching process for the entire portion to be punched in a single operation. More specifically, as shown in FIG. 9, a base plate 38 may first be punched only at the upper and lower parts thereof to form the upper and lower slit portions, and then punched at the central portion, thereby obtaining the leaf spring base plate 25 as shown in FIG. 5.
A further alternative is to punch a base plate progressively in the order of A, B, C, D and E as indicated in FIG. 10, whereby the slit patterns as indicated at E or the leaf spring base plate as shown in FIG. 5 may finally be obtained.
Repetition of such partial punching to provide an ultimate required punching pattern reduces the pressure load on the press tool during each pressing process to thereby prevent the tool from being damaged, and also reduces the shearing stress in the spring plate at each pressing process to thereby prevent the spring plate from being deformed or broken, therefore, this method is effective and appropriate in forming a fine and complicated punching pattern throughout a spring plate.
While formation of the leaf spring base plate 25 by either etching or punching a single base plate has hitherto been described, there is available still a further method as shown in FIG. 11. FIG. 11A shows a leaf spring base plate 40 formed either by etching or by punching which has the edge portions 41 and 42 the same as the leaf spring base plate 25 shown in FIG. 5, but this leaf spring base plate 40 differs from the latter in that the pitch of the leaf springs 43 is double that of the leaf springs 12a and 12b in the leaf spring base plate 25.
The leaf spring base plate 40 is used in a set of two plates as shown in FIG. 11B, wherein one leaf spring base plate 40a is used in its flat form, while the other leaf spring base plate 40b is used with the leaf springs 43b adjacent to the edge portions 41b and 42b being bent in the same direction. This is intended for the purpose of enabling the leaf springs 43a and 43b of the two leaf spring base plates 40a and 40b to lie on a common plane as will further be described. More specifically, the two leaf spring base plates are disposed between the metallic mold halves 28a and 28b of FIG. 6 in such a manner that each leaf spring 43b lies in the center of the slit formed between adjacent leaf springs 43a, while the leaf springs 43a and 43b lie on a common plane. Thereafter, plastic material is poured into the mold in the same manner as described in connection with FIG. 6, to thereby form the hammer portions 44 and the base 45, after which the molded unit is removed from the metallic mold, whereafter the edge portions 41a, 42a and 41b are cut off along dotted lines 46-46' and 47-47' as shown in FIG. 11C, to produce the hammer unit. In this case, the edge portion 42b which remains unremoved so as to be used as a common electrode. In the leaf spring base plate as shown in FIGS. 11A and 11B, the pitch of the leaf springs 43 is double that of the leaf springs shown in FIG. 5, as already noted, and this facilitates formation of such a leaf spring base plate 40 by punching.
FIG. 12 shows still another embodiment of the present invention. The leaf spring base plate 48 as used here is formed by previously cutting off one edge portion 41 in the leaf spring base plate 40 shown in FIG. 11A, so that it comprises only one edge portion 49 and leaf springs 50 connected thereto, as in the form of a comb.
Thus, two leaf spring base plates 48 and 48a of the above configuration are arranged in such a manner that the teeth of the leaf springs 50 and 50a lie opposite the respective edge portions 49 and 49a are mutually inserted into the space interval between the adjacent leaf spring teeth, and at equal intervals and in a common plane as shown by solid and chain lines, after which they are placed between the metallic mold halves 28a and 28b in FIG. 6, into which plastic material is poured in the same manner as described in connection with FIG. 6 to thereby form the hammer portions 51 and the base 52 as shown in FIG. 12B. Subsequently, the edge portion 49a in close proximity to the top part of the hammer portion 51 is cut along a dotted line 53-53' to remove the edge thereby producing the hammer unit as already described. In this case, the edge portion 49 adjacent the base 52 may remain unremoved, so as to be used as a common electrode.
In the manner as explained with respect to FIGS. 11A and 11B, the leaf spring base plate in FIGS. 12A and 12B has, the pitch of the leaf springs 50 and 50a is double that of the leaf springs as shown in FIG. 5, and this again facilitates the formation of the leaf spring base plates 48 and 48a by punching.
FIGS. 13A and 13B illustrate a further embodiment of the present invention, in which each individual hammer portion is first attached to a pair of leaf springs, whereafter the base is attached to a plurality of pairs of leaf springs, and then the edge portions are cut off.
FIG. 13A particularly shows a leaf spring base plate 55 which comprises a pair of leaf springs 54a and 54b and end portions 56a and 56b connecting the leaf springs together. As shown in FIG. 13D, one end part of such leaf spring base plate 55 is fixedly disposed between the upper and lower metallic mold halves 61a and 61b for forming only the hammer portions followed by pouring of plastic material into a hammer portion forming cavity 62 through a feeding channel 63, thereby producing the leaf spring base plate 55 having the hammer portion 57 integrally formed therewith, as shown in FIG. 13B.
Subsequently, as shown in FIG. 13E, a plurality of leaf spring base plates 55 with the hammer portions 57 having been so formed integrally therewith are securely disposed between the upper and lower metallic mold halves 64a and 64b for forming the base 58 in such a manner that the leaf springs 54a and 54b of the leaf spring base plate 55 lie on a common plane and at equal intervals, thereafter plastic material is poured into a base forming cavity 65 through a channel 66 to form the base 58 as shown in FIG. 13C. Thereafter, the molded unit is cut along dotted lines 59-59' and 60-60' to remove the edge portions 56a and 56b, thus forming the desired hammer unit as already described. In this manner, the hammer portion is pre-formed for each pair of leaf springs and the base is commonly formed for a plurality of pairs of leaf springs, each having such a hammer portion. In so contructing the hammer unit, the metal molds for forming the hammer portion and the base may be simple in construction without the need to fabricate with very fine pitches and complicated shape as already described. This in turn leads to lower manufacturing cost of the metallic molds and also eliminates any limitations to be imposed on the raw materials to be molded. Further, each spring leg may be a simple, elongated, flat spring piece which is simple in construction and highly precise in dimensions, so that this is effective in obtaining rows of printing hammers as a unit having a uniform swinging characteristic of the hammers at each place, and with the hammers at each place being disposed adjacent one another with a predetermined fine pitch
Since the embodiment shown in FIGS. 13A, 13B and 13C is of the type in which the hammer portion and the base are molded separately, it has the advantage that the raw materials to be molded by the two molds can be discretely chosen in accordance with the functions of these hammer and base portions. More specifically, by using a thermosetting resin having less thermal contraction at the time of shaping as the base molding material, it is possible to obtain a printing hammer unit in which each spring leg is precisely held with a predetermined fine pitch in the base portion thereof. Also, by using a thermoplastic resin abundant in elasticity as the molding material for the hammer portion it becomes advantageously possible that the core of an electromagnet can easily be urged in the hammer portion 57 without damaging the same when the core is later to be press-fitted and held in the hammer portion.
All the foregoing embodiments have been described as using plastic materials for the hammer portions and base. In the use of such plastic materials, resin materials of particularly small thermal contraction may be used to shape the hammer portions 15, 44, 51 or 57 and the base 11, 45, 52 or 58. When resin materials of large thermal contraction, such as thermoplastics are used, large pitch errors of the order of from 0.7 to 1.0 mm could be caused between adjacent parts due to contraction of the base especially when the edge portions 27a, 27b, 41a, 41b, 42a, 49a, 56a, 56b interconnecting the leaf springs 12a, 12b, 43, 50, 50a, 54a, 54b have been cut off upon completion of molding. In contrast, the use of thermosetting resin material usually suffers less from thermal shrinkage. For example, phenol resin containing 30% glass fiber, would reduce the error down to 0.3mm or less, so that production of the printing hammer unit having high dimensional precision becomes possible.
Also, when resin material is to be poured on one part of the leaf springs placed between the metallic mold halves 28a and 28b, or 64a and 64b of the plastics molding machine, it is preferably that the pouring of the resin material into at least the cavity (30,65) of the mold for the base formation be conducted in a manner wherein the injection channel 33 or 36 is open to the base forming cavity 30 or 65 in the mold, so that the resin may flow in the direction of the thickness of the leaf spring (the direction of F in FIG. 6 or FIG. 13E). If the resin material is poured in the direction of the surface of the leaf spring (the direction perpendicular to the plane of FIG. 6 or 13E), the leaf springs located near the resin injection channel will be forced in the direction of flow of the resin under a heavy injection pressure of the resin and the molding will take place under such condition with the result that the leaf springs in each column will be embedded irregularly (not being arranged flush) with respect to the base, which in turn will result in non-uniform swinging movement characteristic of the hammer at each place. In contrast, if the resin material is poured so that the flow is directed toward the surfce side of the leaf springs, or toward the thickness thereof as mentioned above, the positional discrepancy in each leaf spring due to the injection pressure of the resin material will be minimized, whereby the hammer unit with the root of the leaf springs being aligned with respect to the base.
It is recalled that the leaf spring base plate 25, 40a, 40b, 48a, 55 shown in FIGS. 8, 11C, 12B and 13C is cut along the dotted lines 35-35', 37-37', 46-46', 47-47', 53-53', 59-59' and 60-60'. In order, however, to reduce the shearing stress during the cutting, or to eliminate irregularity in the cutting, it is preferably that the portions to be so cut should in advance be made thinner than the remainder.
FIGS. 14A and 14B show a form of the leaf spring base plate 25 in which the portions to be cut have been made thinner in thickness by providing gooves 67. Such grooves may be formed by applying an anti-corrosion paint to the leaf spring base plate 25 except for the portions where the grooves 67 are to be made and then by immersing the surface of such leaf spring base plate in etching liquid to etch the plate in those particular portions. In other words, only one surface of the leaf spring base plate may be etched.
Adoption of this one-surface etching to form the grooves 67 may result in satisfactory formation of the generally uniform thin-walled grooves without giving adverse effect such as deformation, etc. to the other portion of the leaf spring base plate.
Also, the notches 34a and 34b, the provision of which has been described in connection with FIG. 5, may preferably be formed in any other embodiment and, if desired, the notches may be replaced by protrusions.
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A printing hammer unit is produced by forming a group of hammers having hammer portions secured to resilient members of electrically conductive material connected together by connecting portions and also forming a base integrally secured to the resilient members at locations thereof spaced apart from the hammer portions, and by removing at least a part of the connecting portions to break the electrical connection between at least one of the resilient members secured to the hammer portions and the other resilient members.
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FIELD OF THE INVENTION
The present invention relates to helmets, and more specifically, to retention mechanisms for helmets.
BACKGROUND
Helmets for head protection during bicycle riding falls and accidents have continuously evolved and undergone numerous improvements in recent years. One particular area of refinement has been in the retention mechanism to fit and stabilize the helmet on the bicycle rider's head. An example of a prior art bicycle helmet and a means for securing it from excessive movement is disclosed in U.S. Pat. No. 5,659,900.
In order to fit a people having different head shapes and sizes, helmets are often available in several sizes. The fit is customized to the rider's head by inserting or removing cushions and pads around the interior of the helmet.
Generally prior art helmets have not been shaped to fit the curvature beneath the occipital region of the rider's head to stabilize the helmet. One prior art solution that fits the curvature beneath the occipital region of the rider's head is disclosed in U.S. Pat. No. 5,659,900. In this prior art helmet, an inverted T-shaped articulated member was attached to a back portion of the bicycle helmet shell assembly. The articulated member has a lower distal end. An elastic means connects the T-shaped articulated member and opposite sides of the shell assembly for allowing the distal end of the articulated member to extend rearward when the helmet is donned to provide a resilient forward pressure against an inwardly curved portion on the posterior of a rider's head.
SUMMARY OF THE INVENTION
A retention mechanism for a helmet is described. A helmet including a retention mechanism comprises a shell for protecting a head of a person and a fit system elastically coupled to the shell. The fit system comprises a bowl designed to fit an occipital region of the person's head and a hinge for coupling the fit system to the shell, the hinge permitting the fit system to move. The fit system further including a spring element for positioning the bowl against the occipital region of the person's head, to stabilize the helmet against the person's head.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
FIG. 1 is a side view of a wearer wearing a helmet including one embodiment of the retention mechanism according to the present invention.
FIG. 2 is a perspective view of one embodiment of the retention mechanism.
FIG. 3 is a front view of one embodiment of the retention mechanism.
FIG. 4A is a view of one embodiment of the screw mechanism for the retention mechanism.
FIG. 4B illustrates a bottom view of the helmet including the retention mechanism.
FIG. 5A is one embodiment of an alternative retention mechanism.
FIG. 5B is yet another embodiment of an alternative retention mechanism.
FIG. 6 is a cut-away view of one embodiment of the back of a helmet including one embodiment of the retention mechanism.
DETAILED DESCRIPTION
An improved retention mechanism for a helmet is described. The retention mechanism provides an intuitive wearer interface, permitting tension adjustment while the helmet is worn. A single knob adjustment mechanism provides two-finger adjustment, for one embodiment. The helmet including the retention mechanism covers less head surface, providing maximum heat dissipation. The retention mechanism is relatively light-weight, and provides excellent support for the helmet. For one embodiment, the universal bowl shape of the retention mechanism fits most head shapes and sizes comfortably. For one embodiment, lower strap slots keep helmet straps from becoming tangled. In this way, the new retention mechanism, described in more detail below, provides many benefits to the wearer as well as to the manufacturer of the retention mechanism and helmet.
FIG. 1 is a side view of a wearer wearing a helmet including one embodiment of the retention mechanism according to the present invention. FIG. 1 illustrates a side view of a helmet including the retention mechanism according to the present invention. The helmet 110 is designed to fit on the head of a wearer. The helmet 110 includes a retention mechanism 120 , which is designed to fit on the back of the helmet 110 .
The retention mechanism 120 attaches into the foam on the helmet 110 . The retention mechanism 120 includes an adjustment mechanism 130 , which permits a wearer to tighten or loosen the retention mechanism 120 , while the helmet 110 is on the wearer's head. The retention mechanism 120 includes a bowl shaped portion 150 , which is designed to fit the back of the head of the wearer.
The helmet 110 further includes a helmet strap 140 . The helmet strap 140 is attached to the helmet 110 at the front, and to the retention mechanism 120 in the back. For one embodiment, the helmet strap 140 is threaded through the bowl shaped portion 150 of the of the retention mechanism 120 , and is coupled to the back of the helmet 110 . For one embodiment, this keeps the helmet straps 140 from becoming tangled.
The retention mechanism 120 and the helmet strap 140 together fix the helmet 110 to the wearer's head, such that the helmet should not slip. Because of the configuration of the bowl 150 , sufficient airflow is provided to the wearer's head, to minimize discomfort.
FIG. 2 is a perspective view of one embodiment of the retention mechanism. The retention mechanism 120 includes a spine 250 that is designed to be attached to the helmet (not shown). The spine 250 , for one embodiment is nylon. Alternatively, the spine 250 may be any other rigid material that provides sufficient support for the bowl 210 .
A moving element 230 is coupled to the spine 250 by a hinge (not shown). For one embodiment, the moving element 230 and the hinge are nylon, to provide rigidity and support. Alternative materials may be used. A light-weight but rigid material is preferred. The moving element 230 is designed to hingedly move the bowl 210 between various positions. As described below, the elastic elements 290 tension the moving element 230 , such that movement of the hinge is made easier and/or harder, depending on the tension provided by the elastic elements 290 .
The retention mechanism 120 has a bowl 210 designed to fit the head of a wearer. For one embodiment, the bowl 210 is nylon, or another relatively rigid and easily formed material. The shape of the bowl 210 is designed to fit a variety of head shapes. For one embodiment, the bowl 210 includes a plurality of slots 220 . For one embodiment, at least one of the slots 220 is designed to have a helmet strap (not shown) threaded through the slot 220 .
The retention mechanism 120 includes adjustment mechanism 130 . For one embodiment, the adjustment mechanism 130 is a knob. In an alternative embodiment, the adjustment mechanism 130 may be another shape designed to be grasped by a wearer. For one embodiment, the adjustment mechanism 130 is made of thermoplastic polyurethane. Alternatively, the adjustment mechanism may be made of other materials—such as other plastics, rubbers, or metals—that are relatively rigid, and are not slippery, providing a grip for the wearer to adjust the knob.
The adjustment mechanism 130 is designed to control an adjustor 260 . The adjustor 260 is a screw, for one embodiment. The adjustor 260 is controlled by the adjustment mechanism 130 . For another embodiment, the adjustor 260 may be a ratchet, a pulling mechanism with multiple stops. For yet another embodiment, the adjustor 260 may be a slot/groove configuration, or any other mechanism that can adjust the elastic materials 290 providing tension in the retention mechanism 120 . For one embodiment, if the adjustor 260 is a screw, a holder 280 fixes the screw 260 in place, such that when the screw 260 is turned, the adjustment mechanism 130 does not move vertically, but the elastic materials 290 move vertically.
The elastic materials 290 tension the retention mechanism 120 against the wearer's head. For one embodiment, the elastic materials 290 are springs. For another embodiment, the elastic materials may be rubber, or any other material that can provide adjustable elasticity.
FIG. 3 is a front view of one embodiment of the retention mechanism. The spine 380 is rigid, and defines the center of the retention mechanism. The spine 380 attaches the retention mechanism 120 to the helmet (not shown).
Elastic elements 350 are attached to the spine on one side, and to the nut 370 on the other side. The nut 370 is moved by the screw 340 , such that when a wearer uses the knob 130 to tighten the screw 340 , the elastic elements 350 are stretched, providing more resistance to the hinge (not shown).
For one embodiment, the screw 340 includes a ratchet 320 at its base, such that the screw 340 does not release, except if a wearer turns the knob 130 .
The bowl 360 is shaped with multiple holes, for airflow. The shape of the bowl 360 , for one embodiment, is optimized to fit multiple head shapes and head sizes. The bowl, for one embodiment, may include reflector decals 310 for additional safety, and to identify the retention mechanism 120 .
FIG. 4A is a view of one embodiment of the spine, adjustor, and adjustment mechanism for the retention mechanism. The spine 430 is shaped to receive a screw 460 that is used to attach the retention mechanism to the helmet. For one embodiment, the screw 460 is attached through a washer 465 , which is shaped to fit the top of the helmet (not shown). For one embodiment, a coverlet 470 is designed to fit over the washer 465 . For one embodiment, the coverlet 470 is designed such that it does not interrupt the airflow over the helmet. For one embodiment, the coverlet 470 is designed of the same material as the cover of the helmet. For one embodiment, the helmet is made of foam, and covered with a plastic material. For one embodiment, the coverlet 470 is made of the same type of plastic material.
For one embodiment, the screw 460 may be screwed into the helmet at multiple angles. In this way, the angle of the spine, and thus the retention mechanism, may be adjusted. For one embodiment, this adjustment may be done by the wearer.
The spine 430 includes a hinge 435 , designed to receive the bowl (not shown). The side of the spine 420 is shaped to follow the contour of the bowl.
For one embodiment, the screw 440 is designed to turn to tighten the elastic elements (not shown). For one embodiment, the screw 440 is fixed such that it does not extend further from the spine, when it is turned.
The spine may further include a tooth 455 , designed to further secure the retention mechanism into the helmet. The tooth 455 , for one embodiment, extends the same length as the wings. FIG. 4B illustrates a bottom view of the helmet including the retention mechanism. As can be seen, the teeth 455 are secured directly into the foam 495 of the bottom 490 of the helmet.
FIG. 5A is one embodiment of an alternative retention mechanism. The spine 510 supports the retention mechanism, and is used to attach the retention mechanism to a helmet (not shown). For one embodiment, the spine includes a location for a screw at its top, and a location for a hook or similar device at its bottom, to firmly attach the retention mechanism 120 to the helmet.
The retention mechanism 120 further includes an elastic element 515 , adjusted by adjustment element 520 . For one embodiment, the elastic element 515 is a rubber or similar material, with a relatively high elasticity and adjustable resistance. The wearer can pull on adjustment element 520 , which is a finger-grip for one embodiment. By setting the elastic element 515 at different extensions, the resistance provided by the elastic element is increased. The elastic element 515 is coupled to the hinge (not shown) at the top 540 , such that as the resistance provided by the elastic element is increased, the ease of movement of the hinge is lowered. This provides stronger or weaker support for the wearer, based on the wearer's adjustment.
The retention mechanism 520 further includes a bowl 530 . For one embodiment, the bowl 530 includes a plurality of cut-outs. The cut-outs are shaped to maximize airflow over the wearer's head, yet provide enough support to stabilize the helmet. Furthermore, the bowl 530 must have sufficient rigidity, even including the cut-outs, to provide stable support.
FIG. 5B is another embodiment of an alternative retention mechanism. The spine 550 is designed to be attached to the helmet (not shown) at the top, as well as at the bottom. For one embodiment, teeth 555 are designed to grip into the foam of the helmet when the retention mechanism 120 is in the helmet.
The retention mechanism 120 includes elastic elements 560 which provide resistance to hinge 565 . The hinge 565 is coupled to a bowl 570 . The bowl is designed to fit the back of a wearer's head. The elastic element 560 provides a steady resistance, permitting a wearer to place the helmet on his or her head, but forcing the bowl 570 against the wearer's head. The bowl 570 may include a cut-out 575 , to improve airflow over the wearer's head. The configuration of the cut-out 575 is arbitrary, but is generally designed to optimize airflow while providing stability to the bowl 570 , and thus to the retention mechanism on the wearer's head.
FIG. 6 is a cut-away view of one embodiment of the back of a helmet including one embodiment of the retention mechanism. The retention mechanism 120 is fastened to the helmet by a screw 625 and a molded washer 620 . The molded washer 620 is designed to fit into the helmet. For one embodiment, the molded washer 620 is shaped to fit into a hole in the helmet, such that the aerodynamic qualities of the helmet are not changed.
The retention mechanism 120 further includes an adjustment device 650 , to change the tension of the retention device. The adjustment device 650 is controlled by knob 640 . For one embodiment, a tooth 670 further attaches the retention device 120 into the helmet 610 .
FIGS. 1-6 have shown various elastic element configurations, some of which were configurable while others were non-configurable and provide a steady resistance. It is to be understood that alternative elastic elements may be used. The elastic elements may be adjustable in various ways, including a screw, a ratchet, an elastic band, or other adjusting means. The elastic elements may be non-adjustable, in the alternative. It is to be understood that other types of elastic elements may be used to provide resistance of the bowl against a wearer's head.
The configuration of the cut-outs in the bowl may be varied as well. For one embodiment, no cut-outs may be present, small cut-outs may be present, or various configurations of larger and/or smaller cut-outs may be present.
In the foregoing specification, the invention has been described with reference to specific exemplary embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention as set forth in the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.
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An improved retention mechanism for a bicycle helmet is provided. A helmet including a retention mechanism comprises a shell for protecting a head of a person and a fit system elastically coupled to the shell. The fit system comprises a bowl designed to fit an occipital region of the person's head and a hinge for coupling the fit system to the shell, the hinge permitting the fit system to move. The fit system further including a spring element for positioning the bowl against the occipital region of the person's head, to stabilize the helmet against the person's head.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is directed to roof construction and suspended ceiling system and, more particularly, to a fire rated suspended ceiling system.
2. Description of the Prior Art
This invention concerns a roof structure and suspended ceiling system consisting of a roof with a watertight outer layer and a layer of thermal insulation beneath it, resting on a metal roof-supporting surface that has a vapor barrier, plus a suspended ceiling that is suspended from the roof-supporting surface with the ceiling tile supported by suspended rails.
There is already a known roof structure and suspended ceiling system in which the rails that support the ceiling tiles of the suspended ceiling are suspended from a metal corrugated roof-supporting surface. The roof-supporting surface has a layer of sheet gypsum on its upper side and a layer of thermal insulation such as mineral wool above it, and this is sealed by a watertight outer layer. The roof-supporting surface forms a vapor barrier (German Patent Application No. 2,705,032). It is also known that a layer of asphalt can be applied to the roof-supporting surface to form the vapor barrier.
It has been found that in the event of fire, the fire resistance of this system does not meet the 90-minute requirement, despite the layer of sheet gypsum on the roof-supporting surface that forms a heat sink, because the metal roof-supporting surface reaches excessively high temperatures too rapidly.
To prevent this rapid heating of the metal roof-supporting surface in the space beneath the suspended ceiling in the event of fire, a layer of mineral wool could be appplied as thermal insulation to the ceiling tiles of the suspended ceiling, but the disadvantage of this arrangement is that in unfavorable weather conditions, the dew point in the space between the suspended ceiling and the roof-supporting surface could shift, so the suspended ceiling would be exposed to moisture, and this must be avoided at all costs.
To keep the dew point outside the space, even in very cold weather, the layer of thermal insulation on the roof-supporting surface would have to be increased considerably, so that increased cost due to this method would result in a very expensive roof structure and suspended ceiling system.
SUMMARY OF THE INVENTION
The invention is directed to a roof construction and subceiling assembly consisting of a water impermeable outer layer and a heat insulating layer installed below the outer layer, both of which rest on a metal deck which is a vapor barier. Below the metal deck, a subceiling is suspended with ceiling boards supported by suspended supporting runners. A heat insulating layer is installed between the deck and the subceiling. At points of the subceiling determined by ventilation aspects of the ceiling boards, the overlying intermediate insulation material and ceiling boards are lifted to form an air passage between the area below the suspended ceiling and the area between the subceiling and the deck. Ceiling boards are also maintained at these points in a lifted position by a member which will meet, decompose, or otherwise lose its consistency under the influence of heat and that after the decomposition of said member, said ceiling boards together with the overlying insulation layer, will fall into position substantially closing the subceiling and form a fire barrier between the area below the subceiling and the area above the subceiling.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows one version of a roof structure and suspended ceiling system in sectional view;
FIG. 2 shows a sectional view of a raised ceiling tile; and
FIG. 3 shows the arrangement in FIG. 2 again in prospective.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention herein is based on the task of designing a roof structure and suspended ceiling system of the type described initially in such a way that with a relatively minor addition of expense in terms of material, fire resistance can be achieved that corresponds at least to the 90-minute limit.
Starting with the roof structure and suspended ceiling system of the type described initially, the problem of fire resistance is solved by adding an intermediate layer of thermal insulation in the space between the roof-supporting surface and the suspended ceiling in such a way that the ceiling tiles and the intermediate insulation material above it are elevated at certain points (determined on the basis of ventilation considerations) to form air passages between the spaces above and below the suspended ceiling. These ceiling tiles are held in raised position by at least one element of a substance that melts, dissolves, or otherwise loses its strength under the influence of heat, in such a way that in the absence of this element, the ceiling tiles and the intermediate insulation material above them will drop into a position sealing the suspended ceiling and intermediate layer, where they are held by means of the supporting rails.
The roof structure and suspended ceiling arrangement, according to this invention, has the advantage that despite the intermediate layer of thermal insulation material, the space between the roof-supported surface and the suspended ceiling is sufficiently ventilated so that there cannot be a shift in the dew point in this space. In the event of a fire in the space beneath the suspended ceiling, the element supporting the upward tilted ceiling tiles dissolves, or otherwise loses it strength very rapidly owing to the heat evolved, so the supporting effect is lost and both the ceiling tiles and intermediate insulation on it drop down under the influence of gravity, so they completely cover the ceiling area previously exposed when they were tilted upward, i.e., completely sealing the passage of air in the space between the roof-supporting surface and the suspended ceiling, while at the same time, the intermediate layer of thermal insulation material forms a continuous layer in this space. At this moment, a shift in dew point is no longer of interest. Due to the insulating effect of this suspended ceiling and the intermediate layer above it, the roof-supporting surface will heat only gradually, so the roof structure and suspended ceiling system has a fire resistance that lasts to 90 minutes or more, i.e., it achieves the fire resistance of concrete systems.
A device is already known for sealing an opening in a fireproof ceiling with a solid member that surrounds it in the form of a frame and at least one fireproof sheet to cover the opening, with an element that holds the sheet directly in the open position inserted between the fireproof sheet and a solid member of the fireproof ceiling, such that said element consists of a substance that melts, dissolves, or otherwise loses its strength under the influence of heat (for example polystyrene foam is suitable for this purpose, German Pat. No. 1,658,786). The surprising advantageous use of such a device according to this invention for solving the dew point problem while at the same time achieving a higher fire resistance class for a roof structure and suspended ceiling system cannot, however, be deduced from this state of the art.
It is advantageous for the ceiling tiles with the intermediate insulation material above them to be held in an upward inclined position on a supporting rail and to be held in this position by at least one element consisting of a material that melts, dissolves, or otherwise loses its strength under the influence of heat and is positioned on the supporting rails. The air passage thus achieved at the predetermined locations is great enough to ventilate the space between the roof-supporting surface and the suspended ceiling adequately. In the event of a fire, the raised ceiling tiles drop into the closing position when their supporting element dissolves, completely sealing the suspended ceiling and not preventing any flow of air into the space between the roof-supporting surface and the suspended ceiling. At the same time, the intermediate layer of insulation material above the ceiling tile is tilted in the direction of the suspended ceiling, forming an essentially continuous intermediate layer of thermal insulation.
It is advantageous for the tilted ceiling tiles to be in guide rails that hold the position closing the suspended ceiling and secure the tiles in a continuous suspended ceiling and continuous intermediate layer in the event of a fire. This can be accomplished by means of guide plates, wire clips, etc. An ornamental grill or a light transmitting grill that allows air to pass through can be placed at those locations where the ceiling tiles are raised so the visual impression of this suspended ceiling will not be impaired by the raised ceiling tiles. When the supporting element melts in the event of a fire, the ceiling tile drops down onto the relatively thin grill, or if the grill itself dissolves due to heat, the ceiling tile will drop down onto the supporting rail, so again, a continuous suspended ceiling is formed, preventing the passage of air into the space between the roof-supporting surface and the suspended ceiling, and maintaining a continuous intermediate layer of thermal insulation.
As mentioned above, the element that melts under the influence of heat should consist of a foam plastic such as polystyrene foam that melts at 70° C. to 80° C.
The roof structure and suspended ceiling system shown in the figures consist of a roof-supporting surface of sheet metal with corrugated reinforcements. A vapor barrier may be provided by the roof-supporting surface itself or it may consist of a layer of asphalt or aluminum foil applied to the roof-supporting surface 4. Above layer 3, there is a layer of thermal insulation 2 which may consist of mineral wool, for example. This layer of thermal insulation 3 is sealed on the outside by a water-tight layer 1 which may consist of film or roofing paper.
The ends of T-shaped supporting rails 8 are suspended from the roof-supporting surface 4 with the help of wires 5, the flanges 10 support the ceiling tiles 7 of a suspended ceiling system. Such a suspended ceiling system is also referred to as a strip grid ceiling. An intermediate layer 11 of thermal insulation is applied to the ends 9 of supporting rails 8 and this layer may consist of mineral wool.
At certain locations, a thin grill 15 is laid on the flange 10 of adjacent supporting rails 8. In the area of one supporting rail 8, one edge of a ceiling tile 13 lies on this grill 15, with the tile tilted upward and supported by means of wedge-shaped element 14 that rests on the grill 15 in the area of the adjacent supporting rail 8. Together with the ceiling tile 13, the intermediate layer 16 of insulating material above the ceiling tile is also tilted upward, and for this reason, the intermediate layer 11 is cut along the plane of separation 12.
Owing to the fact that the ceiling tiles 13 are tilted upward, air can flow from space 21 into space 20 and vice versa through the air passage 22 and the grill 15, so that air circulation in space 21 influences space 20 in such a way that despite the intermediate layer 11 of thermal insulation, there cannot be a shift of dew point into the interior of space 20, even under extremely unfavorable weather conditions.
The elements 14 that are in the form of a cube in FIGS. 2 and 3, and in the form of a wedge in FIG. 1 consist of a material such as polystyrene foam that melts and dissolves very rapidly under the influence of heat. In the event of a fire in space 21, ceiling tile 13 therefore drops into a horizontal position on the grill 15 when element 14 loses its strength due to heat, or if the grill is made of the same material as element 14 that dissolves under heat and the ceiling tile drops onto the supporting flange of the adjacent supporting rails 8, closing the air passage 22. At the same time, the intermediate layer 16 of insulation material on the ceiling tile 13 also drops into horizontal position, forming a continuous intermediate layer 11. Air is also prevented from passing between spaces 20 and 21. In addition, good thermal insulation of space 20 against space 21 is also achieved, so the roof-supporting surface 4 can heat only very slowly, and roof structure and suspended ceiling system as a whole has a fire resistance according to the 90-minute limitation and even considerably better.
As shown in FIGS. 2 and 3, the ceiling tiles 13 with the intermediate layer 14 of insulation material above them can be raised into vertical position to form the air passage 22 and kept in this position by cubicle elements 14. When these elements 14 dissolve under the influence of heat in the event of a fire in space 21, the ceiling tiles 13 with the intermediate layer 16 of insulation material will drop into the proper closing position in the U-shaped guides 23 at the side under the influence of gravity.
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A roof construction-suspended ceiling system consists of a watertight outer layer and a layer of thermal insulation beneath it resting on a metal roof-supporting surface that has a vapor barrier. Below this there is a suspended ceiling system that has insulation placed thereon. The suspended ceiling has openings that will vent the area between the roof construction and the suspended ceiling and the above-said openings may be quickly closed in the event of a fire below the suspended ceiling system.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image forming apparatus of an electrophotographic type and such as a copying machine, a printer and the like electrostatic recording type.
2. Related Background Art
For an electrifying (or electrostatic charge) device for charging a photosensitive member, there are available a corona electrifying device, a fur brush (see B in FIG. 11 ), an electrifying roller (see A in FIG. 11) and the like. They are of an electrifying method primarily utilizing electric discharging phenomena.
Instead of such an electric discharging method, an injection charge method for charging without accompanying a discharge is under consideration by directly injecting a charge. With respect to the injection charge method, there is such a method available where an electrical conductive electro-magnetic brush is rubbed against the photosensitive member.
FIG. 11 is a graph showing an example of an electrification efficiency. A bias applied to a contact electrifying member is shown on a transversal axis and a photosensitive member electrification potential is shown on the axis of ordinates.
In the injection charge method, instead of using the magnetic brush method, implementing of the electrification is under consideration by interposing electrical conductive particles (hereinafter referred to as electrification accelerating particles) in the contact portion to accelerate the electrostatic charging by improving the contacting ability by allowing an image bearing member and the contact electrifying member to have a peripheral speed difference.
By this method, it is possible to obtain an electrostatic property equal to or more than that of the electromagnetic brush C as shown in FIG. 11 .
When such an electrifying method is used for a cleaner-less apparatus, which eliminates the needs for a special cleaner by recovering transfer residual toners by a developing device, an abutting pressure between the contact electrifying member and the image bearing member is increased by interposing the electrification accelerating particles in a contact nip portion between an image bearing member and a contact electrifying member with a contact torque being reduced so that no transfer residual developers pass through the contact nip portion between the contact electrifying member and the image bearing member.
However, if there exist developers which are not transferred on a transferring material, not only the image bearing member but also transfer residual developers should be given a proper charge. When transfer residual developers have an improper charge, transfer residual developers in a developing device can not be recovered and no excellent image quality can be obtained.
Moreover, when the electrification accelerating particles are excessively supplied to the image bearing member, there arises an adverse situation where they are transferred on a print image or they interrupt an image exposure.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an image forming apparatus capable of maintaining an injection chargeability over a long period.
Another object of the present invention is to provide the image forming apparatus with a high recovery efficiency of transfer residual toners by a developing device.
Still another object of the present invention is to provide the image forming apparatus capable of unifying the electrifying polarities of the transfer residual toners.
Still another object of the present invention is to provide an image forming apparatus comprising:
an image bearing member for bearing an electrostatic image;
developing means for developing the electrostatic image on the image bearing member by toners charged with a predetermined polarity;
transfer means for transferring a toner image on the image bearing member to a transferring material;
charging means for inject-charging the image bearing member having transfer residual toners ;
an electrical conductive member provided and spaced apart from the above described image bearing member downstream of the above described transfer means and upstream of the above described charging means in the moving direction of the above described image bearing member; and
electric field forming means for forming an alternating electric field between the above described electrical conductive member and the above described image bearing member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of the image forming apparatus in embodiment 1;
FIG. 2 is an explanatory drawing for the potential condition in the embodiment 1;
FIG. 3 is an explanatory drawing for the stay phenomenon of electrostatic accelerating particles in embodiment 2;
FIG. 4 is an explanatory drawing for the potential condition in the embodiment 2;
FIG. 5 is an explanatory drawing for the potential sequence in the image forming apparatus of embodiment 3;
FIG. 6 is a schematic block diagram of the image forming apparatus of embodiment 4;
FIG. 7 is an explanatory drawing for the potential condition in the embodiment 4;
FIG. 8 is an explanatory drawing for the stay phenomenon of electrostatic accelerating particles in embodiment 5;
FIG. 9 is an explanatory drawing for the potential condition in the embodiment 5;
FIG. 10 is an explanatory drawing for the potential sequence in the image forming apparatus of embodiment 6; and
FIG. 11 is a conceptual drawing for an electrification efficiency.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention will be described below with reference to the drawings.
<EMBODIMENT 1> (FIG. 1 and FIG. 2)
FIG. 1 is a schematic block diagram model of one example of the image forming apparatus according to the present invention.
The image forming apparatus of the present invention is a laser printer of a transfer type using an electro-photographic print process, a contact electrification type, a reverse noncontact developing type and a cleanerless and process cartridge type.
The contact electrification is implemented such that a electrification accelerating particles m are interposed in an electrifying nip portion N which is a contact portion between a photosensitive member 1 as the image bearing member and an electrifying roller 2 as an contact electrifying member and, by allowing the photosensitive member 1 and the electrifying roller 2 to have a peripheral speed difference, the photosensitive member 1 and the electrifying roller 2 are closely contacted.
Moreover, in this embodiment, the electrification accelerating particles m are mixed with developers 31 of a developing apparatus 3 (developing device) so that the electrification accelerating particles m are supplied through a photosensitive surface to the electrifying nip portion D from the developing apparatus 3 and placed noncontact-wise in close proximity to a photosensitive surface between the transfer portion T and the electrifying nip portion N with an aluminum rod coated with carbon as an electrical conductive member 6 provided there.
And to this aluminum rod as the electrical conductive member 6 , a voltage superimposed with an alternative current and a direct current is applied. In this manner, transfer residual developers having an improper charge are recovered non-contact-wise on the surface of the aluminum rod and restored to the surface of the photosensitive member 1 after being charged properly. After this, they can be recovered again inside the developing apparatus 3 through the electrifying roller 2 .
Thus, the surface of the photosensitive member 1 is electrostatically charged excellently and transfer residual developers having an improper charge are given a proper charge and the recovery efficiency of transfer residual developers for the developing apparatus 3 is enhanced, thereby an excellent image can be obtained.
(1) OVERALL SCHEMATIC CONFIGURATION OF THE PRESENT EXAMPLE OF PRINTER
[Image bearing member]
Reference numeral 1 denotes an electrophotographic photosensitive member of a rotary drum type as an image bearing member (electrified member). The printer of this embodiment uses a reversal developing, and the photosensitive member 1 uses a negative photosensitive member. The photosensitive member 1 of this embodiment is an OPC photosensitive member having a diameter of 30 mm and is rotatingly driven at a peripheral speed of 94 mm/sec clock-wise in the direction shown by the arrow.
[Electrifying]
Reference numeral 2 denotes an electrical conductive elastic roller (electrifying roller) having a diameter of 12 mm as a flexible contact electrifying member which is provided to contact the photosensitive member 1 with a predetermined abutting pressure. N denotes the nip portion between the photosensitive member 1 and the electrifying roller 2 . This electrifying roller 2 is coated and borne in advance with the electrification accelerating particles m on its peripheral surface and there exist the electrification accelerating particles m in the electrifying nip portion N.
In this embodiment, the electrifying roller 2 is rotatingly driven at a peripheral speed of 100% in a direction opposite (counter) to the rotating direction of the photosensitive member 1 in the electrifying nip portion N and contacts the photosensitive member 1 at a speed difference. To this electrifying roller 2 , a predetermined electrification bias is applied from an electrification bias power source S 1 . In this manner, the peripheral surface of the rotary photosensitive member 1 is uniformly and contact-electrified to a predetermined polarity and potential by a charge injection method.
In this embodiment, the electrification bias is applied to the electrifying roller 2 from the electrification bias power source S 1 so that the outer peripheral surface of the photosensitive member 1 is uniformly charged with −680 V. In this embodiment, the potential applied to the electrifying roller 2 is −700 V.
The electrifying roller 2 is created by forming a medium resistance layer 22 of rubber or foaming member on a core bar 21 . The medium resistance layer 22 was treated with resin (for example, urethane), electrical conductive particles (for example, carbon black), sulfide agent, foaming agent and the like, and was formed roller-like on the core bar 21 . After this, its surface was polished.
The value of the resistance of the electrifying roller 2 was measured as follows. That is, the photosensitive member 1 of the printer is replaced by a drum made of aluminum. After this, a voltage of 100 V is applied between the aluminum drum and the electrifying roller 2 and, by measuring the value of a current flowed at this time, the value of the resistance of the electrifying roller 2 was determined.
The value of the resistance of the electrifying roller 2 used in this embodiment was 5×10 6 Ω. This measurement was conducted under environmental conditions of 25° C. in temperature and 60% in humidity. With regard to the measurement environment, it is identical to this embodiment as well as with other embodiments.
The average cell diameter of 20 μm in the surface of the electrifying roller 2 was used for each value of the resistance. The average cell diameter was measured by an observation by an optical microscope.
[Exposure]
A scanning exposure L is implemented on the electrified surface of the rotaty photosensitive member 1 by a laser beam outputted from a laser beam scanner (not shown) including laser diodes, polygon mirrors and the like. The laser beam outputted from the laser beam scanner is modulated in intensity corresponding to time series electric digital picture elements of an object image information and, through the scanning exposure L by this laser beam, an electrostatic latent image corresponding to the object image information is formed on the outer peripheral surface of the rotary photosensitive member 1 .
[Development]
Reference numeral 3 denotes a developing apparatus (developing device). This developing apparatus 3 is a reverse noncontact developing apparatus using a negatively electrified magnetic one composition insulating developers having an average diameter of 6 μm as developers 31 . The above described electrostatic latent image formed on the outer peripheral surface of the rotary photosensitive member 1 is developed in reverse as a developer image (toner image) by this developing apparatus 3 .
The developers 31 are mixed (applied outside, blended) with the electrification accelerating particles m.
Reference numeral 32 denotes a nonmagnetic developing sleeve containing a magnet 33 and having a diameter of 16 mm. This developing sleeve 32 is coated with the above-described developers 31 (+m) and is made rotated at the speed equal to that of the photosensitive member 1 with the distance from the surface of the photosensitive member 1 being fixed to 500 μm. A developing bias voltage is applied to the developing sleeve 32 from a developing bias power source S 2 .
The developers 31 (+m) are regulated in layer thickness by an elastic blade 34 (regulating blade) during the process of being conveyed on a rotary developing sleeve 32 and are rubbingly charged by rubbing against the elastic blade 34 , thereby having a charge.
The developing bias is 1.6 kHz in frequency, 1.7 kV in peak to peak voltage and −350 V in developing bias DC composition, and one composition jumping development is implemented at a developing portion between the developing sleeve 32 and the photosensitive member 1 . The developing bias is not necessarily limited to the above.
a) Developers 31
The developers 31 used in this embodiment were those having hydrophobic silica particles applied outside 0.8% to a developer weight portion to give a fluidity in the insulating developers having a volume resistivity of about 10 13 Ω.cm which contains 60% by weight of magnetite and 1% by weight of metallic complex salt of monoazo dye as a negative charge control material in binding resin mainly comprising styrene acryl copolymer.
As described above, the developers 31 are mixed with the electrification accelerating particles m and the mixed amount is 2 parts by weight as against 100 parts by weight of the developers.
b) Electrifying accelerating particles m
In this embodiment, the electrification accelerating particles m used were electrical conductive zinc oxide particles having a specific resistance of 10 7 Ω.cm and an average particle diameter of 1 μm.
If the particles are configured as an agglomerate body, the particle diameter was defined as an average particle diameter as the agglomerate body. The measurement of the particle diameter was conducted in such a manner that more than 100 particles were extracted by the observation by an electron microscope and a volume particle size distribution was calculated on the basis of a horizontal maximum length, thereby defining an 50% average particle diameter as the particle diameter.
The measurement of resistance was made, regulated and determined according to a tablet method. That is, a powder sample of about 0.5 g was put inside a cylinder having the base area of 2.26 cm 2 and, to the upper and lower electrodes, a pressurization of 15 kg was given and simultaneously a voltage of 100 V was applied, thereby calculating the value of resistance and then the specific resistance after being regulated.
The electrification accelerating particles m are suitable if they are achromatic or white colored non-magnetic particles so as not cause any interruption at the time of a latent image exposure. Moreover, unless the diameter of the particles is about less than half of the diameter of the particles of the developers 31 , there was often the case where the image exposure was interrupted. For this reason, it should be smaller than that.
As a material of the electrification accelerating particles m, electrical conductive zinc oxide particles were used, but it is not limited to this material. As the material of the particles, the electrical conductive inorganic particles such as other types of metallic oxide and the like or various types of electrical conductive particles such as mixtures with organic matters and the like can be used.
[Transfer]
Reference numeral 4 denotes a transfer roller of medium resistance as a contact transfer means, where a transfer nip portion T is formed by pressing against the photosensitive member 1 in a predetermined manner. To this transfer nip T portion, a transferring material P as a recorded member is fed from a sheet feeding portion not shown at a predetermined timing and, by applying a predetermined transfer bias voltage to the transfer roller 4 from a transfer bias power source S 3 , a developing image at the side of the photosensitive member 1 is transferred sequentially to the surface of the transferring material P fed to the transfer tip portion T.
The transfer roller used in this embodiment is a roller having a core bar 41 formed with medium resistance foaming layer 42 and a roller resistance of 5×10 8 Ω, and a transfer was implemented by applying +3000 V of a DC voltage to the core bar 41 . The transferring material P introduced to the transfer nip portion T is nippingly conveyed and the developing image formed and borne on the surface of the rotary photosensitive member 1 on the surface side is sequentially transferred by an electrostatic force and a pushing force.
[Fixation]
Reference numeral 5 denotes a fixing apparatus of thermal fixing method and the like. The transferring material P fed to the transfer nip portion T and given the transfer of a developer image of the photosensitive member 1 side is separated from the surface of the rotary photosensitive member 1 and introduced to the fixing apparatus 5 and receives the fixing of the developer image and is discharged outside of the apparatus as an image formed matter (print, copy).
[Non-contact electrifying member]
Reference numeral 6 denotes an electrical conductive member, which is placed in close proximity to the surface of the photosensitive member between the transfer portion T and the electrifying nip portion N and arranged approximately in parallel with the photosensitive member.
The electrical conductive member 6 in this embodiment is a rod (aluminum) having a diameter of 8 mm and, on the surface of the aluminum rod, silicon resin dispersed with carbon black was coated. Moreover, by projecting a spacer roller at its end toward the surface of the photosensitive member, an alienating distance c between the electrical conductive member 6 and the photosensitive member 1 was set at 500 μm.
Moreover, the electrical conductive member 6 is rotatingly held in a bearing so as to slave the rotation of the photosensitive member 1 .
To this electrical conductive member 6 , a rectangle wave having a peak to peak voltage of 1600 V, a frequency of 500 Hz and a DC composition of −900 was applied from the bias applying power source S 4 .
The role of this conductive member will be described in a paragraph (3).
[Cartridge]
The printer of this embodiment has four pieces of process equipment such as the photosensitive member 1 , the contact electrifying member 2 , the developing apparatus 3 and the noncontact conductive member 6 contained in a common cartridge and is taken as a collectively detachable attachable cartridge PC against the printer main body. The combination of the process equipment and the like is not limited to the above.
(3) OPERATION OF ELECTRIFYING ACCELERATING PARTICLES m AND NONCONTACT ELECTRICAL CONDUCTIVE MEMBER 6
As described above, in this embodiment, the electrifying roller 2 is coated with the electrification accelerating particles m in advance. Moreover, the developing apparatus 3 has its developers 31 mixed with the electrification accelerating particles m.
The electrification accelerating particles m mixed with the developers 31 inside the developing apparatus are rubbed against the developers 31 . In this embodiment, since the developers 31 are applied outside with the negative charge control material, the electrification accelerating particles m are rubbingly charged with it and have a charge on the plus side of a reverse polarity. For this reason, the electrification accelerating particles m in the developer 31 on the developing sleeve 32 are supplied to the surface of the photosensitive member 1 from above the developing sleeve 32 due to the potential difference between the developing sleeve 32 and the surface of the photosensitive member 1 .
Since the electrification accelerating particles m have a charge which is the reversal of the polarity of the developers 31 , they are substantially not transferred on the transferring material P in the transfer portion T, but supplied to the electrifying nip portion N which is the contact portion between the electrifying roller 2 and the photosensitive member 1 through a proximity alienating portion c between the photosensitive member 1 and the electrical conductive member 6 and, as a result, are coated on the surface of the electrifying roller 2 .
In this manner, the electrification accelerating particles m are adhered to the surface of the electrifying roller 2 so that the electrification accelerating particles m are interposed between the electrifying roller 2 and the surface of the photosensitive member 1 , thereby enhancing a contact density. For this reason, an excellent inject electrification property can be obtained.
The developers (transfer residual developing materials) remained on the surface of the photosensitive member 1 without being transferred on the transferring material P in the transfer portion T are, while being adhered to the surface of the photosensitive member 1 , conveyed to the electrifying nip portion N which is the contact portion between the electrifying roller 2 and the photosensitive member 1 . Different from the cleanerless image forming apparatus used in this embodiment, even in the image forming apparatus having a member (cleaner) for cleaning the surface of the photosensitive member 1 after the transfer portion T, there exists some, if any, of the developers which pass through the cleaning member. Thus, it is the same as this embodiment.
With the charging method as used in this embodiment, the electrifying roller 2 is allowed to rotate in the opposite direction of the photosensitive member 1 so as to have the peripheral speed difference of the photosensitive member 1 and the electrifying roller 2 .
Here, in the cleanerless image forming apparatus which is not provided with the noncontact electrical conductive member 6 as a comparative (conventional) example of the image forming apparatus, the developers which were not transferred at the transfer portion T are, after being conveyed to the position of the electrifying nip portion N which is the contact portion between the photosensitive member 1 and the electrifying roller 2 , adhered on the surface of the electrifying roller 2 . The transfer residual developers 31 are, while being adhered on the surface of the electrifying roller 2 , allowed to rotate a little less than one round on the electrifying roller 2 and restored to the surface of the photosensitive member 1 just before entering the electrifying nip portion N which is the contact portion between the photosensitive member 1 and the electrifying roller 2 .
The point where transfer residual developers move from the surface of the photosensitive member 1 to the surface of the electrifying roller 2 is just before the electrifying nip portion N and there exist practically no transfer residual developers which pass through the electrifying nip portion N.
In order to recover the transfer residual developers in the developing apparatus 3 , it is necessary to give a proper charge to the transfer residual developers. With the electrostatic charging method using the electrification accelerating particles m, a contact is made between the electrification accelerating particles m and the developers 31 on the electrifying roller 2 and thereby the charge can be given to the developers. Thus, in the image forming apparatus of this comparative example too, the giving of the proper charge to the transfer residual developers can be implemented. However, there is no saying that it is sufficiently enough.
In contrast, in this embodiment, since the electrical conductive member 6 is arranged approximately in parallel with the photosensitive member noncontact wise in close proximity to the surface of the photosensitive member between the transfer portion T and the electrifying nip portion N and an alternative current bias composition is applied to this electrical conductive member 6 , the transfer residual developers 31 adhered on the surface of the photosensitive member 1 fly between the photosensitive member 1 and this electrical conductive member 6 .
The developers charged with a plus polarity which is an improper charge polarity adhere to the white matter portion of the surface of the photosensitive member 1 . The potential of the white matter portion after the transfer of the photosensitive member 1 is set at a little less than −680 V which is the electrification fixing potential. In contrast to this, since the electrical conductive member 6 has −900 V as an average potential, the transfer residual developers 31 having a plus charge polarity move from the surface of the photosensitive member 1 to the surface of the electrical conductive member 6 .
After this, the developers 31 restored to the proper polarity through rubbing against the surface of the electrical conductive member 6 coated with carbon are restored to the surface of the photosensitive member 1 .
The developers 31 restored to the surface of the photosensitive member 1 are recovered again (recovery implemented simultaneously with development) inside the developing apparatus 3 through electrifying roller 2 . At this time, since the charge polarity of the developers is properly restored, the re-recovery at the developing apparatus 3 can be implemented without any problem.
By going through such steps, this embodiment makes the charge polarity of transfer residual developers 31 proper and re-recover the properly restored developers alone inside the developing apparatus 3 through the electrifying roller 2 .
With regard to the electrification accelerating particles m, since they have a plus charge, there is some, if any, of the particles which adheres to the electrical conductive member 6 . However, after this, it flies to the surface of the photosensitive member 1 from the surface of the electrical conductive member 6 by a charge injected and is supplied to the surface of the electrifying roller 2 .
The above behaviors of the transfer residual developers 31 and the electrification accelerating particles m can be confirmed by a visualization method referred to as a laser sheet method. To be concrete, a planar laser beam is irradiated at the charge portion in the cross sectional direction of the process and the movement of the particles is measured by a sensitive high speed camera, thereby making it possible to confirm the above-described behaviors.
(4) TEST
Next, what difference there is in a practical print image between the image forming apparatus of this embodiment where the noncontact electrical conductive member 6 is arranged and the image formatting apparatus of the comparative example where the noncontact electrical conductive member is not arranged will be shown below.
<1> COMPARATIVE TEST 1
With respect to the charge of the transfer residual developers which were discharged from the surface of the electrifying roller 2 after passing through the electrifying nip portion N and restored to the surface of the photosensitive member 1 , how different they are between the image forming apparatus of this embodiment and the image formatting apparatus of the comparative example was measured.
This comparative test was conducted on the following three types of the toners 31 A, 31 B and 31 C. The result of the comparative test is shown in Table 1.
Toner type 31 A:
Wherein hydrophobic silica grain is applied outside 0.8% to the developer weight portion in order to give a fluidity to insulating developer having a volume resistibility of approximately 10 13 Ω.cm which contains 60 weight % of magnetite and 1 weight % of metallic complex salt of monoazo dye as a negative charge control material in binding resin mainly comprising styrene acryl copolymer.
Toner type 31 B:
Wherein metallic complex salt of a monoazo dye which is a negative charge control material is changed to 1.1% by weight in the above described toner type 31 A.
Toner type 31 C:
Wherein metallic complex salt of a monoazo dye which is a negative charge control material is changed to 0.9% by weight in the above described toner type 31 A.
TABLE 1
Toner charge [charge (μc)/weight (mg)]
Toner type
Embodiment 1
Comparative example
31A
−12
−5
31B
−15
−5
31C
−9
+1
As will be clear from this table, in contrast to the comparative example, this embodiment can give a proper polarity and a high number of charge quantities to the transfer residual developers, making the number of charge quantities properly.
In contract to the above, in the comparative example, there is some, if any, of the developer which has an improper polarity as in case of the toner type 31 C. Moreover, as is observable from either type of the toners 31 A and 31 B, it does not reach a proper number of charge quantities and the number of charge quantities is small.
<2> COMPARATIVE TEST 2
In order to check the difference of the recoverability of the transfer residual developers in the developing apparatus 3 between this embodiment and the comparative example having the above described differences, the following comparison was conducted.
That is, a solid black image is printed one round around the drum of the photosensitive member and, after this, replaced by a sold white image. Immediately after this, the amount of the developers on the surface of the photosensitive member 1 after having passed through the developing apparatus 3 (developing portion D) was compared.
The amount of the developers adhered on the surface of the photosensitive member 1 after having passed through the developing apparatus 3 is:
(1) the transfer residual developers 3 , not recoverable in the developing apparatus 3 .
(2) if taken as a fog composition which is a background composition naturally carried by the developing apparatus 3 , it can be expressed as (1)+(2).
With regard to the fog composition (2), since this embodiment and the comparative example are equal to each other, it can be taken substantially as “the difference between this embodiment and the comparative example of (1)+(2)=the difference between this embodiment and the comparative example of (2)”. That is, the difference in the amount of the developers adhered on the surface of the photosensitive member 1 after having passed through the developing apparatus indicates the difference in the recoverability of the transfer residual developers.
The measurement was conducted as follows. By attaching a Mylar tape to the developers adhered on the surface of the photosensitive member 1 after having passed through the above described developing apparatus, the developers are peeled off from the surface of the photosensitive member 1 . After this, the Mylar tape is pasted on a white paper. The reflection fog amount of the Mylar tape is measured by a fog amount measuring apparatus TC-6DS made by TOKYO DENSHOKU.
Moreover, the fog amount at the time when the Mylar tape only is pasted on the white paper is also measured, which is taken as a reference reflection fog amount.
By subtracting the measurement value from the reference reflection fog amount, a substantial reflection fog amount is calculated. In this case, the more it is white, that is, the more the amount of transfer residual developers is smaller, the more the value becomes smaller.
As a result of the measurement taken in this manner, in contract to the fog amount of 1.4 of the comparative example, this embodiment results in 0.9. Thus, the fact that the recoverability of the transfer residual developers is enhanced in this embodiment could be confirmed.
Moreover, even in contrast to the ordinary print image, in this embodiment as compared to the comparative example, the fog and the like due to the effect of the transfer residual toners are not detected in the white portion of the print image and thus the improvement of the electrification property and the image property was observed.
<3> MEASUREMENT OF POTENTIAL CONDITION APPLIED TO ELECTRICAL CONDUCTIVE MEMBER 6
Next, a drawing where the potential condition be applied to the electrical conductive member 6 in order to obtain the effect of the improvement of the electrification property and the image property was measured is shown in FIG. 2 .
Here,
the peak to peak voltage of an alternating voltage applied to the electrical conductive member 6 is taken as a[V],
the direct current bias potential applied to the electrical conductive member 6 is taken as b[−V],
the distance between the electrical conductive member 6 and the photosensitive member 1 is taken as c[μm], and
the photosensitive member electrification potential is taken as d[−V].
In FIG. 2, the transversal axis represents (b−d)/c[−V/μm] and the axis of the ordinates represents a/c[V/μm].
Note that the effect of the DC bias potential applied to the electrical conductive member 6 in the present measurement is, similar to the previous comparison between this embodiment and the comparative example, taken as a basis to see if any improvement is observable in the fog value in the case where the comparison example, i.e., the electrical conductive member 6 is not available.
Moreover, the effect of the peak to peak voltage of the alternating voltage applied to the electrical conductive member 6 was based on whether the flying of the transfer residual developer 31 can be confirmed.
As shown in FIG. 2, it was confirmed that, when a/c is equal to or more than 1[V/μm], the transfer residual developers 31 are flying. The reason is that the electrical field required for the transfer residual developer 31 to fly is considered as 1[V/μm].
Moreover, it was confirmed that, when (b−d)/c is equal to or more than 2[−V/μm], the improvement is observable. The reason is that, when the electrical field of the DC composition of approximately 0.2[−V/μm] is working, only the transfer residual developer 31 having the proper charge is considered restorable on the surface of the photosensitive member 1 .
Accordingly, the crosshatched area X as shown in FIG. 2 is the area where the transfer residual developers 31 are allowed to fly from the photosensitive member 1 to the electrical conductive member 6 and, after being recovered there, those having the proper charge can be restored again on the photosensitive member 1 from the electrical conductive member 6 .
In this embodiment, a/c is 3.2[V/μm] and (b−d)/c is 44[−V/μm], both of which have the conditions to fall in the effective area.
In this manner, this embodiment is characterized in that, in the image forming apparatus using the charge which allows the electrification accelerating particles m to interpose between the electrifying roller 2 and the photosensitive member 1 , the electrical conductive member 6 is placed noncontact-wise in close proximity to the photosensitive member 1 and the voltage is applied where the above described a/c is equal to or more than 1[V/μm] and the above described (b−d)/c is equal to or more than 0.2[−V/μm].
Note that, if a/c is equal to or more than 1[V/μm], the effect of the present invention can be obtained. However, if it is too high, there will be some cases where a dielectric breakdown is caused and hence it is preferable to be equal to or less than 8[V/μm].
In this manner, an excellent electrification property can be maintained and the electrification accelerating particles m adhered to the surface of the photosensitive member 1 are prevented from obstructing the image exposure to adversely affecting the print image.
<EMBODIMENT 2> (FIG. 3 and FIG. 4)
This embodiment is characterized in that it is approximately the same as the embodiment 1 except that the above described (b−d)/c is equal to or less than 0.3[−V/μm].
In this manner, the electrification accelerating particles m can be held between the electrical conductive member 6 and the photosensitive member 1 and, for this reason, the electrification accelerating particles m are excessively adhered on the surface of the electrifying roller 2 and the electrification accelerating particle m are prevented from being discharged on the surface of the photosensitive member 1 .
In this manner, an excellent electrification property can be maintained and the electrification accelerating particles m adhered to the surface of the photosensitive member 1 are prevented from obstructing the image exposure to adversely affecting the print image.
To be concrete, in this embodiment, the difference between the direct current component potential applied to the electrical conductive member 6 and the potential applied to the electrifying roller 2 is smaller than 200 V, which is −800 V as a potential.
In this embodiment, similar to the printer of the embodiment 1, the electrical conductive member 6 is placed noncontact wise opposite to the photosensitive member 1 and, by applying a bias including the alternating current to this electrical conductive member 6 , the improper transfer residual developer can be recovered on the electrical conductive member 6 and, after restoring the charge properly, restored to the surface of the photosensitive member 1 .
In addition, in the case where the above described (b−d)/c is equal to or less than 0.3[−V/μm], the behavior of the electrification accelerating particles m become different from the embodiment 1.
That is, in the embodiment 1, similar to the developer 31 , the electrification accelerating particles m moved from the surface of the photosensitive member 1 to the surface of the electrifying roller 2 and, after this, flied on the surface of the photosensitive member 1 and restored there. However, in the condition of this embodiment where (b−d)/c is equal to or less than 0.3[−V/μm], being different from the above, there emerges some, if any, of the developers which draws a locus as depicted by a broken curve line M in the schematic diagram of FIG. 3 . That is, there emerges some, if any, of the electrification accelerating particles m which is no longer able to pass through the proximity alienating portion c between the photosensitive member 1 and the electrical conductive member 6 so that the electrification accelerating particle m begins to stay M in front of the proximity alienating portion c between the photosensitive member 1 and the electrical conductive member 6 . Accordingly, there will arise no such situation where an excessive amount of electrification accelerating particles m pass through the proximity alienating portion c between the photosensitive member 1 and the electrical conductive member 6 and thus the electrification accelerating particles m adhere excessively on the surface of the electrifying roller 2 and then, after this, adhere on the surface of the photosensitive member 1 .
Note that this measurement is possible to be taken by using the laser sheet method similar to the embodiment 1.
FIG. 4 is a drawing where the potential condition in which such a phenomenon occurs is measured. In FIG. 4, similar to FIG. 2, the transversal axis represents (b−d)/c[−V/μm] and the axis of the ordinates represents a/c[V/μm].
In the case where (b−d)/c is equal to or more than −0.3[−V/μm] and less than 0.3[−V/μm], the electrification accelerating particle m began to stay M as shown in FIG. 3 . In this manner, the excessive supply of the electrification accelerating particle m on the surface of the photosensitive member 1 could be prevented.
In this embodiment, since (b−d)/c is 0.24[−V/pm] and equal to or more than 0.2[−V/μm] which is similar to the embodiment 1, the charge of the transfer residual developer was made proper to be equal to or less than 0.3[−V/μm] (that is, the lattice oblique line area Y in FIG. 4) and thus the excessive supply of the electrification accelerating particle m could be prevented.
By the operation as described above, the electrification accelerating particles m adhered on the surface of the photosensitive member 1 will not affect the image exposure harmfully and an excellent print image can be obtained.
<EMBODIMENT 3> (FIG. 5)
The bias for the electrical conductive member 6 can be allowed to have a sequence for fluctuating at least one from the frequency, the amplitude and the direct current component of the alternating voltage to be applied.
This embodiment is approximately the same as the embodiments 1 and 2, which is characterized in that the bias to be applied to the electrical conductive member 6 is made variable at a printing time and a nonprinting time, and which is an image forming apparatus characterized in that, at an image printing time, since (b−d)/c is equal to or more than 0.2[−V/μm] and less than 0.3[−V/μm], the excessive supply of the electrification accelerating particle is controlled while the charge of the transfer residual developer is made proper, and at a nonimage printing time, since the electrification accelerating particles m are supplied to the photosensitive member, (b−d)/c is equal to or more than 0.3[−V/μm].
That is, at the printing time, the same bias as the embodiment 2 is applied to the electrical conductive member 6 and, at the nonprinting time, the same bias as the embodiment 1 is applied.
The sequence of the DC bias potential for the electrical conductive member 6 is shown in FIG. 5 . At the image printing time, similar to the embodiment 2, a rectangular wave having a peak to peak voltage of 1600 V, a frequency of 500 Hz and a DC composition of −800 V is applied and, at the nonprinting time, a rectangular wave having a peak to peak voltage of 1600 V, a frequency of 500 Hz and a DC composition of −900 V is applied.
As shown in FIG. 5, at the image printing time, the DC composition is −800 V, that is, (b−d)/c is 0.24[−V/μm] and, at the nonimage printing time, the DC composition is −900 V, that is, (b−d)/c is 0.44[−V/μm].
In this embodiment, during the image printing time, similar to the embodiment 2, the excessively supplied electrification accelerating particles m are allowed to stay M in the proximity alienating portion c between the electrical conductive member 6 and the photosensitive member 1 as shown in FIG. 3 so that the electrification accelerating particles m are prevented to be supplied excessively on the surface of the photosensitive member 1 .
At the nonprinting time, since (b−d)/c becomes larger than 0.3[−V/μm], the stay M of the electrification accelerating particles m as shown in FIG. 3 is not caused, but the accumulated electrification accelerating particles m are discharged and the excessive amount of the electrification accelerating particles m can be recovered inside the developing apparatus 3 through the surface of the photosensitive member 1 .
In this embodiment, since the electrification accelerating particles m stay M in front of the proximity alienating portion c between the electrical conductive member 6 and the photosensitive member 1 and have a high number of charge quantities, the re-recovery thereof toward the developing apparatus 3 is possible in a highly efficient manner.
For this reason, the continuous adherence of the electrification accelerating particles m on the surface of the photosensitive member 1 is prevented and an excellent print image can be obtained without affecting the print image harmfully.
<EMBODIMENT 4> (FIG. 6 and FIG. 7)
(1) CONFIGURATION OF IMAGE FORMING APPARATUS
FIG. 6 is a schematic block diagram of the printer in this embodiment.
In contrast to the printer (FIG. 1) of the embodiment 1, the printer in this embodiment has the electrical conductive member 6 placed noncontact-wise in close proximity to the electrifying roller 2 . The other configuration of the apparatus is similar to the printer of the embodiment 1 and therefore the description thereof for the second time will be omitted.
That is, in the printer of this embodiment too, the contact electrostatic charging is implemented such that the electrification accelerating particles m are interposed in the electrifying nip portion N which is the contact portion between the photosensitive member 1 as an image bearing member and the electrifying roller 2 as a contact electrifying portion and, by allowing the photosensitive member 1 and the electrifying roller 2 to have a peripheral speed difference, the photosensitive member 1 and the electrifying roller 2 are closely contacted, thereby making the injection charge mechanism to work dominantly. Moreover, the electrification accelerating particles m are mixed with the developers 31 of the developing apparatus 3 so that the electrification accelerating particles m are supplied from the inside of the developing apparatus to the electrifying nip portion N through the surface of the photosensitive member.
In case of this embodiment, the aluminum bar 6 which is the electrical conductive member is arranged approximately in parallel to the electrifying roller 2 noncontact-wise in close proximity to the electrifying roller 2 and applied with the voltage superimposed with the alternating current and the direct current. In this manner, the transfer residual developers having an improper charge is recovered on the surface of the aluminum bar noncontact-wise and can be recovered again inside the developing apparatus 3 through the electrifying roller 2 after being charged properly.
Thus, it is possible to make an excellent charging of the surface of the photosensitive member 1 and give a proper charge to the transfer residual developer having an improper charge and, by enhancing the recoverability of the transfer residual toward the developing apparatus 3 , the excellent image can be obtained.
The electrical conductive member 6 in this embodiment is a aluminum bar having a diameter of 8 mm and, on the surface of the aluminum bar, carbon black is dispersed in silicon resin so as to adjust resistance and a surface layer adjusted with a volume resistivity of 10 2 Ω.cm is arranged. This electrical conductive member 6 is arranged and positioned so as to maintain an alienating distance e of 500 μm with the electrifying roller 2 .
Moreover, the electrical conductive member 6 is rotatively held in bearing so as to slave the rotation of the electrifying roller 2 .
To this electrical conductive member 6 , a rectangular wave having a peak to peak voltage of 1600 V, a frequency of 500 Hz and a DC composition of −900 V was applied from a bias applying power source S 4 .
In the printer of this embodiment too, similar to the printer of the embodiment 1, the electrifying roller 2 is coated in advance with the electrification accelerating particles m. Moreover, the developing apparatus 3 has the developers 31 mixed with the electrifying accelerating particles m. The electrification accelerating particles m mixed with the developers 31 inside the developing apparatus is rubbed against the developer 31 . Since the developers 31 are applied outside with a negative charge control material, the electrification accelerating particles m are frictionally electrified against it so as to have a charge on the plus side of a reverse polarity. For this reason, the electrification accelerating particles m inside the developer 31 on a developing sleeve 32 are supplied on the surface of the photosensitive member 1 from above the developing sleeve 32 due to the potential difference between the developing sleeve 32 and the photosensitive member 1 .
Since the electrification accelerating particles m have the charge in reverse to the polarity of the developers 31 , they are substantially not transferred to a transferring material P in a transfer portion T, but supplied to the electrifying nip portion T which is a contact portion between the electrifying roller 2 and the photosensitive member 1 and, as a result, coated on the surface of the electrifying roller 2 .
In this manner, the electrification accelerating particles m are adhered on the surface of the electrifying roller 2 so that the electrification accelerating particles me are interposed between the electrifying roller 2 and the photosensitive member 1 , thereby enhancing a contact density. As a result, an excellent injection electrification property can be obtained.
The developers (transfer residual developers) remained on the surface of the photosensitive member 1 without being transferred to the transferring material P in the transfer portion T are kept adhered on the surface of the photosensitive member 1 and conveyed to the electrifying nip portion T which is the contact portion between the electrifying roller 2 and the photosensitive member 1 . Different from the cleaner-less image forming apparatus used in this embodiment, even in the image forming apparatus having a member (cleaner) for cleaning the surface of the photosensitive member 1 after the transfer portion T, there exists some, if any, of the developers which passes through the cleaning portion. Hence it is the same as this embodiment.
With the electrostatic charging method as with this embodiment, the electrifying roller 2 is rotated in the direction opposite to the photosensitive member 1 so as to have the peripheral speed difference between the photosensitive member 1 and the electrifying roller 2 .
The developers which were not transferred in the transfer portion T are adhered on the surface of the electrifying roller 2 after being conveyed to the electrifying nip portion T which is the contact portion between the photosensitive member 1 and the electrifying roller 2 . The transfer residual developers are kept adhered on the surface of the electrifying roller 2 and rotated a little less than one round on the electrifying roller 2 and restored on the surface of the photosensitive member 1 just before entering the electrifying nip portion N which is the contact portion between the photosensitive member 1 and the electrifying roller 2 .
The point where the transfer residual developers move from the surface of the photosensitive member 1 to the electrifying roller 2 is just before the electrifying nip portion T and there exist practically no transfer residual developers which pass through the electrifying nip portion T.
In order to recover the transfer residual developers in the developing apparatus 3 , it is necessary to give a proper charge to the transfer residual developers. With the charging method using the electrification accelerating particles m, a contact is made between the electrification accelerating particles m and the developers 31 on the electrifying roller 2 and thereby the charge can be given to the developers. Accordingly, in the image forming apparatus of this comparative example too, the giving of the proper charge to the transfer residual developers can be implemented. However, there is no saying that it is sufficiently enough.
In contrast, in this embodiment, the electrical conductive member 6 is placed noncontact-wise opposite to the electrifying roller 2 . Since the alternating current bias composition is applied to this electrical conductive member 6 , the transfer residual developers 31 adhered on the surface of the electrifying roller 2 fly between the electrifying roller 2 and this electrical conductive member 6 .
A voltage of −700 V is applied to the electrifying roller 2 and, since the direct current component of the electrical conductive member is −900 V, those having a plus charge polarity among the transfer residual developers, that is, the transfer residual developers having an improper charge polarity are adhered on the surface of the electrical conductive member 6 . On the contrary, the transfer residual developers having a proper minus charge polarity are, after flying between the electrifying roller 2 and the electrical conductive member 6 , adhered on the surface of the electrifying roller 2 and, after this, adhered on the surface of the photosensitive member 1 and recovered inside the developing apparatus 3 . Since the charge polarity of the developers 31 is proper, the re-recovery inside the developing apparatus 3 can be made without any problem.
The transfer residual developers having an improper charge polarity adhered on the surface of the electrical conductive member 6 have a minus charge polarity by the rubbing against the surface layer of the electrical conductive member and a charge injection and, after flying between the electrifying roller 2 and the electrical conductive member 6 , are discharged on the surface of the electrifying roller 2 .
By going through such steps as described above, the charge polarity of the transfer residual developers is made proper and only those properly charged can be re-recovered inside the developing apparatus 3 through the electrifying roller 2 .
Note that, since the electrification accelerating particles m have a plus charge, there is a number of those adhering on the surface of the electrical conductive member 6 which, however, after flying from the surface of the electrical conductive member 6 by the charge injection, are supplied to the surface of the electrifying roller 2 .
The above described behaviors of the transfer residual developers 31 and the electrification accelerating particles m can be confirmed by the above described laser sheet method.
(2) TEST
In the actual print image, the result confirming what difference there is between the image forming apparatus of this embodiment providing a noncontact electrical conductive member 6 and the image forming apparatus of the comparative example without providing the noncontact electrical conductive member 6 will be shown below.
<1> COMPARATIVE TEST 1
A test on how different is the charge of the transfer residual developers, which was discharged from the surface of the electrifying roller 2 after passing through the electrifying nip portion N and restored on the surface of the photosensitive member 1 , between the image forming apparatus of this embodiment and the image forming apparatus of the comparative example was conducted in the similar manner with the comparative test 1 of the above described embodiment 1 with respect to the above described three types of toners (developers) 31 A, 31 B and 31 C. The result of the comparative test will be shown in Table 2.
TABLE 2
Toner charge [charge (μc)/weight (mg)]
Toner type
Embodiment 4
Comparative example
31A
−8
−1
31B
−9
−2
31C
−7
+1
As will be clear from this table, in contrast to the comparative example, this embodiment can give a proper polarity and a high number of charge quantities to the transfer residual developers, making the number of charge quantities properly.
In contrast to the above, in the comparative example, there is some, if any, of the developers which has an improper polarity as in case of the toner type 31 C. Moreover, as is observable from either type of the toners 31 A and 31 B, it does not reach a proper number of charge quantities and the number of charge quantities is small.
<2> COMPARATIVE TEST 2
In order to check the difference of the recoverability of the transfer residual developers in the developing apparatus 3 between this embodiment and the comparative example having the differences as described above, a comparison was made in the same manner as the comparison test 2 in the above described embodiment 1.
As a result of the measurement taken in this manner, in contrast to the fog amount of 1.5 of the comparison example, this embodiment results in 0.9. Thus, the fact that the recoverability of the transfer residual developers is enhanced in this embodiment could be confirmed.
Moreover, even in contrast to the ordinary pint image, in this embodiment as compared to the comparative example, the fog and the like due to the effect of the transfer residual toners are not detected in the white portion of the print image and thus the improvement of the electrification property and the image property was observed.
<3> MEASUREMENT OF POTENTIAL CONDITION APPLIED TO ELECTRICAL CONDUCTIVE MEMBER 6
Next, a drawing where the potential condition be applied to the electrical conductive member 6 in order to obtain the effect of the improvement of the electrification property and the image property was measured is shown in FIG. 7 .
Here,
the peak to peak voltage of an alternating voltage applied to the electrical conductive member 6 is taken as a[V],
the direct current bias potential applied to the electrical conductive member 6 is taken as b[−V],
the distance between the electrical conductive member 6 and the photosensitive member 1 is taken as e[μm], and
the potential applied to the electrifying roller is taken as f[−V].
In FIG. 7, the transversal axis represents (b−f)/e[−V/μm] and the axis of the ordinates represents a/e[V/μm].
Note that the effect of the DC bias potential applied to the electrical conductive member 6 in the present measurement is, similar to the previous comparison between this embodiment and the comparative example, taken as a basis to see if any improvement is observable in the fog value in the case where the comparison example, i.e., the electrical conductive member 6 is not available.
Moreover, the effect of the peak to peak voltages of the alternating voltage which is applied to the electrical conductive member 6 was based whether the flying of the transfer residual developers 31 can be confirmed.
As shown in FIG. 7, when a/e is equal to or more than 1[V/μm], it was confirmed that the transfer residual developers 31 are flying. The reason is that the electrical field required for the transfer residual developers 31 to fly is considered as 1[V/μm].
Moreover, it was confirmed that, if (b−d)/e is equal to or more than 2[−V/μm] is working, the improvement is observable. The reason is that, if the electrical field of the DC composition of approximately 0.2[−V/μm] is working, only the transfer residual developers 31 having the proper charge are considered restorable on the surface of the photosensitive member 1 .
Accordingly, the crosshatched area X as shown in FIG. 7 is the area where the transfer residual developers 31 are allowed to fly from the electrifying roller 2 to the electrical conductive member 6 and, after being recovered there, those having the proper charge can be restored again on the electrifying roller 2 from the electrical conductive member 6 .
In this embodiment, a/e is 3.2[V/μm] and (b−f)/e is 44[−V/μm], both of which have the conditions to fall in the effective area.
In this manner, this embodiment is characterized in that, in the image forming apparatus using the charge which allows the electrification accelerating particles m to be interposed between the electrifying roller 2 and the photosensitive member 1 , the electrical conductive member 6 is placed noncontact-wise in close proximity to the electrifying roller 2 and the voltage is applied where the above described a/e is equal to or more than 1[V/μm] and (b−f)/e is equal to or more than 0.2[−V/μm].
Note that, if a/e is equal to or more than 1[Vμm], the effect of the present invention can be obtained. However, if it is too high, there will be some cases where a dielectric breakdown is caused and hence it is preferable to be equal to or less than 8[V/μm].
In this manner, the transfer residual developers having an improper charge are adhered on the surface of the electrical conductive member and, after being charged there properly, recovered inside the developing apparatus through the electrifying roller 2 , thereby enhancing the recoverability of the developers inside the developing apparatus and enabling to obtain an excellent image property.
<EMBODIMENT 5> (FIG. 8 and FIG. 9)
This embodiment is characterized in that it is approximately the same as the embodiment 4 except that the above described (b−d)/c is equal to or less than 0.3[−V/μm].
In this manner, the electrification accelerating particles m can be held between the electrical conductive member 6 and the electrifying roller 2 and, for this reason, the electrification accelerating particles m are prevented from adhering excessively on the surface of the electrifying roller 2 and being discharged on the surface of the photosensitive member 1 .
In this manner, an excellent electrification property can be maintained and the electrifying accelerating particles m adhered to the surface of the photosensitive member 1 are prevented from obstructing the image exposure to adversely affecting the print image.
To be concrete, in this embodiment, the difference between the direct current component potential of the bias applied to the electrical conductive member 6 and the potential applied to the electrifying roller 2 is small than 200 V, which is −800 as a potential.
In this embodiment, similar to the printer of the embodiment 1, the electrical conductive member 6 is placed noncontact-wise opposite to the electrifying roller 2 and, by applying a bias including the alternating current to this electrical conductive member 6 , the improper transfer residual developers can be recovered on the electrical conductive member 6 and, after restoring the charge thereof properly, restored to the surface of the electrifying roller 2 .
In addition this, in the case where the above described (b−f)/e is equal to or less than 0.3[−V/μm], the behavior of the electrification accelerating particle m becomes different from the embodiment 4.
That is, in the embodiment 4, similar to the developers 31 , the electrification accelerating particles m moved from the surface of the photosensitive member 1 to the surface of the electrifying roller 2 and, after this, flied on the surface of the photosensitive member 1 . However, in the condition of this embodiment where (b−d)/c is equal to or less than 0.3[−V/μm], being different from the above, there emerges some, if any, of the developers which draws a locus as depicted by a broken curve line M in the schematic diagram of FIG. 8 . That is, there emerges some, if any, of the electrification accelerating particles m which is no longer able to pass through the proximity alienating portion e between the electrifying roller 2 and the electrical conductive member 6 so that the electrification accelerating particle m begins to stay M in front the proximity alienating portion e between the electrifying roller 2 and the electrical conductive member 6 . Accordingly, there will arise no such situation where an excessive amount of electrification accelerating particles m pass through the proximity alienating portion e between the electrostatic roller 2 and the electrical conductive member 6 and thus the electrification accelerating particles m adhere excessively on the surface of the electrifying roller 2 and then, after this, adhere on the surface of the photosensitive member 1 .
Note that this measurement is possible to be taken buy using the above described laser sheet method.
FIG. 9 is a drawing where the potential condition in which such a phenomenon occurs is measured. In FIG. 9, similar to FIG. 7, the transversal axis represents (b−f)/e [−V/μm] and the axis of the ordinates represents a/f[V/m].
In the case where (b−f)/c is equal to or more than −0.3[−V/μm] and less than 0.3[−V/μm], the electrification accelerating particles m began to stay M as shown in FIG. 8 . In this manner, the excessive supply of the electrification accelerating particles m on the surface of the photosensitive member 1 could be prevented.
In this embodiment, since (b−f)/c is 0.24[−V/μm] and equal to or more than 0.2[−V/μm] which is similar to the embodiment 4, the charge of the transfer residual developers was made proper to be equal to or less than 0.3[−V/μm] (that is, the lattice oblique line area Y in FIG. 9) and thus the excessive supply of the electrification accelerating particles m could be prevented.
By the operation as described above, the electrostatic charge accelerating particles m adhered on the surface of the photosensitive member 1 will not affect the image exposure harmfully and an excellent print image can be obtained.
<EMBODIMENT 6> (FIG. 10)
The bias for the electrical conductive member 6 can be allowed to have a sequence for fluctuating at lease one from the frequency, the amplitude and the direct current component of the alternating voltage to be applied.
This embodiment is approximately the same as embodiment 3 and 4, which is characterized in that the bias to be applied to the electrical conductive member 6 is made variable to the electrical conductive member 6 is made variable at a printing time and a nonprinting time, and which is an image forming apparatus characterized in that, at an image printing time, since (b−f)/e is equal to or more than 0.2[−V/μm] and less than 0.3[−V/μm], the excessive supply of the electrification accelerating particles is controlled while the charge of the transfer residual developers is made proper, and at a nonimage printing time, since the electrification accelerating particles are supplied to the photosensitive member, (b−f)/e is equal to or more than 0.3[−V/μm].
That is, at the image printing, the same bias as the embodiment 5 is applied to the electrical conductive member 6 and, at the nonprinting time, the same bias as the embodiment 4 is applied.
The sequence of the DC bias potential for the electrical conductive member 6 is shown in FIG. 10 .
At the image printing time, similar to the embodiment 5, a rectangular wave having a peak to peak voltage of 1600 V, a frequency of 500 Hz and a DC composition of −800 V is applied and, at the nonprinting time, a rectangular wave having a peak to peak voltage of 1600 V, a frequency of 500 Hz and a DC composition of −900 V is applied.
As shown in FIG. 10, at the image printing time, the DC composition is −800, that is, (b−f)e is 0.24[−V/μm] and, at the nonimage printing time, the DC composition is −900 V, that is, (b−f)/e is 0.44[−V/μm].
In this embodiment, during the image printing time, similar to the embodiment 5, the excessively supplied electrification accelerating particles m are allowed to stay M in the proximity alienating portion e between the electrical conductive member 6 and the electrifying roller 2 as shown in FIG. 8 so that the electrification accelerating particles m are prevented to be supplied excessively on the surface of the photosensitive member 1 .
At the nonprinting time, since (b−f)/e becomes larger than 0.3[−V/μm], the stay M of the electrification accelerating particles m as shown in FIG. 8 is not caused, but the accumulated electrification accelerating particles m are discharged and the excessive amount of the electrification accelerating particles can be recovered inside the developing apparatus 3 through the surface of the photosensitive member 1 .
In this embodiment, since the electrification accelerating particles m stay M in front of the proximity alienating portion e between the electrical conductive member 6 and the electrifying roller 2 and have a high number of charge quantities, the re-recovery thereof toward the developing apparatus 3 is possible in a highly efficient manner.
For this reason, the continuous adherence of the electrification accelerating particles m on the surface of the photosensitive member 1 is prevented and an excellent print image can be obtained without affecting the print image harmfully.
<OTHERS>
1) The electrifying roller 2 as a contact electrifying member is not limited to the configuration of the electrostatic roller of the embodiments. It can be replaced with a rotating belt member. A material or a form such as a felt, a cloth and the like can be used. Moreover, by laminating them, it is possible to obtain more proper elasticity and conductivity.
2) The injection charge mechanism in the electrostatic charging is such that a contacting ability to the electrified member of the contact electrifying member has a noticeable effect on the electrification property. Hence, the contact electrifying member is not only more precisely configured, but also configured to have a number of peripheral speed differences with the electrified member and to contact the electrified member at higher frequencies.
Moreover, the charge injection layer is provided on the surface of the electrified member, thereby controlling the resistance of the electrified member to make the injection charging mechanism in the contact electrification dominantly workable.
The charge injection layer is formed in a film by a photo-curing method after coating SnO 2 ultra-micro particle (a diameter of about 0.03μm) as an electrical conductive particle (electrical conductive filler), lubricating agents such as 4 fluoride ethylene resin (trade name: TEFULON), polymerization initiator and the like which are mixed and dispersed in photo-curing type acryl resin as a binder.
The important point as the charge injection layer is found in the resistance of surface layer. In the electrostatic charging method by the direct injection of a charge, by reducing the resistance at the side of the electrified member, the giving and receiving of the charge is made more efficiently. On the other hand, when it is used as a photosensitive member, since it is necessary to hold an electrostatic latent image for a certain time, the volume resistivity of the charge injection layer is acceptable to be kept in a range of 1×10 9 -1×10 14 (Ω.cm).
Moreover, even in the case where the charge injection layer is not used, the same effect can be obtained when, for example, the charge conveying layer is within the range of the above described volume resistivity.
Further, even when an amorphous silicon photosensitive member having the volume resistivity of the surface layer of 10 13 Ω.cm is used, the same effect is obtained.
3) When an AC voltage (alternating voltage) composition is applied to the contact electrifying member, the developing apparatus and the like, a sine wave, a rectangular wave, a chopping wave and the like as the AC voltage waveform can be used as occasion demands. Moreover, the rectangular wave formed by periodically turning a direct current power source on and off may be used. In this manner, a bias where the value of the voltage is periodically changed as a waveform of the alternating voltage can be used.
4) An image exposing means for forming an electrostatic latent image is not limited to a laser scanning exposing means for forming a digital-like latent image such as the example of the embodiment, but other light-emitting element such as an ordinary analogue-like image exposure, LED and the like may be acceptable. Whatever it may be, it is acceptable if it can form an latent image corresponding to the image information such as the combination of the light-emitting elements such as fluorescent lamp and the like and a liquid-crystal shutter and the like.
An image bearing member 1 may be an electrifying recording dielectric substance. In this case, the surface of the dielectric substance is uniformly primarily charged with a predetermined polarity and potential and, after this, selectively rejected from the charge by a charge rejecting means such as a charge rejecting needle head, an electron gun and the like so that the object electrostatic latent image is written and formed.
5) The developing means 3 were described in the example of the embodiment with reference to the reversal developing which is caused by the non-magnetic one composition insulating developers. Needles to mention, however, the developing method and configuration thereof should not be limited to those described in the embodiments. Even normal developing means may be acceptable.
6) The image forming apparatus of the present invention may be provided with a cleaner for removing the transfer residual developers and papers from the surface of the image bearing member after the transfer.
7) The recorded member for receiving the transfer of the developer image from the image bearing member 1 may be an intermediate transferring material such as a transfer drum and the like.
8) The electrical conductive member 6 can be also replaced with a nonrotary fixed member.
As described above, according to the present invention, in the contact electrifying method using the electrification accelerating particles, the electrical conductive member is placed noncontact-wise opposite to the image bearing member between the transfer process and the electrification process and, by applying a voltage including the alternating current to the electrical conductive member or by placing the electrical conductive member noncontact-wise in close proximity to the rotating contact electrifying member so as to apply the alternating current, the transfer residual developers are allowed to have a proper charge, thereby preventing the excessive amount of the electrification accelerating particles from adhering on the surface of the image bearing member to affect the print image with the result that an excellent electrification property and print image can be obtained.
While the embodiments of the present invention have been described as above, it is evident that the present invention is not limited to these embodiments but all modifications and variations will be possible in the light of the technological concept.
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An image forming apparatus includes an image bearing member for bearing an electrostatic image. A developing device develops the electrostatic image on the image bearing member by toners charged with a predetermined polarity. A transfer device transfers a toner image on the image bearing member to a transferring material. An electrifying device inject-charges the image bearing member having transfer residual toners. An electrical conductive member provided and spaced apart from the image bearing member in a moving direction of the image bearing member downstream farther than the transfer means and upstream farther than the electrifying device. An electrical field forming device for forming an alternative electrical field between the electrical conductive member and the image bearing member.
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