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FIELD OF THE INVENTION
[0001] The field of the invention is isoflavones.
BACKGROUND OF THE INVENTION
[0002] The isoflavones are a group of naturally occurring plant compounds having the aromatic heterocyclic skeleton of flavan. Soybeans are the most common and well known source of isoflavones, reported to contain the isoflavones, daidzin, genistin, glycitin, 6″-dadidzin-O-acetyl, 6″-O-acetyl genistin, 6″-O-malonyl daidzin, and 6″-O-malonyl genistin. (see U.S. Pat. No. 5,679,806 to Zheng et al., (October 1997) incorporated herein by reference). Isoflavones are present in processed soy foods as well, including miso and soy sauce. Legumes, lupine, fava bean, kudzu and psoralea may also be important sources. The existence of isoflavones in Pueraria has long been known, with the roots of Pueraria containing several isoflavone compounds, such as daidzin, and puerarin.
[0003] Isoflavones are known in aglucone forms, as well as 7-acetylated and 7-substituted glycosides. Especially important isoflavones in aglucone form include daidzein, genistein, and glycitein. Especially important isoflavones in 7-glycoside form include daidzin, genistin, and glycitin. Genistein is also known to occur naturally as a 4′-glucoside (sophoricoside), and a 4′-methyl ether (biochanin A).
[0004] Isoflavones in general, and genistein in particular, have structural similarities to that of certain human estrogens, and such compounds are said to have estrogenic activity. Isoflavones are also said to have other useful biological and pharmacological activities, including antiangiogenic, antihemolytic, antiischemic, antileukemic, antimitogenic, antimutagenic, antioxidant, fungicidal, pesticidal, MAO-inhibition, phytoalexin, and tyrosine kinase inhibition activities (1).
[0005] The anticancer effects of genistein are of particular interest. Genistein may exert antitumor effects in part by inhibiting angiogenesis, i.e., reducing formation of vasulature and blood flow to the tumor. Its affinity to estrogenic sites in the vicinity of cancer cells may also inhibit tumor growth. As a well-known inhibitor of the enzyme tyrosine kinase, genistein may also inhibit energy and signaling pathways in tumors. Examples of research are described in references 4 and 5.
[0006] Genistein and other isoflavones are also said to be important contributors to bone health, resulting at least in part from the ability of these compounds to inhibit protein kinase activity, and thereby inhibit osteoclast cell activity. The isoflavones are especially attractive in this regard because they generally have a low toxicity relative to many other known protein kinase inhibitors. Examples of research along these lines are described in references 6 and 7. Citations for still other research articles describing beneficial effects of isoflavonoids are set forth as references.
[0007] Because of its many beneficial effects, enriched sources of genistein are marketed to consumers around the world in a wide variety of nutritional supplements. Many of the health benefits of soy products are ascribed to the presence of genistein.
[0008] Unfortunately genistein and other isoflavones are very insoluble in water. See, for example, descriptions of genistein, genistin, biochanin A, and sophoricoside in the Merck Index (3). The insolubility of the isoflavones complicates their formulation into foodstuffs and cosmetics, many of which are aqueous-based systems. Low solubility is also frequently an impediment to efficient bioavailability in orally administered products. Low solubility is a particularly serious impediment to formulation of intravenous medications, which are most often delivered in aqueous media.
[0009] Thus, there is a continuing need to provide isoflavones in forms which have increased bioavailability, especially enhanced aqueous solubility relative to the unmodified compounds, while retaining the active properties of such unmodified compounds.
SUMMARY OF THE INVENTION
[0010] Methods and compositions of the present invention provide increased bioavailability of isoflavones by converting a starting isoflavone into a pro-compound. This is preferably accomplished by attaching a polar (solubilizing) leaving group which can be readily hydrolyzed under physiologic conditions to produce the starting isoflavone.
[0011] In preferred embodiments, an alcohol functionality of an isoflavone is esterified using a carboxylic acid group or a phosphoric acid group. This yields a carboxylic acid hemiester or a phosphate ester. In general, fluids of the digestive and absorptive gastrointestinal tract, other acids, and various enzymes are capable of hydrolyzing the esterified isoflavone to the starting isoflavone.
[0012] In another aspect of the invention, the starting isoflavone preferably comprises a natural isoflavone, more preferably comprises genistin or daidzin, and still more preferably comprises an aglycone form such as genistein or daidzein.
[0013] In still other aspects of the invention, the pro-compounds may advantageously be employed therapeutically or prophylactically for a variety of conditions, provided as a dietary supplement, or added to natural or processed food-stuffs. Thus, the pro-compounds may be used as pro-drugs or pro-nutrients.
[0014] Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a structural representation of a generalized isoflavone.
DETAILED DESCRIPTION
[0016] [0016]FIG. 1 depicts a generalized isoflavone.
[0017] Using this structure as a reference, known isoflavones include the following (where the 6″ position is on the glucose ring):
Isoflavone R 8 R 7 R 6 R 5 R 4 ′ daidzin H O-glucose H H OH genistin H O-glucose H OH OH glycitein H OH OMe H H puerarin glucose OH H H H 6″-O-acetyl daidzin H O-acetyl glucose H H OH 6″-O-acetyl genistin H O-acetyl glucose H OH OH 6″-O-malonyl daidzin H O-malonyl H H OH glucose 6″-O-malonyl genistin H O-malonyl H OH OH glucose genistein H OH H OH OH daidzein H OH H H OH glycitin H O-glucose OMe H H
[0018] It is now contemplated that a natural or modified isoflavone may be esterified to provide a pro-compound having increased bioavailability, and in particular enhanced aqueous solubility relative to the unesterified isoflavone. In preferred embodiments one or more of R 7 , R 6 , R 5 and R 4 ′ comprise ZCOO— or ZPO 4 —, where Z is selected from the group consisting of a straight or branched aliphatic chain, including an alkyl, alkenyl, alkynyl, alkoxyalkyl, alkylthioalkyl, aminoalkyl group, including substituted derivatives of such groups, a substitute or non-substituted cycloalkyl, and an aromatic group, including aryl, aralkyl, or alkylaryl, and substituted derivatives such as where a ring contains one or more nitrogen, sulfur, oxygen, phosphorous or silicon heteroatoms. Such compounds are considered herein to be esterified isoflavones in which an isoflavones is modified by esterification in at least one of the C4′, C5, C6, and C7 positions.
[0019] To clarify further, it is contemplated that Z may comprise hydrogen; hydroxyl; cyano; nitro; halo; alkyl such as methyl, ethyl, butyl, pentyl, octyl, nonyl, tert-butyl, neopentyl, isopropyl, sec-butyl, dodecyl and the like, alkenyl such as 1-propenyl, 4-butenyl, 1-pentenyl, 6-hexenyl, 1-heptenyl, 8-octenyl and the like; alkoxy such as propoxy, butoxy, methoxy, isopropoxy, pentoxy, nonyloxy, ethoxy, octyloxy, and the like; alkanoyl such as butanoyl, pentanoyl, octanoyl, ethanoyl, propanoyl and the like; arylamino and diarylamino such as phenylamino, diphenylamino and the like; alkylsulfinyl, alkylsulfonyl, alkylthio, arylsulfonyl, arylthio, and the like, such as butylthio, neopentylthio, methylsulfinyl, benzylsulfinyl, phenylsulfinyl, propylthio, octylthio, nonylsulfonyl, octylsulfonyl, methylthio, isopropylthio, phenylsulfonyl, methylsulfonyl, nonylthio, phenylthio, ethylthio, bezylthio, phenethylthio, sec-butylthio, naphthylthio and the like; alkoxycarbonyl such as methoxycarbonyl, ethoxycarbonyl, butoxycarbonyl and the like; alkyl amino and dialkylamino such as dimethylamino, methylamino, diethylamino, ethylamino, dibutylamino, butylamino and the like; cycloalkyl such as cyclohexyl, cyclopentyl, cyclooctyl, cycloheptanyl and the like; alkoxyalkyl such as methoxymethylene, ethoxymethylene, butoxymethylene, propoxyethylene, pentoxybutylene and the like; arylalkylamino such as methylphenylamino, ethylphenylamino and the like; aryloxyalkyl and aryloxyaryl such as phenoxyphenylene, phenoxymethylene and the like; and various substituted alkyl and aryl groups such as 1-hydroxybutyl, 1-aminobutyl, 1-hydroxylpropyl, 1-hydroxypentyl 1-hydroxyoctyl, 1-hydroxyethyl, 2-nitroethyl, trifluoromethyl, 3,4-epoxy-butyl, cyanomethyl, 3-chloropropyl, 4-nitrophenyl, 3-cyanophenyl, 1-hydroxymethyl, and the like; hydroxyl terminated alkyl and aryl groups such as, 2-hydroxy ethyl, 4-hydroxy butyl and 4-hydroxy phenyl; sulfonic, sulfuric, carboxylic, phosphoric and phosphoric acid terminated alkyl and aryl groups such as ethylsulfonic acid, propylsulfonic acid, butylsulfonic acid, phenylsulfonic acid, and the corresponding carboxylic and phosphoric acids and derivatives of said sulfonic, carboxylic and phosphoric acids as for example salts, esters and the like.
[0020] Of course, those skilled in the art will appreciate that higher solubility in aqueous environments is generally preferred over lower solubility. Thus, where R 7 , R 6 , R 5 or R 4 ′ comprise ZCOO—, Z is advantageously selected to have a polar group, and any alkyl segment is advantageously selected to be small. Among the dicarboxylic acid groups, hemisuccinate is by far the most common, useful and biocompatible group, and is specifically contemplated for this purpose. Glutarate and adipate are also preferred.
[0021] Where R 7 , R 6 , R 5 and R 4 ′ comprise ZPO 4 —, a (OH) 2 PO 2 ester is preferred because it has two polar groups, is a good solubilizer, and has high biological compatibility. Any additions to the PO 4 (such as (RO) 2 PO 2 —) are contemplated to generally reduce aqueous solubility, and are therefore disfavored.
[0022] With respect to complexes, it is contemplated to employ metal salts of the esterified isoflavones, especially Li+, Na+, K+, Mg++ and ammonium salts, including NH4+ and low molecular weight mono- or polyalkylammonium.
EXAMPLES
[0023] By way of example, and not of limitation, several embodiments of the inventive subject matter have been prepared and characterized. These examples all fall within the group of pro-compounds where at least one of R 7 , R 6 , R 5 and R 4 ′ is H 2 PO 4 —, and HOOC—(CH 2 )x—COO— where x=2, 3, or 4. These new phosphate esters and hemiesters are all water soluble and readily hydrolyzed. They are also stable. In aqueous solutions of the exemplified compounds, for example, hydrolysis occurs to the extent of less than 1% per day, when stored at pH 7.4 and 37° C. Dry formulations of the same compounds appear to be indefinitely stable.
Example 1
Mixed Phosphate Esters of Genistein
[0024] A solution of genistein (135 mg, 0.5 mmole) and di-tert-butyl phosphoramidite (330 ul, 1.0 mmole) in DMF (1 ml) was stirred under argon while 1H-tetrazole (210 mg in 0.5 ml of DMF; 3.0 mmole) was added dropwise. After a few minutes, the solution was cooled to −20° C., then a solution of m-chloroperbenzoic acid (260 mg in 0.5 ml of methylene chloride, 1.5 mmole) was added dropwise. After warming to room temperature, the mixture was diluted threefold with ethyl acetate, then washed with 10% sodium metabisulfie and 10% sodium bicarbonate. A wash with 5% sodium carbonate removed a trace of unreacted genistein.
[0025] The ethyl acetate solution, containing the butyl esters of the genistein phosphates, was washed with 1M HCl and dried over sodium sulfate. After removal of the solvent in vacuo, the residue was treated with 30% TFA in acetic acid for 90 minutes at room temperature. The solvents were removed in vacuo, and the residue was taken up in ethanol and neutralized with sodium hydroxide to pH 5.5. Removal of the solvent in vacuo left a mixture of sodium salts of genistein phosphates, 145 mg.
[0026] HPLC analyses were performed using a Chrompack Intersil C8 column, 4.6×250 mm. The solvent was a mixture of 25% acetonitrile and 75% 0.1 M diammonium phosphate, pH 2.5, at a flow rate of 1 ml/min. Detection was by UV at a wavelength of 260 nm.
[0027] HPLC analysis of the phosphate mixture showed approximately equal amounts of the 4′-phosphate, the 7-phosphate and the 4′,7-diphosphate, and only a small amount of the 5-phosphate.
Example 2
Genistein-7-phosphate
[0028] a) Genistein-7-tosylate: p-Toluenesulfonyl chloride (540 mg, 2.8 mmoles) was added during 4 hours to a stirred mixture of genistein (730 mg, 2.7 mmoles) and potassium carbonate (2 g) in 25 ml of acetone. After stirring overnight, the mixture was poured into brine and extracted with ethyl acetate. The extract was evaporated under vacuum, and the residue chromatogrammed through silica gel with dichloromethane and chloroform. Crystallization from methanol yielded 920 mg (80.2% yield) of genistein-7-tosylate. The proton magnetic resonance spectrum was consistent with the expected structure.
[0029] b) 4′,5-Di(methoxymethyl)-genistein-7-tosylate: Chloromethyl methyl ether (90 ul, 1.12 mmoles) was added to a solution of genistein-7-tosylate (106 mg, 0.25 mmoles) and diisopropylethylamine (200 ul, 1.15 mmoles) in 0.6 ml of dioxane, under argon atmosphere, and stirred overnight. The mixture was poured into brine, extracted with ethyl acetate, and chromatogrammed through silica gel with dichloromethane. Crystallization from methanol yielded 115 mg (90% yield) of 4′,5-Di(methoxymethyl)-genistein-7-tosylate. The proton magnetic resonance spectrum was consistent with the expected structure.
[0030] c) 4′,5-Di(methoxymethyl)-genistein: Potassium carbonate (700 mg) in water (5 ml) was added to a solution of 4′,5-di(methoxymethyl)-genistein-7-tosylate (600 mg, 1.17 mmoles) in 15 ml methanol under argon, and stirred overnight. The mixture was poured into brine, extracted with ethyl acetate, and recrystallized from methanol. The yield of 4′,5-Di(methoxymethyl)-genistein was 344 mg (82%).
[0031] The electrospray mass spectrum in negative mode showed ion m/z 357[M−1] which confirmed the expected molecular weight of 358. The proton and carbon magnetic resonance spectra were consistent with the expected structure.
[0032] d) Genistein-7-phosphate: 1H-Tetrazole (120 mg, 1.7 mmoles) was added to a solution of di-tert-butyl-diethylphosphoramidite (180 ul, 0.64 mmoles) and 4′,5-di(methoxymethyl)-genistein (200 mg, 0.56 mmoles) in 1.5 ml of N,N-dimethylacetamide under argon. After 10 minutes at room temperature, the mixture was cooled to −40° C., and a solution of m-chloroperbenzoic acid (130 mg, 0.75 mmoles) in dichloromethane was added rapidly. After warming to room temperature, the mixture was diluted with ether and washed with brine containing sodium bicarbonate. The solvent was removed, and the residue treated with 40% trifluoroacetic acid in acetic acid for 30 minutes. The volatile acids were removed under vacuum, and the residue dissolved in 2-propanol (4 ml) containing 0.2 ml 6N HCl and left overnight. The mixture was poured into brine and extracted with ethyl acetate. The solvent was removed, and the residue was dissolved in ethanol (3 ml) and adjusted to pH 5.5 with NaOH. After evaporation, the residue was crystallized from ethanol, yielding 155 mg (75% yield) of genistein-7-phosphate as the sodium salt.
[0033] The electrospray mass spectrum in negative mode showed ion m/z 349[M−1] which confirmed the expected molecular weight of 350. The nuclear magnetic resonance spectra were consistent with the expected structure.
Example 3
Mixed Hemisuccinate Esters of Genistein
[0034] A solution of genistein (135 mg, 0.5 mmole) in 2.0 ml of pyridine was stirred at room temperature while succinic anhydride (100 mg, 1.0 mmole) was added in several portions. After stirring overnight at room temperature, the solvent was removed in vacuo. The gummy residue was taken up in water, adjusted to pH 3.0, and extracted three times with ethyl acetate. The ethyl acetate extracts were washed with water, then evaporated to dryness in vacuo. The crude mixture of mixed hemisuccinic acid esters weighed 205 mg.
[0035] Thin layer chromatography of the product showed principally the presence of mixed mono- and disuccinate esters of genistein. The product was completely soluble in phosphate buffer at pH 7.
Example 4
-Genistein-7-hemisuccinate
[0036] To a solution of 4′,5-Di(methoxymethyl)-genistein (see example 2c) (100 mg, 0.28 mmole) in 1.5 ml of pyridine was added succinic anhydride (50 mg, 0.5 mmole) with stirring at room temperature. After stirring overnight, the solvent was removed in vacuo. The residue was taken up in water containing one drop of glacial acetic acid, and again evaporated to dryness in vacuo. The residue was chromatogrammed through silica gel with dichloromethane and ethyl acetate. The yield of the 7-hemisuccinic ester of 4′,5-di(methoxymethyl)-genistein was 102 mg (78%). The product was dissolved in 2-propanol (3 ml) containing 0.2 ml 6N HCl and left overnight. The solution was evaporated to dryness. The residue taken up in 1 ml of ethyl acetate and crystallized by the addition of hexane. The yield of genistein-7-hemisuccinate was 52 mg (50%).
Example 5
Non-Enzymatic Hydrolysis of Hydrolysis of Genistein Esters
[0037] HPLC analysis was conducted using a Partisil ODS-3 column (9.5×250 mm), with methanol as the mobile phase, and UV detection at 260 nm.
[0038] A solution of genistein-7-phosphate (2.5 mg) in 5 ml of phosphate-buffered saline (0.1 M) at pH 7.4 was incubated at 37° for 10 days. Analysis by HPLC showed that absence of free genistein.
[0039] A solution of genistein-7-hemisuccinate (2.5 mg) in 5 ml of phosphate-buffered saline (0.1 M) at pH 7.4 was incubated at 37° for 10 days. Analysis by HPLC showed a conversion of about 4% of the hemisuccinate ester to free genistein.
Example 6
Hydrolysis of Genistein-7-phosphate by Various Enzymes and Biological Media
[0040] In each of these experiments, free genistein was extracted with a 1:1 mixture of ethyl acetate and hexane, then analyzed by HPLC under the conditions described in example 5.
[0041] a) In human serum (Sierra Biologicals) at 37° C., the half-life for hydrolysis to free genistein was about 5 hours.
[0042] b) In human blood (Sierra Biologicals) at 37° C., the half-life for hydrolysis to free genistein was about 6 hours.
[0043] c) In rat blood (Sierra Biologicals) at 37° C., the half-life for hydrolysis to free genistein was about 30 minutes.
[0044] d) In human serum (Sierra Biologicals) at 37° C., the half-life for hydrolysis to free genistein was about 5 hours.
[0045] e) In alkaline phosphatese type VII-S at 37° C., the initial rate of hydrolysis to free genistein was 0.08% per minute.
[0046] This enzyme is from bovine intestinal mucosa (Sigma cat no. P5521). 0.5 DEA units were dissolved in 1.0 ml of 0.1 M glycine buffer pH 10.4, and the initial substrate concentration was 1.07 mM.
[0047] f) In alkaline phosphatese type XXIV at 37° C., the initial rate of hydrolysis to free genistein was 0.05% per minute.
[0048] This enzyme is from human placenta (Sigma cat no. P3895). 0.1 glycine units were dissolved in 1.0 ml of 0.1 M glycine buffer pH 10.4, and the initial substrate concentration was 1.07 mM.
[0049] Uses
[0050] It is contemplated that esterified isoflavones will be readily converted to free isoflavone in biological media such as gastrointestinal fluid and blood. Among other things, gastrointestinal fluids often have enzymes and sufficiently high pH to hydrolyze ester bonds, and blood generally contains enzymes such as phosphatases and esterases which can hydrolyze phosphate ester and carboxylate ester bonds.
[0051] Contemplated uses of esterified isoflavones include any presently known or later discovered uses for isoflavones or isoflavonoids. Among other things, it is contemplated that esterified isoflavones can be administered to (which term is used herein to include “taken by”) a person for any of the beneficial effects for which a natural isoflavonoid is thought to be advantageous. This specifically includes any of the effects listed above or described in any of the literature cited herein, and includes uses where the desired effect is antiangiogenic, antihemolytic, antiischemic, antileukemic, antimitogenic, antimutagenic, antioxidant, fungicidal, pesticidal, MAO-inhibition, phytoalexin, and tyrosine kinase inhibition. It is especially contemplated that esterified isoflavones can be used to treat osteoporosis and other symptoms of estrogen deficiency in postmenopausal women. Also, it is contemplated that the compounds of the present invention can be used to prevent osteoporosis and consequent fractures that result from osteoporosis, which are major contributors to morbidity and mortality in the elderly. Still further, it is contemplated that esterified isoflavones can be used prophylactically to provide UV protection and in other ways to improve general skin health, to stimulate the immune system, and to reduce undesirable effects of oxidation (i.e., provide antioxidant benefits).
[0052] Those skilled in the art will recognize that esterified isoflavones may be employed in many different ways. When taken orally, esterified isoflavones may be incorporated into food or beverage material, for nutritional, therapeutic, prophylactic value, or any combination of these. Esterified isoflavones may also be administered by any appropriate form of in vivo delivery, which is defined herein to include oral, intravenous, subcutaneous, intraperitoneal, intrathecal, intramuscular, intracranial, inhalational, topical, transdermal, suppository (rectal), pessary (vaginal), administration and the like. Thus, delivery may occur through foods, pills, capsules or liquids as a nutritional supplement, or as a pharmaceutical.
[0053] By way of example, it is contemplated that compounds according to the present invention can be administered alone, or formulated in admixture with a pharmaceutically acceptable carrier. For example, the compounds of the present invention can be administered orally as pharmacologically acceptable salts. Because preferred compounds of the present invention are relatively water soluble, they can be administered intravenously in physiological saline solution (e.g., buffered to a pH of about 7.2 to 7.5). Conventional buffers such as phosphates, bicarbonates or citrates can be used for this purpose. Of course, one of ordinary skill in the art may modify the formulations within the teachings of the specification to provide numerous formulations for a particular route of administration without rendering the compositions of the present invention unstable or compromising their therapeutic activity. It is also well within the ordinary skill of the art to modify the route of administration and dosage regimen of a particular compound in order to manage the pharmacokinetics of the present compounds for maximum beneficial effect in patients. One of ordinary skill in the art will also take advantage of favorable pharmacokinetic parameters of the pro-drug forms, where applicable, in delivering the present compounds to a targeted site within the host organism or patient to maximize the intended effect of the compound.
[0054] In addition, compounds according to the present invention may be administered alone or in combination with other agents for the treatment of the above mentioned diseases or conditions. Combination therapies according to the present invention may comprise the administration of at least one compound of the present invention or a functional derivative thereof, and at least one other pharmaceutically active ingredient. The active ingredient(s) and pharmaceutically active agents may be administered separately or together and when administered separately this may occur simultaneously or separately in any order. The amounts of the active ingredient(s) and pharmaceutically active agent(s) and the relative timings of administration will be selected in order to achieve the desired combined therapeutic effect.
[0055] To prepare the pharmaceutical compositions according to the present invention, a therapeutically effective amount of one or more of the compounds according to the present invention is preferably intimately admixed with a pharmaceutically acceptable carrier according to conventional pharmaceutical compounding techniques to produce a dose. A carrier may take a wide variety of forms depending on the form of preparation desired for administration, e.g., oral or parenteral. In preparing pharmaceutical compositions in oral dosage form, any of the usual pharmaceutical media may be used. Thus, for liquid oral preparations such as suspensions, elixirs and solutions, suitable carriers and additives including water, glycols, oils, alcohols, flavouring agents, preservatives, colouring agents and the like may be used. For solid oral preparations such as powders, tablets, capsules, and for solid preparations such as suppositories, suitable carriers and additives including starches, sugar carrier, such as dextrose, mannitol, lactose and related carriers, diluents, granulating agents, lubricants, binders, disintegrating agents and the like may be used. If desired, the tablets or capsules may be enteric-coated or sustained release by standard techniques.
[0056] Thus, specific embodiments and applications of esterified isoflavones have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.
REFERENCES: (INCORPORATED HEREIN BY REFERENCE)
[0057] 1. Phytochemical Database of the USDA Agricultural Research Service, Stephen M. Beckstrom-Sternberg & James A. Duke, Internet address: www.ars-grin.gov/˜ngrlsb/
[0058] 2. A comparative survey of leguminous plants as sources of the isoflavones, genistein and daidzein: implications for human nutrition and health. Kaufman P B; Duke J A; Brielmann H; Boik J; Hoyt J E, J Altern Complement Med, 1997, vol. 3 (1) p7-12.
[0059] 3. The Merck Index, 12th Edition (1996), Merck & Co., Inc, Whitehouse Station, N.J., genistein, genistin, biochanin A: entry no. 4395 sophoricoside: entry no. 8867
[0060] 4. Genistein inhibits growth of B16 melanoma cells in vivo and in vitro and promotes differentiation in vitro. Record I R; Broadbent J L; King R A; Dreosti I E; Head R J; Tonkin A L. Int. J. Cancer, 1997, vol 72 (5) p860-4
[0061] 5. Genistein inhibits proliferation and in vitro invasive potential of human prostatic cancer cell lines. Santibanez J F; Navarro A; Martinez J. Anticancer Res, 1997, vol 17 (2A) p1199-204
[0062] 6. Action of genistein and other tyrosine kinase inhibitors in preventing osteoporosis. Presented by H. C. Blair at: Second International Symposium on the Role of Soy in Preventing and Treating Chronic Disease, Sept.15-18, 1996, Brussels, Belgium.
[0063] 7. Inhibitory effect of genistein on bone resorption in tissue culture. Yamaguchi M; Gao Y H. Biochem Pharmacol, 1998, vol 55 (1) p71-6.
[0064] 8. Effect of soybean phytoestrogen intake on low density lipoprotein oxidation resistance. Tikkanen M J et al., Proc Natl Acad Sci (USA), March 1998, vol 95 (6), p3106-10.
[0065] 9. Genistein, the dietary-derived angiogenesis inhibitor, prevents LDL oxidation & protects endothelial cells from damage by atherogenic LDL. Kapiotis S, et al. Arterioscler Thromb Vasc Biol (US), November 1997, vol 17(11), p2868-74.
[0066] 10. Effect of structurally related flavones/isoflavones on hydrogen peroxide production and oxidative DNA damage in phorbol ester-stimulated HL-60 cells. Giles D, Wei H. Nutr Cancer (US), 1997, vol 29(1), p77-82.
[0067] 11. Antioxidant activity of phytoestrogeneic isoflavones. Ruiz-Larrea M B, et al. Free Radic Res. (Switzerland), January 1997, vol 26(1), p63-70.
[0068] 12. Antioxidant and antipromotional effects of the soybean isoflavone genistein. Wei H., et al. Proc Soc Exp Biol Med (US), January 1995, vol 208(1), p124-30.
[0069] 13. Mechanism of antioxidant action of pueraria glycoside (PG)-1 (an isoflavonoid) and mangiferin (a xanthonoid). Sato T, et al., Chem Pharm Bull (Japan), March 1992, vol 40 (3) p721-4.
[0070] 14. Inhibition of UV light- and Fenton reaction-induced oxidative DNA damage by the soybean isoflavone genistein. Wei H, et al. Carcinogenesis (England), January 1996, vol 17(1) p73-7.
[0071] 15. Evolution of the health benefits of soy isoflavones. Barnes S. Proc Soc Exp Biol Med (US) March 1998, vol 217 (3), p386-92.
[0072] 16. Natural and synthetic isoflavones in the prevention and treatment of chronic diseases. Brandi M L, Calcif Tissue Int (US) 1997, 61 Suppl 1, pS5-8.
[0073] 17. Effect of isoflavones genistein and daidzein in the inhibition of lung metastasis in mice induced by B 16F-10 melanoma cells. Menon L G, et al. Nutr Cancer (US), 1998, vol 30 (1) p74-7.
[0074] 18. Enhancement of immune function in mice fed high doses of soy daidzein. Zhang R., et al.; Nutr Cancer (US), 1997, vol. 29(1) p24-8.
[0075] 19. Inhibition of N-methyl-N-nitrosourea-induced mammary tumors in rats by the soybean isoflavones. Constantinou A., Anticancer Res (GREECE) November-December 1996, vol. 16(6A), p3293-8.
[0076] 20. Kudzu root: an ancient Chinese source of modern antidipsotropic agents. Keung W. M., et al.; Phytochemistry (US), February 1998, vol. 47(4), p499-506.
[0077] 21. Isoflavonoid compounds extracted from Pueraria lobata suppress alcohol preference in a pharmacogenetic rat model of alcoholism. Lin R. C., et al.; Alcohol Clin Exp Res (US), June 1996, vol. 20(4), p659-63.
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Isoflavones are modified by esterification at one or more of the C4′, C5, C6, and C7 positions to promote bioavailability, and especially to enhance solubility over the corresponding unesterified isoflavones. Preferred modifications produce a carboxylic acid hemiester or a phosphate ester which is biologically hyrolyzable. Preferred starting isoflavones are genistin and daidzin, and still more preferably comprises an aglycone form such as genistein or daidzein. Esterified isoflavones may be employed therapeutically or prophylactically for a variety of conditions, provided as a dietary supplement, or added to natural or processed food-stuffs.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is:
a continuation of copending U.S. patent application Ser. No. 14/561,333, filed, Dec. 5, 2014; and a continuation of U.S. patent application Ser. No. 14/191,014, filed Feb. 26, 2014, now U.S. Pat. No. 8,945,827 (which application claims the priority, under 35 U.S.C. §119, of U.S. Provisional Patent Application No. 61/778,544, filed Mar. 13, 2013), of which priority is claimed under 35 U.S.C. §120; the prior applications are herewith incorporated by reference herein in their entireties.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0004] Not Applicable
FIELD OF THE INVENTION
[0005] The present invention lies in the field of medical testing. The present disclosure relates to serological methods and diagnostic tests for syphilis antibodies.
BACKGROUND OF THE INVENTION
[0006] Syphilis is a sexually transmitted infection caused by the spirochete bacterium treponema pallidum subspecies pallidum . The primary route of transmission is through sexual contact; it may also be transmitted from mother to fetus during pregnancy or at birth, resulting in congenital syphilis. Other human diseases caused by related treponema pallidum include yaws (subspecies pertenue), pinta (subspecies carateum ), and bejel (subspecies endemicum ).
[0007] The signs and symptoms of syphilis vary depending in which of the four stages it presents (primary, secondary, latent, and tertiary). The primary stage classically presents with a single chancre (a firm, painless, non-itchy skin ulceration), secondary syphilis with a diffuse rash which frequently involves the palms of the hands and soles of the feet, latent syphilis with little to no symptoms, and tertiary syphilis with gummas, neurological, or cardiac symptoms. It has, however, been known as “the great imitator” due to its frequent atypical presentations. Diagnosis is usually via blood tests; however, the bacteria can also be detected using dark field microscopy. Syphilis can be effectively treated with antibiotics, specifically the preferred intramuscular penicillin G (given intravenously for neurosyphilis), or else ceftriaxone, and in those who have a severe penicillin allergy, oral doxycycline, or azithromycin.
[0008] Syphilis is believed to have infected 12 million people worldwide in 1999, with greater than 90% of cases in the developing world. After decreasing dramatically since the widespread availability of penicillin in the 1940s, rates of infection have increased since the turn of the millennium in many countries, often in combination with human immunodeficiency virus (HIV). This has been attributed partly to unsafe sexual practices among men who have sex with men, increased promiscuity, prostitution, and decreasing use of barrier protection.
[0009] As set forth above, diagnosis of syphilis is usually through blood tests. There are presently two types of serological tests used for the diagnosis and treatment of syphilis infection: treponemal tests, which utilize antigens prepared from the causative agent treponema pallidum , and non-treponemal tests, which employ antigens not derived directly from the causative agent.
[0010] The Centers for Disease Control (CDC), Atlanta, Ga., recommends that syphilis screening, and the assessment of treatment, be performed first using non-treponemal tests because it is believed that non-treponemal tests are more sensitive. In such tests, a false positive is possible. The CDC further recommends that positive screening test results be confirmed with a treponemal test. It is noted that the non-treponemal tests can be used for monitoring post-treatment and for detection of re-infection. There are currently two non-treponemal tests in common usage: the Venereal Disease Research Laboratory (VDRL) Test and the Rapid Plasma Reagin (RPR) Test.
[0011] The VDRL Test is a non-treponemal serological screening for syphilis used to assess response to therapy, to detect CNS involvement, and as an aid in the diagnosis of congenital syphilis. The basis of the test is that antibody (IgG, IgM or IgA), produced by a patient with syphilis, reacts with a compound comprised of cardiolipin, cholesterol, and lecithin. The test is performed by mixing the patients serum with compound described above. Positive sera result in “flocculation.” Simply put, the VDRL Test is a manual coagulation test with a qualitative, subjective, visual readout requiring the use of a microscope. More specifically, a sample of the patient's antibody is mixed in a test tube, or on a microscope slide. A clinician is required to view the test tube, or slide and determine, based upon the clinician's own experience and training, if the visual presentation indicates coagulation to an extent sufficient to call the results positive. Quantitative test results require a serial dilution of the test sample and testing of multiple dilutions. Thus, the VDRL Test is labor intensive and unable to be automated. It is known that false negatives arise in the VDRL Test due to the Prozone Effect, or “Hook” Effect, in cases of strongly positive samples.
[0012] The RPR Test is a particle agglutination test. The RPR Test also is a manual test, with a qualitative, subjective, visual readout. The RPR Test utilizes a colloidal suspension of cardiolipin, cholesterol, and lecithin, mixed with micro-particulate carbon. Thus, the RPR Test uses the same antigen as the VDRL Test, but, in the RPR Test, the antigen has been bound to a carbon particle to allow visualization of the flocculation reaction without the need of a microscope. The mixture is placed on a test area of a card and the clinician is able to read the results based upon a visually detectable clumping of the carbon particles. Like the VDRL Test, the RPR Test is a quantitative test where the results require a serial dilution of the test sample and testing of multiple dilutions. Thus, the RPR Test is labor intensive and unable to be automated. Similarly, false negatives arise due to the Prozone Effect. FIG. 1 is a photograph of a RPR Test card. The clumping of the carbon particles is shown in a positive test result on the left (circle number 9 ). The right test area of the card (circle number 10 ), in contrast, where no clumping has occurred, is indicative of a negative result.
[0013] Three components comprise the VDRL antigen: cardiolipin; cholesterol; and lecithin. These components are lipid in nature. As such, they are not soluble in aqueous solution. In the classical VDRL test, therefore, the three-component antigen complex is used as a colloidal suspension. It must be prepared under very carefully controlled conditions, just prior to performing the test. Due to its inherent lack of stability, the colloidal suspension must be prepared daily for immediate use. Because of the inherent unstable property, there is no way to preserve the mixed antigens in colloidal suspension for long periods of time. It would be beneficial to provide a sensitive and specific non-treponemal syphilis screening and assessment of treatment test, that is stable and has a long shelf life.
[0014] Neither the VDRL Test nor the RPR Test lend themselves to automation. It would be beneficial to provide a syphilis screening and assessment of treatment test that is able to be automated.
[0015] A need exists to overcome the problems with the prior art systems, designs, and processes as discussed above.
SUMMARY OF THE INVENTION
[0016] The invention provides serological methods and diagnostic tests for syphilis antibodies that overcome the hereinafore-mentioned disadvantages of the heretofore-known devices and methods of this general type and enables automation and the test has a long shelf life.
[0017] The serological methods and diagnostic tests for syphilis antibodies according to the invention combine features of the non-treponemal VDRL Test with the Enzyme Linked Immunosorbent Assay (ELISA) process to create an inventive VDRL ELISA Test. ELISA is a test that uses antibodies and color change to identify a substance. It is a type of analytic biochemistry assay that uses a solid-phase enzyme immunoassay (EIA) to detect the presence of a substance, usually an antigen or an antibody, in a liquid sample or wet sample.
[0018] The steps of ELISA, in this iteration also referred to as “indirect” ELISA, follows the mechanism below:
A buffered solution of the antigen is added to each well of a microtiter plate, where it is given time to adhere to the plastic through charge interactions. A solution of non-reacting protein, such as bovine serum albumin or casein, is added to block any plastic surface in the well that remains uncoated by the antigen. The primary antibody is added, which binds specifically to the test antigen coating the well. This primary antibody could also be in the serum of a donor to be tested for reactivity towards the antigen. After a suitable incubation period, the unbound antibody is decanted and the wells are rinsed with a buffered solution. A secondary antibody is added, which will bind the primary antibody. This secondary antibody has an enzyme attached to it, which has a negligible effect on the binding properties of the antibody. After a suitable incubation period, the unbound antibody is decanted and the wells are rinsed with a buffered solution. A substrate for this enzyme is then added. Often, this substrate changes color upon reaction with the enzyme. The color change shows the secondary antibody has bound to primary antibody, which strongly implies the donor has had an immune reaction to the test antigen. The higher the concentration of the primary antibody present in the serum, the stronger the color change. Often, a spectrometer is used to give quantitative values for color strength.
[0025] In ELISA, the enzyme acts as an amplifier; even if only few enzyme-linked antibodies remain bound, the enzyme molecules will produce many signal molecules. Within common-sense limitations, the enzyme can go on producing color indefinitely, but the more primary antibody is present in the donor serum, the more secondary antibody+enzyme will bind, and the faster the color will develop.
[0026] ELISA may be run in a qualitative or quantitative format. Qualitative results provide a simple positive or negative result (yes or no) for a sample. The cutoff between positive and negative is determined by the analyst and may be statistical. The addition of two or three times the standard deviation (error inherent in a test) of the mean value obtained for known negative samples, is often used to distinguish positive from negative samples. In quantitative ELISA, the optical density (OD) of the sample is compared to a standard curve, which is typically a serial dilution of a known-concentration solution of the target molecule. For example, if a test sample returns an OD of 1.0, the point on the standard curve that gave OD=1.0 must be of the same analyte concentration as the sample.
[0027] In sharp contrast to the VDRL and RPR Tests, the VDRL ELISA Test of the invention, is an enzyme immunoassay, the results of which can be read objectively with a spectrophotometer. The inventive syphilis test is, therefore, capable of producing standardized, quantitative, and reproducible results, in a single test and to do so in automation. The VDRL ELISA Test is as sensitive and specific as both the VDRL and RPR test and is compatible with a wide variety of automated analyzers.
[0028] The VDRL and RPR Tests are performed using the antigen complex in the form of a colloidal suspension. In contrast, the antigen complex used in the inventive VDRL ELISA Test is prepared by dissolving the three lipid components in a mixture of organic solvents. This produces a uniform, homogeneous antigen that can be accurately dispensed into microwells, and dried in place. This results in VDRL antigen wells that are uniformly coated. The uniformity of coating facilitates accurate and reproducible test results. The VDRL ELISA antigen coated wells may be stored for extended periods then used to perform an ELISA test. Heretofore, it has been generally understood that wells coated with the VDRL antigen complex could not be stored for extended periods of time and, after such storage, be used to perform in an ELISA test in an accurate and reproducible manner.
[0029] The exemplary embodiments described herein utilize microwells, for example, polystyrene microwells, as the solid-phase of the VDRL ELISA test. Use of the term microwells is not to be taken as limiting any platform of any embodiment only to such microwells. This term, as used anywhere herein, is defined as equally including all other solid-phase platforms that can be substituted for microwells, which platforms are defined to include, but are not limited to, microtubes, columns, beads, dipsticks, nitrocellulose membranes, lateral flow devices, and other containers, to name a few. As such, the solid-phase platforms can also be described in general as containers.
[0030] The design of the VDRL ELISA Test is significantly improved over the prior art and permits quantization and standardization of the test results, as follows:
1) A kit calibrator facilitates standardization and normalization of the test results. The calibrator(s) is a standard serum sample that is traceable to a primary, or secondary, standard, and has been assigned a known value. The calibrator(s) is included with the patient samples in each test run to produce a result of known value against which patients test results may be compared and thereby interpreted as either positive or negative. 2) The kit's negative and positive controls facilitate the validation of the test results. The positive and negative controls are serum samples that have been assigned expected value ranges and that are included with the patient samples in each test run. If the values obtained for the positive and negative controls fall within their assigned ranges when compared to the kit calibrator, the results obtained for the patient samples are valid, if the values do not fall within the assigned ranges, the results obtained for the patient samples are invalid and the test must be repeated.
[0033] The formulations contributing to the sensitivity and specificity of the VDRL ELISA Test include the following:
1) The formulation, i.e., relative concentrations of the cardiolipin, cholesterol, lecithin antigen preparation, contributes to the sensitivity and specificity of the test. 2) The formulation of a post-coating solution prevents non-specific binding of human antibody to the antigen-coated wells. 3) The formulation of a sample diluent prevents the non-specific binding of human antibody to the antigen-coated wells. The sample diluent is a buffered solution that contains an inert protein that does not interfere with the binding of the patient antibody that is specifically directed against the antigen coated on the wells. Concurrently, the inert protein prevents the binding of extraneous patient antibody that is not specifically directed against the antigen coated on the wells, thereby preventing potentially false positive results. 4) In cases of very high levels of non-treponemal antibody, the VDRL ELISA Test is not subject to the Prozone or Hook Effect, which can lead to false negative results in the VDRL and RPR Tests.
[0038] The properties of the VDRL antigen mixture that have heretofore prevented the development of a stable and reproducible VDRL ELISA test, are as follows:
[0039] 1) Cardiolipin, a major component of the VDRL antigen preparation, is inherently unstable.
2) Cardiolipin and the other components of the antigen preparation, cholesterol and lecithin, are not soluble in aqueous solution and, therefore, cannot be bound to polystyrene wells by conventional measures.
[0041] The inventive systems and processes are not limited to particular cardiolipins or cholesterol. The inventive systems and processes are envisioned to use natural or purified-from-natural cardiolipins or even synthesized cardiolipins. It is possible that synthesized cardiolipins could be used even if they are inherently stable. The inventive systems and processes are envisioned to also be used with synthesized cholesterol and/or synthesized lecithin.
[0042] The following procedures were used to prepare VDRL antigen coated wells that are stable and capable of producing reproducible test results:
[0043] 1) The cholesterol is initially dissolved in an organic solvent, and is then further diluted in an ethanol solution containing cardiolipin and lecithin.
2) A small volume (e.g., 50 microliter) of the antigen solution is permitted to evaporate in place, in polystyrene microwells. 3) The coated wells are rinsed once with buffered saline. 4) The antigen coating is then stabilized by overcoating with an inert protein dissolved in buffered saline. 5) The overcoat solution is decanted and the wells are air-dried and then sealed in vapor-proof pouches with desiccant. 6) The enzyme-labeled conjugate component of the test is formulated to be compatible with the lipid nature of the VDRL antigens coated on the wells. 7) The sample diluent is formulated to be compatible with the lipid nature of the VDRL antigens coated on the wells. 8) The wash fluid is formulated to be compatible with the lipid nature of the VDRL antigens coated on the wells. 9) The enzyme substrate is formulated to be compatible with the lipid nature of the VDRL antigens coated on the wells.
[0052] With the foregoing and other objects in view, there is provided, in accordance with the invention, a method of manufacturing a non-treponemal diagnostic test for syphilis infection includes the steps of initially dissolving cholesterol in an organic solvent and further diluting the dissolved cholesterol in an ethanol solution comprising cardiolipin and lecithin to form an antigen solution, permitting a volume of the antigen solution to evaporate in place within a container and at least partially coat the container with an antigen coating, and stabilizing the antigen coating into a syphilis antigen complex by overcoating the antigen coating with an overcoat solution comprising an inert protein.
[0053] With the objects of the invention in view, there is also provided a method of manufacturing a non-treponemal diagnostic test for syphilis infection including the steps of initially dissolving cholesterol in an organic solvent and further diluting the dissolved cholesterol in an ethanol solution comprising cardiolipin and lecithin to form an antigen solution, permitting a volume of the antigen solution to evaporate in place within a container and at least partially coat the container with an antigen coating, stabilizing the antigen coating into a syphilis antigen complex by overcoating the antigen coating with an overcoat solution comprising an inert protein, providing an enzyme-labeled conjugate component of a syphilis infection test that is formulated to be compatible with a lipid nature of the cholesterol, the cardiolipin, and the lecithin, providing a sample diluent that is formulated to be compatible with the lipid nature of the cholesterol, the cardiolipin, and the lecithin, providing a wash fluid that is formulated to be compatible with the lipid nature of the cholesterol, the cardiolipin, and the lecithin, and providing an enzyme substrate that is formulated to be compatible with the lipid nature of the cholesterol, the cardiolipin, and the lecithin.
[0054] In accordance with another mode of the invention, there are also provided the steps of rinsing the at least partially coated container with buffered saline and decanting the overcoat solution, drying the container, and sealing the container in a vapor-proof pouch.
[0055] In accordance with a further mode of the invention, there are also provided the steps of, after the step of permitting a volume of the antigen solution to evaporate, rinsing the at least partially coated container with buffered saline, and, after the step of stabilizing the antigen coating into a syphilis antigen complex, decanting the overcoat solution, drying the container, and sealing the container in a vapor-proof pouch.
[0056] In accordance with an added mode of the invention, the volume of the antigen solution is approximately 50 microliters.
[0057] In accordance with an additional mode of the invention, the container is one or more of a microwell, a polystyrene microwell, a microtube, a column, a bead, a dipstick, a nitrocellulose membrane, and a lateral flow device.
[0058] In accordance with yet another mode of the invention, the organic solvent is one or more of acetone, chloroform, butanol, methanol, or ether.
[0059] In accordance with yet a further mode of the invention, the cholesterol is a natural cholesterol, a purified-from-natural cholesterol, and/or a synthesized cholesterol.
[0060] In accordance with yet an added mode of the invention, the cardiolipin is a natural cardiolipin, a purified-from-natural cardiolipin, and/or a synthesized cardiolipin.
[0061] In accordance with yet an additional mode of the invention, the lecithin is a natural lecithin, a purified-from-natural lecithin, and/or a synthesized lecithin.
[0062] In accordance with again another mode of the invention, the container is air-dried.
[0063] In accordance with again a further mode of the invention, there is provided the step of sealing the container in the vapor-proof pouch with desiccant.
[0064] In accordance with again an added mode of the invention, the overcoating step is carried out with the inert protein selected from one or more of bovine serum, bovine serum albumin, fetal bovine serum, gelatin, goat serum, horse serum, and milk protein. In accordance with again an additional mode of the invention, the overcoating step is carried out by dissolving the inert protein in buffered saline.
[0065] In accordance with still another mode of the invention, the overcoating step is carried out by leaving the saline solution of the inert protein in the at least partially coated container for a period of time sufficient to allow the inert protein to bind to non-coated portions of the container.
[0066] In accordance with still a further mode of the invention, the period of time is at least one of between approximately 30 minutes and approximately 5 hours, between approximately 1 and approximately 3 hours, between approximately 1.5 and approximately 2.5 hours, or approximately 2 hours.
[0067] In accordance with still an added mode of the invention, the stabilized antigen coating overcoated with the inert protein has a shelf life of between approximately 6 months and approximately 1 year.
[0068] In accordance with still an additional mode of the invention, an enzyme-labeled conjugate component of a syphilis infection test that is formulated to be compatible with a lipid nature of the cholesterol, the cardiolipin, and the lecithin is provided, a sample diluent that is formulated to be compatible with the lipid nature of the cholesterol, the cardiolipin, and the lecithin is provided, a wash fluid that is formulated to be compatible with the lipid nature of the cholesterol, the cardiolipin, and the lecithin is provided, and an enzyme substrate that is formulated to be compatible with the lipid nature of the cholesterol, the cardiolipin, and the lecithin is provided.
[0069] In accordance with another mode of the invention, there are provided the steps of adding serum of a donor to be tested for reactivity towards the syphilis antigen complex into the container and allowing the syphilis antibody to bind to the antigen coating if the syphilis antibody exists in the patient's serum, rinsing the container with buffered saline, adding a secondary antibody designed to bind to the primary antibody in the serum to the container, the secondary antibody having an attached enzyme that changes color when the enzyme substrate for the enzyme is added thereto and reacts with the enzyme, rinsing the container with buffered saline, and adding the enzyme substrate to produce a color change if the serum contains the syphilis antibody.
[0070] In accordance with another mode of the invention, there is provided the step of examining contents of the container with an automated spectrophotometric analyzer to detect the color change of the tested serum and, if there is a color change showing that the secondary antibody has bound to the primary antibody, forming a test result concluding that the donor of the serum has had an immune reaction to the test syphilis antigen.
[0071] In accordance with a concomitant mode of the invention, there is provided the step of producing with the spectrophotometer quantitative values corresponding to a strength of the color change.
[0072] Although the invention is illustrated and described herein as embodied in serological methods and diagnostic tests for syphilis antibodies, it is, nevertheless, not intended to be limited to the details shown because 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. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention.
[0073] Additional advantages and other features characteristic of the present invention will be set forth in the detailed description that follows and may be apparent from the detailed description or may be learned by practice of exemplary embodiments of the invention. Still other advantages of the invention may be realized by any of the instrumentalities, methods, or combinations particularly pointed out in the claims.
[0074] Other features that are considered as characteristic for the invention are set forth in the appended claims. As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the invention. While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward.
BRIEF DESCRIPTION OF THE DRAWINGS
[0075] The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, which are not true to scale, and which, together with the detailed description below, are incorporated in and form part of the specification, serve to illustrate further various embodiments and to explain various principles and advantages all in accordance with the present invention. Advantages of embodiments of the present invention will be apparent from the following detailed description of the exemplary embodiments thereof, which description should be considered in conjunction with the accompanying drawings in which:
[0076] FIG. 1 is a photograph of a portion of an RPR Test card showing one test area with a positive result and one test area with a negative result;
[0077] FIG. 2 is a process flow diagram for manufacturing an exemplary embodiment of a VDRL ELISA Test;
[0078] FIG. 3 is a process flow diagram for conducting the VDRL ELISA Test;
[0079] FIG. 4 is a diagram illustrating the reaction in the VDRL ELISA Test; and
[0080] FIG. 5 is a graph illustrating a comparison of results between the VDRL ELISA Test and the RPR Test and demonstrating a prozone or “hook” effect in the RPR test.
DETAILED DESCRIPTION OF THE INVENTION
[0081] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the invention. While the specification concludes with claims defining the features of the invention that are regarded as novel, it is believed that the invention will be better understood from a consideration of the following description in conjunction with the drawing figures, in which like reference numerals are carried forward.
DEFINITIONS
[0082] Before the present invention is disclosed and described, it is to be understood that the terminology herein is not intended to be limiting and is only being used for the purpose of describing particular embodiments. Unless otherwise specified, all technological terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention belongs.
[0083] Alternate embodiments may be devised without departing from the spirit or the scope of the invention. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention.
[0084] As used herein, the terms “a” or “an”, are defined as one or more than one. The term “plurality”, as used herein, is defined as two or more than two. The term “another”, as used herein, is defined as at least a second or more.
[0085] As used herein, the terms “including” and/or “having”, are defined as comprising (i.e., open language). The terms “comprises,” “comprising,” or any other variation thereof are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.
[0086] As used herein, relational terms, such as first and second, may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions.
[0087] As used herein, the term “coupled” is defined as connected, although not necessarily directly, and not necessarily mechanically.
[0088] As used herein, the term “about” or “approximately” applies to all numeric values, whether or not explicitly indicated. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure.
[0089] Herein various embodiments of the present invention are described. In many of the different embodiments, features are similar. Therefore, to avoid redundancy, repetitive description of these similar features may not be made in some circumstances. It shall be understood, however, that description of a first-appearing feature applies to the later described similar feature and each respective description, therefore, is to be incorporated therein without such repetition.
[0090] Described now are exemplary embodiments of the present invention. Referring now to the figures of the drawings in detail and first, particularly to FIG. 2 , there is shown a first exemplary embodiment of a process for creating and manufacturing a VDRL ELISA Test. The inventive VDRL ELISA Test starts with the previous understanding that the antigen complex for syphilis is formed from a combination of cardiolipin, cholesterol and lecithin, which, due to its lipid nature, does not readily remain in a microwell. From this, it was necessary to find a way to obtain a deposition of the antigen complex in a microwell that not only remains for periods of time sufficient to perform a non-treponemal test for syphilis, but also to perform that test with microwells having a desirably long shelf life.
[0091] The process for creating such a microwell according to the invention is illustrated with the flow chart of FIG. 2 . It is noted that, as described above, use of the term “microwells” in the exemplary embodiments is not to be taken as limiting the platform only to microwells and equally includes all other solid-phase platforms can be substituted for microwells, which can include microtubes, columns, beads, dipsticks, nitrocellulose membranes, and lateral flow devices.
[0092] As set forth above, the non-binding of the antigen complex to a microwell is due the lipid nature of cardiolipin, cholesterol and lecithin, which compounds are not soluble in aqueous solution. The inventors discovered, however, that these compounds can be dissolved in organic solvents and dried in wells without a deleterious affect upon the compounds. The inventors have further discovered that the relative proportions of the compounds used in the classical VDRL method, when diluted to one-tenth the concentration, i.e., 0.003% W/V cardiolipin, 0.09% W/V cholesterol and 0.02% W/V lecithin, produce the desired results when dried in wells in the VDRL-ELISA method. Furthermore, by examining the aforementioned compounds in the VDRL ELISA method, either separately or in various relative proportions, the inventors determined that the relative concentrations stated above are more reactive with non-treponemal syphilis antibodies than any of the compounds individually or in any of the other relative proportions examined. Accordingly, in Step 210 , cholesterol is dissolved in an organic solvent, such as acetone, chloroform, butanol, methanol, and/or ether. In Step 220 , cardiolipin and lecithin are dissolved in ethanol, and the organic solvent mixture is further diluted in the ethanol solution containing the cardiolipin and lecithin. In Step 230 , the two mixtures are combined and an amount of this mixture is placed in microwells, for example, polystyrene microwells. In an exemplary embodiment, the amount of the mixture placed in each microwell is between approximately 40 and 60 microliters, in particular, approximately 50 microliters.
[0093] It is known that both the organic solvent and ethanol evaporate readily. From this, evaporation of the organic solvent and ethanol is allowed to occur in Step 240 , which evaporation can be aided with air circulation devices such as fans. In an exemplary embodiment, the evaporation occurs at room temperature (20° C. to 25° C.). Evaporation continues until the liquid in the microwells has dried. At this point, the three components of the antigen complex become bound to the interior surface of the microwells. The microwells are washed once, for example, with buffered saline in Step 250 .
[0094] After the microwells are coated with the antigen complex, it was found that this coating is not present on the entirety of the microwell interior. Where such uncoated portions occur, it is possible that, when used in the actual testing procedure, the test material (i.e., the patient's serum potentially containing the syphilis antibody) could bind or be adversely affected by the interior surface of the microwell. In such a case, the test material could bond to the non-coated surfaces and undesirably augment the result, which occurs, as set forth above, by spectrophotometric reading. In such a situation, the color reading will be more intense than it should be for that test specimen. Therefore, it would be desirable to prevent this detrimental situation from occurring. To solve this problem, the inventive manufacturing process binds a non-reactive compound to the uncoated portions of the microwells. The selected non-reactive compound is an inert protein, such as any one of bovine serum, bovine serum albumin, fetal bovine serum, gelatin, goat serum, horse serum, and milk protein, to name a few. Utilizing the known property that cardiolipin, cholesterol, and lecithin are not soluble in aqueous solution, in Step 260 , the coated microwells are filled with a post-coating mixture of the inert protein dissolved in buffered saline. This aqueous solution is left in the microwells (not adversely affecting the coating of the antigen complex) in Step 270 for a given period of time sufficient to allow the inert protein to bind to the non-coated portions of the microwell. This post-coating soaking occurs for between approximately 30 minutes and approximately 5 hours, for example, between approximately 1 and approximately 3 hours, between approximately 1.5 and approximately 2.5 hours, and, in particular, for approximately 2 hours, resulting in a bond of the inert protein in all areas where the antigen complex does not appear. Removal of the inert protein soak occurs in Step 280 by decanting or aspirating the remaining solution. The microwell interiors are air dried and then sealed in vapor-proof pouches with desiccant in Step 290 . When the so-coated microwells are packaged with desiccant, it was discovered that the antigen complex and the post-coating inert protein remained stable for many months, which stability was found to be augmented by the non-specific binding of the inert protein. In such a packed state, the shelf-life of the so-coated interior is at least 12 months. In particular, the shelf-life is between 6 months and 1 year.
[0095] With these coated microwells, the steps of the VDRL ELISA Test follow the mechanism below and is illustrated with reference to the flow chart of FIG. 3 and the diagram of FIG. 4 . In Step 310 , the serum 410 of a donor to be tested for reactivity towards the syphilis antigen complex 420 is added into one or more microwells in a microtiter plate. Because the syphilis antigen complex 420 coats each microwell, if the syphilis antibody exists in the patient's serum 410 binds, that antibody will bind to the coating 420 in Step 320 . The microwell is rinsed, for example, with buffered saline in Step 330 . A secondary antibody 430 is added in Step 340 , which antibody 430 is designed to bind to the primary antibody in the serum 410 , and the microwell is rinsed, for example, with buffered saline in Step 350 . This secondary antibody 430 has an enzyme E attached to it, which has a negligible effect on the binding properties of the antibody. However, when a substrate for the enzyme E is added, the substrate will change color upon reaction with the enzyme E. This substrate is added in Step 360 to produce a color change in Step 370 if the serum 410 contains the syphilis antibody. An automated spectrophotometric analyzer examines the reactions in Step 380 to detect the color change of the tested serum 410 . Any color change in the microwell shows that the secondary antibody 430 has bound to primary antibody 410 , which strongly implies that the donor of the serum 410 has had an immune reaction to the test syphilis antigen. The higher the concentration of the primary syphilis antibody present in the serum 410 , the stronger the color change will be in Step 370 . The spectrophotometer produces, in Step 390 , quantitative values for the color strength. As those having skill in the art know, this test entirely eliminates the Prozone Effect, which means, in practice, that a lab does not need to perform further testing where the sample is diluted and the sample is re-tested, perhaps repeatedly. The difference between the results of the VDRL ELISA Test and the tests that have the Prozone Effect is shown in the graph of FIG. 5 , where a plateau occurs in the inventive test with later titration demonstrating a decreasing the dose effect. Moreover, this test is able to be readily and easily automated by standard automated spectrophotometric analyzers. It has been found that the sensitivity is at least as equivalent to the RPR and VDRL Tests but the long shelf life and ability to be automated (thereby eliminating the need for subjective analysis by a clinician).
[0096] The classical non-treponemal tests, VDRL and RPR, are known to detect both IgG and IgM class antibodies, but they not capable of distinguishing between the two antibody classes. The inventors are aware that the VDRL ELISA Test can be modified based upon the specificity of the enzyme-labeled conjugate being used in the test. Therefore, it is possible to detect IgG only, IgM only, or both. In one iteration, the VDRL test can be used for screening for the presence of non-treponemal syphilis antibodies in adults by employing conjugates that detect both IgG and IgM. This is the approach recommended by the Centers for Disease Control (CDC) for syphilis screening. In another iteration, the VDRL ELISA Test can be modified to detect only IgM antibodies. It is known that IgM antibodies of maternal origin do not cross the placental barrier, therefore, IgM antibodies to syphilis detected in the newborn's serum is an indication of syphilis infection in the newborn. It follows that this iteration of the VDRL ELISA Test can be applied to the diagnosis of syphilis in the newborn in a novel exemplary embodiment of the VDRL ELISA Test.
[0097] The foregoing description and accompanying drawings illustrate the principles, exemplary embodiments, and modes of operation of the invention. However, the invention should not be construed as being limited to the particular embodiments discussed above. Additional variations of the embodiments discussed above will be appreciated by those skilled in the art and the above-described embodiments should be regarded as illustrative rather than restrictive. Accordingly, it should be appreciated that variations to those embodiments can be made by those skilled in the art without departing from the scope of the invention as defined by the following claims.
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A method of detecting antibodies to syphilis antigens includes providing a syphilis detection kit having a screening solid-phase platform with a screening portion coated with non-treponemal syphilis antigens. The screening portion is fabricated by initially dissolving cholesterol in an organic solvent and further diluting the dissolved cholesterol in an ethanol solution comprising cardiolipin and lecithin to form an antigen solution, permitting the antigen solution to evaporate at the screening portion and at least partially coating the screening portion with an antigen coating, and stabilizing the antigen coating into a syphilis antigen complex by overcoating the antigen coating with an overcoat solution comprising an inert protein.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method and apparatus for processing an audio signal and apparatuses using the same. More particularly, the present invention relates to a method an apparatus for eliminating shot noise, discontinuity, and a data loss and repairing an audio signal and apparatuses using the same.
[0003] The present invention is applied to compensation for loss of sound occurring when performing high speed reproduction (special reproduction) etc. in a receiver of a broadcasted audio signal, a reproduction system of an audio signal recorded on a magnetic tape, an optical disk, an opto-magnetic disk, or the like, and a decoding system of a digitally transmitted audio signal, for example, a Hi-Fi video apparatus, a digital video apparatus (digital video signal recording and/or reproducing apparatus), and an 8 mm video apparatus.
[0004] 2. Description of the Related Art
[0005] In a receiver of a broadcasted audio signal, a reproduction system of an audio signal recorded on a magnetic tape, optical disk, opto-magnetic disk, or the like, a decoder of a digitally transmitted audio signal, etc., there is sometimes shot noise, discontinuity of data, and data loss—frequently occurrences in a communication path, a recording apparatus, a reproducing apparatus, packet communication, etc.
[0006] Such noise is generated everywhere due to, for example, noise generated in the air or in the apparatus, scratches or dust on the magnetic tape, scratches or dust on the optical disk, scratches or dust on an analog record disk, and reading error of the reproducing apparatus. Such noise causes a remarkably incongruity in sound.
[0007] In the past, when such noise and discontinuity occurred, the method of reducing the noise component by a low pass filter, a high pass filter, or the like and the method of replacing segments of data loss by the signal before and after them (Japanese Unexamined Patent Publication (Kokai) No. 9-274772) have been tried. Further, particularly, when digital data is used, the noise and the discontinuity have been reduced by means of prevalue hold, mean value interpolation, attenuation interpolation, muting, or the like
[0008] However, a frequency filter distorts the normal signal portion as well and further is not that effective in elimination of short time and wide frequency band signals such as shot noise and discontinuity.
[0009] Further, prevalue hold and mean value interpolation are problematic in that a discontinuity newly occurs with the preceding and following data, so incongruity in sound is newly caused.
[0010] As concrete audio signal processing apparatuses, related art of Hi-Fi video apparatuses, digital video signal recording and/or reproducing apparatuses, 8 mm video apparatuses, etc. and problems thereof will be explained.
[0011] A Hi-Fi video apparatus using a magnetic tape has, as illustrated in FIG. 3 , two tracks, that is, a fixed audio track and a Hi-Fi audio track, as tracks for recording an audio signal on the magnetic tape.
[0012] The fixed track is oriented parallel to the tape running direction and is provided at a position independent from the video signal track. It is scanned by a fixed head 17 illustrated in FIG. 2 and has a low dynamic range, a low frequency range, and a high noise level in structure. It is usually used for only monaural recording.
[0013] The Hi-Fi track is helically scanned by a rotary head drum 16 illustrated in FIG. 2 and records an audio signal by deep layer recording etc.* at the same position as the video track. It has a high dynamic range, a high frequency range, and a low noise level and is usually used for stereo recording.
[0014] In general, the Hi-Fi track is used for high quality sound reproduction at the time of normal reproduction, while the fixed track is used for low quality sound reproduction at the time of special (high speed) reproduction.
[0015] For example, Japanese Unexamined Patent Publication (Kokai) No. 5-292449 discloses a method of reproducing a video signal recorded on a video track at an (N+1)/N speed. However, the fixed track has to be used for reproduction of the audio signal. The reason for this is that, as shown in FIG. 4 , at the time of special reproduction, the rotary head scans a plurality of Hi-Fi tracks by obliquely traversing them (helically scans them), so the video signal can be reproduced as one image by combining a plurality of fields, but, in contrast, noise due to discontinuity of the scanning of the rotary head frequently occurs in the audio signal to cause remarkable incongruity in sound, so the Hi-Fi track cannot be used. Therefore, the Hi-Fi track is not used. Instead, the fixed track is used using the fixed head 17 —which is free from the problem of discontinuous scanning of the head.
[0016] In high speed reproduction for a head search or the like, in the case of high speed reproduction at 2× speed or more, a high quality of sound is not always required, so there is little problem.
[0017] However, when trying to save time while fully viewing and listening to the content by reproduction at a slightly high speed, for example, a 1.2× speed, the quality of sound when reproducing the audio signal recorded on the fixed audio track, which is fixed to such high speed reproduction, is insufficient. Therefore, utilization of the Hi-Fi audio track providing a high quality audio signal has been demanded.
[0018] In a digital video signal recording and/or reproducing apparatus using a magnetic tape, when giving as an example the format of for example a consumer digital video system, as shown in FIG. 24 , a helical track inclined with respect to the tape running direction is divided into units of blocks. A compressed and encoded video signal is recorded at the center, while the audio signal and auxiliary signals are recorded on the two sides.
[0019] At the time of high speed reproduction in the digital video signal recording and/or reproducing apparatus, as shown in FIG. 25 , a skip in the middle of a track is avoided by an auto-tracking mechanism. However, the discontinuity of the audio signal occurring due to the tracks not being read at the time of high speed reproduction causes a remarkable incongruity in sound at the time of reproduction in the same way as the case of a Hi-Fi video apparatus.
[0020] As the audio signal processing for reducing such incongruity in sound at the time of high speed reproduction in such a digital video signal recording and/or reproducing apparatus, various countermeasures have been considered heretofore. Examples thereof will be explained below.
(1) The method of permitting the discontinuity and connecting the signal as it is (Japanese Patent No. 2,687.706), (2) The method of muting the discontinuous portion, (3) The method of changing the speed of the rotary head to match the tape running speed and reading all data (Japanese Patent No. 2,766,065), (4) The method of replacing the lost portions of the audio signal by the data before and after it (Japanese Unexamined Patent Publication (Kokai) No. 9-274772), and (5) The method of connecting the audio signal before and after a lost portion by a cross fading (Japanese Patent No. 2,737,182).
[0026] With the methods of (1) and (2), however, discontinuity or muting periodically occurs, so the incongruity cannot be solved.
[0027] With the method of (3), the apparatus becomes complex and further the data becomes too large, so time compression and sampling rate conversion are necessary. As a result, a new incongruity in sound such as a rise in sound pitch is caused.
[0028] With the method of (4), although there is the effect of reduction of the incongruity without muting the frames from which data has been lost, discontinuity still occurs before and after the replaced data. Accordingly, there is a problem of how to repair the audio signal without incongruity.
[0029] With the method of (5), although the discontinuity is solved by a cross fading of the data before and after the discontinuity, this is done without considering waveform periodicity etc., so there is a problem in that incongruity due to mismatch of phase is newly caused.
[0030] An 8 mm video apparatus recording and reproducing an audio signal by a rotary head suffers from problems similar to those described above.
[0031] A magnetic recording apparatus using not magnetic tape, but a fixed disk is excellent in random accessability, so the problem such as the skip of a track due to the physical structure described above does not occur. However, a certain time is required for reading data. Therefore, at the time of high speed reproduction, it is sometimes necessary to deliberately reduce the number of read fields. At this time, the problem of discontinuity of sound similar to the above arises.
SUMMARY OF THE INVENTION
[0032] An object of the present invention is to provide an audio signal processing method and apparatus for eliminating shot noise and smoothly interpolating discontinuity of an audio signal without distorting a normal portion and thereby reducing the incongruity in sound and apparatuses using the same.
[0033] Another object of the present invention is to provide a method an apparatus for processing a reproduced audio signal to an audio signal free from incongruity in sound at the time of high speed reproduction in a magnetic tape type audio signal reproducing apparatus reproducing an audio signal recorded by helical scanning of a rotary audio head on a magnetic tape such as a Hi-Fi video apparatus, digital video signal recording and/or reproducing apparatus, and 8 mm video apparatus and such apparatuses using the same.
[0034] Still another object of the present invention is to provide a method and apparatus for processing a reproduced audio signal to an audio signal free from incongruity in sound at the time of high speed reproduction in a rotary audio signal reproducing apparatus reproducing an audio signal recorded on a substantially randomly accessable rotary recording medium such as a magnetic disk, optical disk, and opto-magnetic disk and such apparatuses using the same.
[0035] According to a first aspect of the present invention, there is provided an audio signal processing method comprising the steps of deleting an audio signal in an anomalous segment, deducing a correct audio signal by referring to the waveform of the audio signal before and after the deleted segment, generating a repair signal for repairing the signal of the deleted segment based on the deduced result, inserting the repair signal into the deleted segment, and connecting the same with the audio signal before and after the deleted segment.
[0036] Preferably, the method further comprises detecting an anomalous state of the audio signal and performing the above processing when detecting the anomalous state.
[0037] Preferably, the method further comprises evaluating the similarity of signal waveform before and after the deleted segment in the step of deducing the audio signal, generating the repair signal by the waveform with the greatest similarity in the step of generating the repair signal, and smoothly connecting the inserted repair signal and the audio signal before and after the deleted segment in the step of connecting the audio signal.
[0038] Further preferably, the method further comprises measuring and successively adding a time discrepancy between a segment with the waveform connected by using the repair signal and a segment with the anomalous signal deleted therefrom and performing the processing of the deducing step, repair signal generation step, and signal connection step again when a sum of the time discrepancy exceeds a constant time discrepancy so as to adjust the time discrepancy.
[0039] Preferably, the method further comprises calculating a correlation function for the audio signal before and after the deleted segment in the step of deducing the audio signal and evaluating the similarity by referring to the calculated correlation function.
[0040] Alternatively, the method further comprises calculating a correlation function for the audio signal before and after the deleted segment in the step of generating the repair signal and cross fading the audio signal or cross fading the audio signal before and after the deleted segment to smoothly connect it in the step of connecting the audio signal.
[0041] The method may detect the anomalous state by detecting skip scanning of a reading means when reading an audio signal from a recording medium.
[0042] Alternatively, it may detect the anomalous state by statistically processing the audio signal and detecting a sudden fluctuation in the audio signal.
[0043] According to a second aspect of the present invention, there is provided an audio signal processing method comprising the steps of deleting an audio signal of a noise segment of noise and discontinuity due to shot noise superposed on the audio signal or a signal skip, evaluating a similarity of signal waveform before and after the noise segment, and smoothly connecting waveforms to give a maximum similarity.
[0044] According to a third aspect of the present invention, there is provided an audio signal processing apparatus utilizing the above audio signal processing methods.
[0045] The audio signal processing apparatus comprises a signal deleting means for deleting an audio signal of an anomalous segment, a deducing means for deducing a correct audio signal by referring to waveform of the audio signal before and after the deleted segment, a repair signal generating means for generating a repair signal for repairing the signal of the deleted segment based on the deduced result, and a signal connecting means for inserting the repair signal into the deleted segment and connecting the same with the audio signal before and after the deleted segment.
[0046] The audio signal processing apparatus may further comprise an anomaly detecting means for detecting an anomalous state of the audio signal and performing the processing when detecting the anomalous state. The anomalous state is generated at for example a track skip at the time of high speed reproduction or switching of the rotary head in a Hi-Fi video apparatus.
[0047] When detecting the anomalous state, the apparatus deletes the audio signal of the anomalous state portion. Then, considering the continuity of the audio signal, it deduces the audio signal of the deleted portion by referring to the audio signal before and after the deleted portion. Next, it generates a repair signal corresponding to the correct audio signal. Finally, it inserts the repair signal into the deleted segment and connects it to the audio signal before and after the deletion.
[0048] The present invention may be applied to a Hi-Fi video apparatus, digital video apparatus (digital video signal recording and/or reproducing apparatus), 8 mm video apparatus, magnetic disk apparatus, etc.
[0049] As a result, even in the case of high speed reproduction in for example a Hi-Fi video apparatus and 8 mm video apparatus, a high quality Hi-Fi audio signal can be reproduced. Further, pulse noise generated at the time of high speed reproduction of a digital video apparatus is reduced, the incongruity in sound is reduced, and high quality reproduction becomes possible.
[0050] For example, in a Hi-Fi video apparatus, even when trying to save time while fully viewing and listening to the content by reproduction at 1.2× speed, a high quality audio signal can be reproduced. In a magnetic disk apparatus, it becomes possible to obtain a greater margin in the access time and therefore perform time division processing with other tasks without exceeding the limit of the access time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] These and other objects and features of the present invention will become clearer from the following description of the preferred embodiments given with reference to the attached drawings, in which:
[0052] FIG. 1 is a schematic view of the configuration of a first example of a Hi-Fi video apparatus according to an embodiment of the present invention;
[0053] FIG. 2 is a schematic view of tape running and a rotary head of the Hi-Fi video apparatus illustrated in FIG. 1 ;
[0054] FIG. 3 is a view of a track structure of a tape recording surface of a magnetic tape in the Hi-Fi video apparatus illustrated in FIG. 1 ;
[0055] FIG. 4 is a view of a trace of a head when reproducing a video Hi-Fi audio track of the magnetic tape illustrated in FIG. 3 at the time of high speed reproduction;
[0056] FIG. 5 is a view of details of the track structure of the magnetic tape of the Hi-Fi video apparatus illustrated in FIG. 1 and a head trace at the time of high speed reproduction;
[0057] FIG. 6 is a flow chart of an operation of a track skip detector illustrated in FIG. 1 ;
[0058] FIGS. 7A to 7 C are views of a rotary head switch operation in a Hi-Fi video apparatus, in which FIG. 7A is a view of a recording track, a used head, and an azimuth thereof, FIG. 7B is a view of a rotary head pulse and a track skip pulse at the time of high speed reproduction, and FIG. 7C is a view of a reproduction track, a used head, and the azimuth thereof by a head switch operation;
[0059] FIG. 8 is a flow chart of the rotary head switch operation in a head switch illustrated in FIG. 1 ;
[0060] FIG. 9 is a view of the configuration of a waveform connector illustrated in FIG. 1 ;
[0061] FIG. 10 is a view of the configuration of a signal buffer illustrated in FIG. 9 ;
[0062] FIG. 11 is a flow chart of the operation of a signal processor in the waveform connector illustrated in FIG. 9 ;
[0063] FIG. 12 is a waveform diagram of an input signal subjected to the signal processing in the waveform connector of FIG. 9 ;
[0064] FIG. 13 is a waveform diagram of a signal with an anomalous portion deleted therefrom in the waveform connector of FIG. 9 ;
[0065] FIG. 14 is a signal waveform diagram for explaining a method of detecting similar waveforms in the waveform connector of FIG. 9 ;
[0066] FIG. 15 is a signal waveform diagram for explaining a method of connecting the waveform in the waveform connector of FIG. 9 ;
[0067] FIG. 16 is a signal waveform diagram for explaining a second method of detecting similar waveforms in the waveform connector of FIG. 9 ;
[0068] FIG. 17 is a signal waveform diagram for explaining a method of shifting waveform signals for connecting the waveform in the waveform connector of FIG. 9 ;
[0069] FIG. 18 is a signal waveform diagram for explaining a method of preparing a similar waveform for connecting the waveform in the waveform connector of FIG. 9 and inserting the same;
[0070] FIG. 19 is a schematic view of the configuration of a second example of a Hi-Fi video apparatus according to an embodiment of the present invention;
[0071] FIG. 20 is a view of the configuration of the waveform connector in FIG. 19 ;
[0072] FIG. 21 is a view of the configuration of an anomaly detector in FIG. 20 ;
[0073] FIG. 22 is a flow chart of the operation of a signal processor in the waveform connector illustrated in FIG. 19 ;
[0074] FIG. 23 is a view of the configuration of a digital video signal recording and/or reproducing apparatus according to a second embodiment of the present invention;
[0075] FIG. 24 is a view of a track structure of a recording surface of a consumer use digital video tape in FIG. 23 ;
[0076] FIG. 25 is a view of a head scanning trace at the time of high speed reproduction of the digital video signal recording and/or reproducing apparatus of FIG. 23 ;
[0077] FIG. 26 is a view of the configuration of the waveform connector illustrated in FIG. 23 ;
[0078] FIG. 27 is a view of the track structure of an 8 mm video tape according to a third embodiment of the present invention;
[0079] FIG. 28 is a view of the configuration of a magnetic disk apparatus according to a fourth embodiment of the present invention; and
[0080] FIG. 29 is a graph of the operation timing of the magnetic disk apparatus of FIG. 28 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0081] First, preferred embodiments of the audio signal processing method and apparatus of the present invention will be explained.
[0082] Note that the gist of the present invention resides in the processing for repairing anomaly of an audio signal—not the recording of the audio signal. Similarly, processing of a video signals is not its gist. Accordingly, so far as they do not particularly relate to the present invention, the recording of an audio signal and the processing of a video signal will not be referred to.
[0083] However, the present invention is not limited to only an audio signal reproducing apparatus. The present invention can also be applied to a digital video signal recording and/or reproducing apparatus using the audio signal processing method and apparatus of the present invention and an audio signal and/or video signal recording and/or reproducing apparatus using the audio signal processing method and apparatus of the present invention.
FIRST EXAMPLE OF HI-FI VIDEO APPARATUS
[0084] As a first embodiment of use of the audio signal processing apparatus of the present invention, a first example of a Hi-Fi video apparatus will be explained by referring to FIG. 1 to FIG. 8 .
[0085] FIG. 1 is a view of the configuration of a Hi-Fi video apparatus according to the first embodiment of the present invention, while FIG. 2 is a schematic view of tape running and a rotary head of the Hi-Fi video apparatus illustrated in FIG. 1 .
[0086] The Hi-Fi video apparatus 1 has a rotary head controller 11 , a head switch 12 , a track skip detector 13 , an FM demodulator 14 , a waveform connector 15 , a rotary head drum 16 with rotary heads A 1 and A 2 and B 1 and B 2 mounted thereon, a fixed head 17 , a not illustrated rotation drive controller of the rotary head drum 16 , a not illustrated running drive controller of a magnetic tape 18 , a not illustrated audio signal reproducing apparatus, and a not illustrated video signal reproducing apparatus.
[0087] The rotation drive controller of the rotary head drum 16 , the running drive controller of the magnetic tape 18 , the audio signal reproducing apparatus, and the video signal reproducing apparatus are not directly related to the present invention, so the illustration was omitted, but they are similar to those in the well known apparatuses.
[0088] The Hi-Fi video apparatus 1 records an audio signal and a video signal on the magnetic tape 18 and reproduces the audio signal and the video signal recorded on the magnetic tape 18 by helical scanning using the rotary head drum 16 with the rotary heads A 1 , A 2 , B 1 , and B 2 .
[0089] FIG. 3 is a view of a track structure of the tape recording surface in the Hi-Fi video apparatus.
[0090] A pair of rotary heads A 1 and A 2 and a pair of rotary heads B 1 and B 2 shown in FIG. 1 are arranged, as shown in FIG. 2 , at positions rotationally symmetric with respect to a center O of the rotary head drum 16 , that is, facing positions 180 degrees apart, at the rotary head drum 16 . The rotary heads A 1 and A 2 are arranged at adjacent positions and have azimuth angles reverse to each other. Also, the rotary heads B 1 and B 2 are similarly arranged at adjacent positions and have azimuth angles reverse to each other. The rotary heads A 1 and B 2 and the rotary heads A 2 and B 1 are given the same azimuth angles. This arrangement is called a double azimuth type. As will be explained later, such a configuration is employed at the time of high speed reproduction so that the reproduction head scans the recorded track at a different azimuth angle from that at the time of recording.
[0091] The rotary head controller 11 , head switch 12 , track skip detector 13 , FM demodulator 14 , and the waveform connector 15 will be briefly explained next.
[0092] The rotary head controller 11 controls a not illustrated drive system so as to rotate the rotary head drum 16 at a designated speed. At the same time, it generates a rotary head pulse S 11 whenever the rotary heads A 1 and B 1 pass an origin C illustrated in FIG. 2 and outputs it to the head switch 12 .
[0093] The track skip detector 13 compares the signal levels of the signals obtained from the rotary heads A 1 , A 2 , B 1 , and B 2 to monitor if the rotary head having the maximum signal level changes from the rotary head A 1 to A 2 , from the rotary head A 2 to A 1 , from the rotary head B 1 to B 2 , or from the rotary head B 2 to B 1 . Where it detects a change of the rotary heads, it concludes there was a track skip, generates a track skip pulse S 13 at that time, and outputs the track skip pulse to the head switch 12 and the waveform connector 15 .
[0094] The head switch 12 receives as its inputs the detection signals of the rotary heads A 1 , A 2 , B 1 , and B 2 and selects one of the detection signals of the rotary heads A 1 , A 2 , B 1 , and B 2 in accordance with the rotary head pulse S 11 from the rotary head controller 11 and the track skip pulse S 13 from the track skip detector 13 .
[0095] The rotary head pulse S 11 output from the rotary head controller 11 is the signal detecting the passage of the rotary head drum 16 through the position C, so indicates one revolution of the rotary head drum 16 . It is also the signal for discriminating the positions of the pair of rotary heads A 1 and A 2 and the pair of rotary heads B 1 and B 2 . On the other hand, the track skip pulse S 13 detected at the track skip detector 13 is a signal indicating that the rotary heads A 1 and A 2 or the rotary heads B 1 and B 2 skipped a track in the magnetic tape 18 . Accordingly, the head switch 12 switches between the rotary heads An and B by the rotary head pulse S 11 from the rotary head controller 11 and switches between the rotary heads 1 and 2 by the track skip pulse S 13 from the track skip detector 13 . Note that, the rotary head A indicates the rotary heads A 1 and A 2 , and similarly the rotary head B indicates the rotary heads B 1 and B 2 . Further, the rotary head 1 indicates the rotary heads A 1 and B 1 , and the rotary head 2 indicates the rotary heads A 2 and B 2 .
[0096] The FM demodulator 14 demodulates the audio signal selected at the head switch 12 and inputs the same to the waveform connector 15 .
[0097] The waveform connector 15 smoothly connects the signal FM demodulated at the FM demodulator 14 while maintaining the continuity and outputs the same as the repaired audio signal to deal with the anomalous state such as the discontinuity of the signal or skip or noise from the timing based on the track skip pulse S 13 detected at the track skip detector 13 .
[0098] Details of the high speed reproduction operation of the Hi-Fi video apparatus 1 will be explained next.
[0099] Track Skip Detector
[0100] FIG. 3 is a view of the track structure of the tape recording surface of the magnetic tape 18 of a Hi-Fi video apparatus.
[0101] FIG. 4 is a view of the trace of the head at the time of high speed reproduction of the video Hi-Fi audio track of the magnetic tape 18 illustrated in FIG. 3 .
[0102] FIG. 5 is a view of the track structure of the magnetic tape 18 and the head trace at the time of high speed reproduction. Symbols R 1 to R 7 shown in FIG. 5 are track numbers attached for convenience for the explanation of the present embodiment, while symbols Q 1 to Q 7 are scanning numbers attached for convenience for the explanation of the present embodiment
[0103] The track skip detector detects the time of occurrence of a track skip indicated by a mark O at the time of high speed reproduction as shown in FIG. 4 and FIG. 5 , generates a track skip pulse S 13 at that time, and outputs the track skip pulse S 13 to the head switch 12 and the waveform connector 15 .
[0104] The principle of generation the track skip pulse S 13 in the track skip detector 13 will be explained next.
[0105] In the helical scanning of the Hi-Fi video tape shown in FIG. 3 , as partially indicated by hatching in the track, the recording azimuth angles of the adjoining tracks are different. In the case of for example a VHS Hi-Fi video, an angle of +30 degrees is given for every track. When head scanning over a plurality of tracks as shown in FIG. 4 and FIG. 5 , the azimuth angle of the recording surface becomes reverse at the time when the track skip indicated by the mark O occurs, the angle of the head in use loses compatibility, and the other head forming the pair becomes compatible. Due to this, the magnitudes of the output levels of the paired (A 1 and A 2 and B 1 and B 2 ) heads are switched with each other.
[0106] FIG. 6 is a flow chart of the processing of the track skip detector 13 .
[0107] The track skip detector 13 follows the above principle of detection and refers to the rotary head pulse S 11 from the rotary head controller 11 to judge whether the rotary heads A 1 and A 2 are located at the tape surface of the magnetic tape 18 or the rotary heads B 1 and B 2 are located at the tape surface of the magnetic tape 18 (S 1 ). When the rotary heads A 1 and A 2 are located at the tape surface of the magnetic tape 18 , it compares the signal levels of the rotary heads A 1 and A 2 . When detecting that they are replaced with heads outputting signals having a larger level (S 2 , S 4 : S 2 , S 4 ), it generates the track skip pulse S 13 (S 5 ). Similarly, when the rotary heads B 1 and B 2 are located on the tape surface of the magnetic tape 18 , it compares the signal levels of the rotary heads B 1 and B 2 . When detecting that they are replaced with heads outputting signals having a larger level (S 6 to S 8 ), it generates the track skip pulse S 13 (S 5 )
[0108] FIGS. 7A to 7 C are graphs showing the rotary head switch operation.
[0109] The track skip pulse S 13 may be a single pulse in the head switch 12 as illustrated in FIG. 7B . However, the waveform connector 15 explained later requires the time when the track skip was generated. Therefore, the track skip pulse S 13 to be given to the head switch 12 is made a one-pulse signal as illustrated in FIG. 7B . On the other hand, as the track skip pulse S 13 to be given to the waveform connector 15 , other than the one-pulse signal, the track skip generation time is informed. Alternatively, only a one-pulse signal is given to the waveform connector 15 and the time when receiving the track skip pulse S 13 is stored in the waveform connector 15 . In the present embodiment, as will be explained later by referring to FIG. 9 and FIG. 10 , the case is illustrated where, when one pulse of the track skip pulse S 13 is supplied from the track skip detector 13 to the waveform connector 15 , a buffer controller 1551 in the waveform connector 15 sets the position anomaly flag indicating that time in a signal buffer 152 .
[0110] Rotary Head Switch
[0111] The rotary head switch 12 receives as its input the rotary head pulse S 11 output from the rotary head controller 11 and the track skip pulse S 13 output from the track skip detector 13 and switches the detection signals of the reproduction heads A 1 , A 2 , B 1 , and B 2 .
[0112] At the time of recording, as illustrated in FIG. 7A , the data is recorded by azimuth angles alternating for every track by using the rotary heads A 1 and B 1 having reverse azimuths located at facing positions. Namely, as illustrated in FIG. 5 , the audio signal is recorded on a track R 1 by the rotary head A 1 with a positive azimuth (for example +30 degrees), and audio signal is recorded on a track R 2 by the rotary head B 1 with a negative azimuth (for example −30 degrees). The audio signal is then alternately recorded in a similar way to that described above. Note that an explanation of the recording of the video signal is omitted.
[0113] At the time of normal reproduction of the recorded audio signal, in the same way as the time of recording explained above by referring to FIG. 7A , the data is reproduced by azimuth angles alternating for every track by using the rotary heads A 1 and B 1 having the reverse azimuths located at facing positions.
[0114] At the time of recording in the Hi-Fi video apparatus 1 of the present embodiment, the operation at the time of normal reproduction is similar to the operation of the usual well known Hi-Fi video apparatus.
[0115] At the time of high speed reproduction, as illustrated in FIG. 7B , the rotary head controller 11 generates the rotary head pulse S 11 at the time when the reproduction head trace returns to the lowermost end and the track skip detector 13 generates the track skip pulse S 13 at the position of the track skip given the mark O in FIG. 5 .
[0116] FIG. 7C is a graph of the head switch operation in the head switch 12 .
[0117] FIG. 8 is a flow chart of the rotary head switch operation in the head switch 12 .
[0118] The rotary heads “A” and “B” in the head switch 12 are switched at the timing of generation of the rotary head pulse S 11 output from the rotary head controller 11 , while the rotary heads “1” and “2” in the head switch 12 are switched matching with the timing of the generation of the track skip pulse S 13 in the track skip detector 13 .
[0119] For example, as exemplified in FIG. 7C , the head switch first uses the rotary heads (A 1 , B 1 ) (step 11 in FIG. 8 ). In a scanning period Q 1 , it scans the R 1 track (positive azimuth) by the rotary head A 1 (positive azimuth).
[0120] When the rotary head A 1 finishes scanning the R 1 track and shifts to the R 2 track, the head switch 12 switches the rotary head A 1 to the rotary head B 1 (step 13 ) matching with the reception of the rotary head pulse S 11 from the rotary head controller 11 ( FIG. 8 , step 12 ).
[0121] In a scanning period Q 2 , the scanning of the R 2 track (negative azimuth) is started by the rotary head B 1 (negative azimuth), but a skip to an R 3 track (positive azimuth) occurs in the middle. The head switch 12 switches the use of the rotary heads (A 1 , B 1 ) to the use of the rotary heads (A 2 , B 2 ) (step 15 ) at the time of generation of the track skip pulse S 13 from the track skip detector 13 (step 15 ) and scans the remainder of the R 3 track (positive azimuth) by the rotary head B 2 (positive azimuth).
[0122] In a scanning period Q 3 , an R 4 track (negative azimuth) is scanned by the rotary head A 2 (negative azimuth). In a scanning period Q 4 , an R 5 track (positive azimuth) is scanned by the rotary head B 2 (positive azimuth).
[0123] In a scanning period Q 5 , an R 6 track (negative azimuth) is scanned by the rotary head A 2 (negative azimuth), a switch is made to the use of the rotary heads (A 1 , B 1 ) matching with the generation of the track skip pulse S 13 , and an R 7 track (positive azimuth) is scanned by the rotary head A 1 (positive azimuth).
[0124] The head switch 12 repeats the above operations. Note that, along with the switching of the rotary heads in the head switch 12 , a pulse-like noise is sometimes generated. This noise is one of the anomalous signals of the present invention.
[0125] Due to the above operation, the head switch 12 transmits the detection signals of the rotary heads A 1 , A 2 , B 1 , and B 2 compatible with the operation (scanning) of the rotary heads A 1 , A 2 , B 1 , and B 2 at the time of high speed reproduction to the FM demodulator 14 .
[0126] The FM demodulator 14 demodulates the audio signals transmitted from the head switch 12 by a well known method.
[0127] Waveform Connector
First Embodiment
[0128] The waveform connector 15 of the first embodiment of the audio signal processing method of the present invention will be explained by referring to FIG. 9 to FIG. 11 and FIG. 12 to FIG. 18 .
[0129] FIG. 9 is a view of the configuration of the waveform connector 15 .
[0130] FIG. 10 is a view of the processing of the signal buffer 152 .
[0131] FIG. 11 is a flow chart of the processing of a signal processor 155 .
[0132] FIG. 12 to FIG. 18 are views of the waveforms of the signals processed at the waveform connector.
[0133] The waveform connector 15 is a waveform connector utilizing the track skip pulse S 13 generated in the track skip detector 13 . The track skip time becomes clear from the track skip pulse S 13 , so the waveform connector 15 connects the waveform by utilizing this.
[0134] The waveform connector 15 illustrated in FIG. 9 has an A/D converter 151 , a signal buffer 152 , a D/A converter 154 , and a signal processor 155 .
[0135] When the audio signal is input in a digital format, the A/D converter 151 and the D/A converter 154 are unnecessary.
[0136] The A/D converter 151 converts an analog audio signal S 14 demodulated at the FM demodulator 14 shown in FIG. 12 to a digital audio signal.
[0137] Signal Buffer
[0138] As illustrated in FIG. 10 , the signal buffer 152 comprises a for example 16-bit signal buffer and a 1-bit anomaly flag located at a position corresponding to the position of the audio signal to be stored. The content of the signal buffer 152 is shifted rightward every sampling time. New data is added to the input position and the data at the output position is output. The audio signal stored in the signal buffer 152 is stored in time series, so the storage position of the audio signal corresponds to the time. The output position and the processing center position do not vary, but the input position varies in accordance with the time discrepancy due the processing of the signal processor.
[0139] The D/A converter 154 converts the digital audio signal output from the signal buffer 152 to an analog audio signal.
[0140] Signal Processor
[0141] The signal processor 155 illustrated in FIG. 9 has a buffer controller 1551 , an anomaly deleter 1552 , a waveform connector 1553 , a pseudo waveform generator 1554 , a time discrepancy storage 1555 , and a pseudo waveform detector 1556 .
[0142] The signal processor 155 monitors the existence of generation of the track skip pulse S 13 and performs a series of processing of anomalous segment deletion, waveform connection, and pseudo waveform insertion when an anomalous state arises in the waveform due to the generation of the track skip pulse S 13 .
[0143] Buffer Controller
[0144] The buffer controller 1551 concludes that there is an anomaly in the waveform of the audio signal when there is a reception of the track skip pulse S 13 and sets the anomaly flag portion in the signal buffer 152 corresponding to that time at “1”.
[0145] FIG. 12 is a waveform diagram of an audio signal S 141 output from the A/D converter 151 to the signal processor 155 . Assume that an anomalous portion exists in a period T. The period T indicates the center time of the processing of the signal buffer 152 .
[0146] The buffer controller 1551 further exchanges the audio signal processed in the waveform connector 1553 , pseudo waveform generator 1554 , time discrepancy storage 1555 , and pseudo waveform detector 1556 with the signal buffer 152 to shift and replace the data in the signal buffer 152 along with the series of processing.
[0147] Anomaly Deleter
[0148] The anomaly deleter 1552 deletes the signal of the anomalous portion.
[0149] FIG. 13 is a signal waveform diagram of the case where the anomalous portion is deleted from the signal waveform illustrated in FIG. 12 by the anomaly deleter 1552 .
[0150] W represents a deletion time width (deleted segment length), TS represents a deletion start time, and Te represents a deletion end time.
[0151] Details of the deletion time width (deleted segment length) W, deletion start time TS, and deletion end time Te will be explained later. The deleted segment length W may be set longer than the maximum time length of the shot noise. It is set at for example 20 ms in the case of shot noise, and while is set at for example 5 ms in the case of discontinuity or signal skip.
[0152] Waveform Connector
[0153] The waveform connector 1553 overlaps and connects the waveform before and after the deleted segment illustrated in FIG. 13 to give a maximum similarity. The similarity is evaluated according to a mutual correlation coefficient.
[0154] The waveform of the input audio signal is defined as f(t) and the waveform in the forward direction of the deleted segment is represented by the following equation 1.
f a ( t ) = { f ( t ) ( t ≦ T s ) 0 ( t > T s ) , ( 1 )
[0155] The waveform in back of the deleted segment is represented by the following equation 2.
f b ( t ) = { 0 ( t < T e ) f ( t ) ( t ≧ T e ) , ( 2 )
[0156] As illustrated in FIG. 14 , when superposed on each other by exactly a length p, the mutual correlation coefficient of the superposed portions becomes as shown in the following equation 3.
R ( p ) = ∫ 0 p f a ( t + T s - p ) f b ( t + T e ) ⅆ t ∫ 0 p f a 2 ( t + T s - p ) ⅆ t ∫ 0 p f b 2 ( t + T e ) ⅆ t ( 3 )
[0157] This processing corresponds to calculation of the correlation by shifting the waveform in back of the deleted segment forward by exactly a length (p+W). That is calculated within a range of p min ≦p≦p max . The time difference p giving the maximum correlation coefficient is determined as an overlap segment length P.
P={p|R ( p )→maximum, p min ≦p≦p max } (4)
[0158] Here, the search range of P is made about the same degree as one pitch period of the speech or music (audio signal). For example, p min =4 ms and p max =20 ms are set.
[0159] After the overlap segment length is determined, as shown in FIG. 15 , the front and back waveform are superposed over the segment P and cross faded.
g ( t ) = { f a ( t ) ( t ≦ T q ) { ( T s - t ) f a ( t ) + ( t - T q ) f b ( t + W ) } P ( T q < t < T s ) f b ( t + W ) ( t ≧ T s ) ( 5 )
[0160] Note that, Tq=Ts−P.
[0161] Due to this method, the followings are realized:
1. Sound having periodicity in the waveform like speech (vowels) or music usually has the maximum correlation in that period or a whole multiple of the same, so can be connected while maintaining the periodicity. 2. Even if not a periodic waveform, it can be connected by the portion having the highest correlation, that is, similar in waveform. 3. Due to the cross fading, it can be smoothly connected without discontinuity in the waveform.
[0165]
[0166] Time Discrepancy Storage and Pseudo Waveform Generator
[0167] According to the above processing, the waveform is shortened by (W+P) time for each anomaly. Therefore, if left as it is, the discrepancy between the original sound and the processed sound will accumulate. Therefore, the cumulative time discrepancy from the point of time of start of the processing is stored in the time discrepancy storage 1555 . When the waveform is shortened by a constant value or more, a short pseudo waveform is prepared in the pseudo waveform generator 1554 and inserted to thereby stretch the total length.
[0168] As shown at step 31 of FIG. 11 , first, at the start of the processing, the time discrepancy storage 1555 resets the cumulative time discrepancy stored. The time discrepancy storage 1555 subtracts (X+P) from the cumulative time discrepancy stored at step 38 whenever the anomaly processing is carried out at steps 33 to 37 . When the time discrepancy storage 1555 detects that the cumulative time discrepancy exceeds a set value during the processing (step 39 ), the pseudo waveform detector 1556 , the pseudo waveform generator 1554 , and the waveform connector 1553 perform the pseudo waveform detection processing, pseudo waveform generation processing, and the pseudo waveform insertion processing shown at steps 40 to 42 . This set value may be for example 0 second. In that case, the waveform is always stretched in the initial processing and the signal is adjusted to maintain a slightly longer time than the original sound.
[0169] The pseudo waveform generation and insertion processing will be explained below. An example of the waveform after the waveform connection processing is shown in FIG. 16 .
[0170] First, a waveform having a length 1 is taken in the front of the frontmost portion Tq of the connection point, and the mutual correlation coefficient with the waveform further in front from that by a length 1 is calculated.
R ( l ) = ∫ 0 l g ( t + T q - l ) g ( t + T q - 2 l ) ⅆ t ∫ 0 l g 2 ( t + T q - l ) ⅆ t ∫ 0 l g 2 ( t + T q - 2 l ) ⅆ t ( 6 )
[0171] This is calculated over a segment of 1 min ≦1≦1 max . The 1 which becomes the maximum is determined as the pseudo waveform time length L.
L={ 1 |R (1}→maximum, 1 min ≦1≦1 max } (7)
[0172] Here, the search range of the length 1 is made about the same degree as one pitch period of speech or music in the same way as the waveform connection portion. For example, 1 min is made 4 ms and 1 max is made 20 ms.
[0173] After the pseudo waveform time length L is determined, as shown in FIG. 17 , the waveform is divided at the time T 1 =Tq−L. The back waveform is moved back by exactly L. When the front waveform is ga(t) and the back waveform after the movement is ga(t), they can be represented as follows by using g(t) of equation 5.
g a ( t ) = { g ( t ) ( t ≦ T l ) , 0 ( t > T l ) , ( 8 ) g b ( t ) = { 0 ( t ≦ T q ) , g ( t - W ) ( t > T q ) , ( 9 )
[0174] Finally, as shown in FIG. 18 , a pseudo waveform prepared by cross fading the waveform on the two sides shown in equation 10 is inserted in the segment T 1 <t<Tq which becomes empty by the above processing,
F ( t ) = { g a ( t ) ( t ≦ T l ) , { ( T q - t ) g a ( t ) + ( t - T l ) g b ( t ) } L ( T l < t < t q ) , g b ( t ) ( t ≧ T q ) , ( 10 )
[0175] The following can be realized by such a method.
1. Sound having periodicity in waveform like speech (vowels) or music has the maximum correlation in a whole multiple of the period, so the waveform is stretched while maintaining the periodicity. 2. Even if not a periodic waveform, it can be connected by the portion having the highest correlation, that is, similar in waveform. 3. Due to the cross fading, it can be smoothly connected without discontinuity in the waveform.
[0179] Time Discrepancy Storage
[0180] The time discrepancy storage 1555 stores the shortened time from the start of the processing and the cumulative time of the extension.
[0181] The series of operation of the waveform connector 15 will be explained next by referring to FIG. 11 .
[0182] Step 31 : Before storing the audio signal in the signal buffer 152 , as the initial operation, the buffer controller 1551 in the signal processor 155 resets the cumulative time discrepancy storage data.
[0183] Step 32 : The analog audio signal S 14 illustrated in FIG. 12 demodulated in the FM demodulator 14 is converted to a digital audio signal in the A/D converter 151 . The converted digital audio signal S 151 is successively stored in the signal buffer 152 every sample time. The signal buffer 152 is configured by a ring buffer or FIFO. The digital data is given from its output end to the D/A converter 154 every sample time and output as an output audio signal S 15 .
[0184] Step 33 : The buffer controller 1551 decides that an anomalous state occurred when receiving a track skip pulse S 13 , sets the anomaly flag at the position corresponding to that time in the signal buffer 152 ( FIG. 10 ), and proceeds to the processing of step 35 and the following steps. When it does not receive the track skip pulse S 13 , the operation routine shifts to the processing of step 34 .
[0185] Step 34 : When there is no anomaly, the buffer controller 1551 does nothing. In that case, the audio signal successively stored in the signal buffer 152 is successively output to the D/A converter 154 after a predetermined time.
[0186] Step 35 : When an anomalous state is detected at the buffer controller 1551 , the anomaly deleter 1552 deletes the data of the anomalous portion in the vicinity of the time T in FIG. 12 described above. Namely, when the anomalous state is detected, the anomaly deleter 1552 deletes the signal before and after the processing center time as illustrated in FIG. 13 . The noise, data loss, or the like to be eliminated by the present invention is instantaneous shot noise or discontinuity, so the deleted segment may be made for example about 5 ms.
[0187] Steps 36 to 37 : When the anomalous data is deleted, the waveform connector 1553 connects the signal before and after the deleted segment in cooperation with the pseudo waveform detector 1556 and the pseudo waveform generator 1554 .
[0188] The pseudo waveform detector 1556 searches for a similar portion by shifting the waveform data in back of the deletion portion as illustrated in FIG. 14 and overlaps and adds it so that the parts of the waveform before and after the deleted portion resemble each other the most.
[0189] The pseudo waveform generator 1554 detects the similar waveform of the data stored in the signal buffer 152 by utilizing the pseudo waveform detector 1556 again in order to compensate for the portion shortened in the total length of the data by the processing of the anomaly deleter 1552 and the waveform connector 1553 , generates the pseudo waveform for stretching the waveform, and inserts the generated waveform data into the portion deleted by the anomaly deleter 1552 .
[0190] Step 38 : The time discrepancy storage 1555 adds and stores the time length of the shortening/extension of the waveform by the anomaly deleter 1552 , waveform connector 1553 , and the pseudo waveform generator 1554 .
[0191] Step 39 : The time discrepancy storage 1555 decides whether or not the time discrepancy is within a constant value. When it is within the constant value, the operation routine shifts to the processing of step 34 .
[0192] Steps 40 to 42 : When the time discrepancy exceeds the constant value, the above processing is repeated. Namely, the similar waveform detector 1556 evaluates the similarity of the waveform at a different time in the signal buffer 152 as explained above.
[0193] Since the time discrepancy storage 1555 manages the amount of data of the audio signal in the deleted segment as time, so disconnection or overlap of the audio signal is eliminated.
[0194] The above waveform connector 15 is able to delete the noise segment for shot noise superposed on the signal, signal skip, discontinuity, etc., smoothly connect the waveform before and after the deletion, and limit the time discrepancy from the original signal to the smallest level by inserting a pseudo waveform into the signal. Namely, the waveform connector 15 of the present embodiment can delete noise derived from shot noise or discontinuity of the audio signal without distorting the normal portion, smoothly interpolate the discontinuous portion, and reduce incongruity in sound.
[0195] Further, the Hi-Fi video apparatus 1 of the embodiment of the present invention illustrated in FIG. 1 generates an audio signal compensated for discontinuity even in the case where there is a discontinuity of the audio signal due to a track skip at the time of high speed reproduction or switching of the rotary head sat the head switch 12 and as a result can reproduce an audio signal without concern as to discontinuity.
SECOND EXAMPLE OF HI-FI VIDEO APPARATUS
[0196] A second example of the Hi-Fi video apparatus of the present invention will be explained by referring to FIG. 19 to FIG. 20 .
[0197] The Hi-Fi video apparatus 1 A of the second example has a rotary head controller 11 , head switch 12 , track skip detector 13 , FM demodulator 14 , waveform connector 15 A, a rotary head drum 16 illustrated in FIG. 2 , a fixed head 17 illustrated in FIG. 2 , a not illustrated rotation drive controller of the rotary head drum 16 , a not illustrated running drive controller of the magnetic tape 18 , a not illustrated audio signal reproducing apparatus, and a not illustrated video signal reproducing apparatus.
[0198] The Hi-Fi video apparatus 1 A illustrated in FIG. 19 has a similar configuration to that of the Hi-Fi video apparatus 1 illustrated in FIG. 1 , but the track skip pulse S 13 is not output from the track skip detector 13 to the waveform connector 15 An and the configuration of the waveform connector 15 A is different from that of FIG. 9 as illustrated in FIG. 20 . The other portions are similar to those of the Hi-Fi video apparatus 1 of FIG. 1 , however. Accordingly, the following description will be made focusing on portions different from the first example.
[0199] Waveform Connector
[0200] The waveform connector 15 A will be explained by referring to FIG. 20 .
[0201] The waveform connector 15 A has an A/D converter 151 , signal buffer 152 , D/A converter 154 , signal processor 155 A, and anomaly detector 156 . When the audio signal is input in a digital form, the A/D converter 151 and the D/A converter 154 are unnecessary.
[0202] The waveform connector 15 A does not use a track skip pulse S 13 generated in the track skip detector 13 unlike the waveform connector 15 of FIG. 9 . For this reason, the anomaly detector 156 is provided in the waveform connector 15 A, and the processing of the signal processor 155 A is slightly different from the processing of the signal processor 155 illustrated in FIG. 9 .
[0203] Anomaly Detector
[0204] FIG. 21 is a view of the configuration of the anomaly detector 156 .
[0205] The anomaly detector 156 has a high pass filter 1561 , a power detector 1562 , a mean value calculator 1563 , and a power comparator 1564 .
[0206] The anomaly to be eliminated by the present invention is short time shot noise or signal loss, short time signal skip (so-called sound skip), or discontinuity due to track skip, the switching of the rotary heads, etc. At the time of detection of an anomaly, the fact that a high frequency component is instantaneously largely generated due to the nature of the shot noise or skip is utilized. For example, in speech or music, the component up to about 10 kHz at most is dominant, but in contrast, in shot noise, a component up to near the Nyquist frequency is instantaneously generated.
[0207] The high pass filter 1561 passes the high frequency component of an audio signal S 151 output from the A/D converter 151 therethrough. The power detector 1562 calculates the power of the signal passed through the high pass filter 1561 , that is, the square of the signal passed through the high pass filter 1561 . The mean value calculator 1563 calculates the mean value of the power over for example past 50 ms of the audio signal of the high frequency component. The power comparator 1564 compares the mean value of the power calculated at the mean value calculator 1563 and the power of the audio signal calculated at the power detector 1562 . When the power value is larger than the mean power value, the time is detected as the time of generation of instantaneous noise or a skip.
[0208] FIG. 12 illustrates an example of a waveform having an anomalous portion due to the disturbance of the waveform on the periphery of the time T. When the audio signal behaves as in the period T of FIG. 12 , the value deviates from the mean value of the audio signal, so the anomalous state can be detected at the power comparator 1564 .
[0209] The anomalous state detected at the anomaly detector 156 is notified to the signal buffer 152 illustrated in FIG. 10 . The signal buffer 152 sets the anomaly flag in the corresponding data.
[0210] The signal buffer 152 is similar to the signal buffer 152 explained above. Namely, as illustrated in FIG. 10 , it comprises for example a 16-bit signal buffer and a 1-bit anomaly flag. The content of the signal buffer 152 is shifted rightward every sample time. New data is added to the input position and the data at the output position is output. The output position and the processing center position do not vary, but the input position varies in accordance with the time discrepancy due the processing of the signal processor.
[0211] In the present example, the anomaly flag is set in accordance with not the track skip pulse S 13 , but the detection of the anomaly detector 156 .
[0212] Signal Processor
[0213] The signal processor 155 A illustrated in FIG. 20 has a buffer controller 1551 A, anomaly deleter 1552 , waveform connector 1553 , pseudo waveform generator 1554 , time discrepancy storage 1555 , and pseudo waveform detector 1556 .
[0214] The signal processor 155 monitors the anomaly flag stored in the signal buffer 152 by the anomaly detector 156 , performs no operation where the anomaly flag is “0” (where there is no anomaly), and performs a series of processing of anomalous segment deletion, waveform connection, and pseudo waveform insertion where the anomaly flag is “1” (where there is an anomaly).
[0215] FIG. 22 is a flow chart of the processing of the signal processor 155 A.
[0216] Buffer Controller
[0217] The buffer controller 1551 A monitors the anomaly flag at the processing center for the data stored in the signal buffer 152 illustrated in FIG. 10 . Namely, the track skip pulse S 13 is not input to the buffer controller 1551 A, so the set state of the anomaly flag set by the anomaly detector 156 is achieved by the buffer controller 1551 A. Accordingly, the decision of the anomaly by the buffer controller 1551 A of step 33 A in FIG. 22 becomes the monitoring of the set state of the anomaly flag of the signal buffer 152 .
[0218] The buffer controller 1551 A further shifts and replaces the data in the buffer along with the series of processing for the signal with the waveform shown in FIG. 12 to FIG. 18 .
[0219] Anomaly Deleter, Waveform Connector, Pseudo Waveform Generator, Time Discrepancy Storage
[0220] The anomaly deleter 1552 , waveform connector 1553 , pseudo waveform generator 1554 , and time discrepancy storage 1555 perform similar processing to that explained above by referring to FIG. 9 .
[0221] As explained above, the waveform connector 15 of FIG. 9 and the waveform connector 15 A of FIG. 20 are different in only the method of detection of the anomalous state. Accordingly, the waveform connector 15 A-of FIG. 20 can perform similar waveform connection processing to that of the waveform connector 15 of FIG. 9 .
[0222] As a result, the Hi-Fi video apparatus 1 A illustrated in FIG. 19 , similar to the Hi-Fi video apparatus 1 of FIG. 1 , can perform signal processing to eliminate anomalous due to track skip, switching of the rotary heads, or the like. Namely, the Hi-Fi video apparatus 1 A using the waveform connector 15 A illustrated in FIG. 19 generates an audio signal compensated for anomaly even when there is an anomaly of the audio signal due to track skip at the time of high speed reproduction and the switching of the rotary heads in the head switch 12 and as a result can reproduce an audio signal without concern as to anomaly.
THIRD EXAMPLE OF HI-FI VIDEO APPARATUS
[0223] The method of detection of the anomalous portion in the waveform connectors 15 and 15 A is not limited to the examples explained above. Other various methods can be employed.
[0224] For example, in the same way as a track skip being detected at the track skip detector 13 and a track skip pulse S 13 being output to the waveform connector 15 , a signal indicating an anomalous state in the apparatus using the waveform connector 15 from that apparatus and an auxiliary signal can be input to for example the buffer controller 1551 of the signal processor 155 illustrated in FIG. 9 .
[0225] As such an auxiliary signal, use can be made of for example an error correction code used at the time of reproduction of a CD etc. By this, the time of generation of the anomaly becomes clear, and the processing in the waveform connector 15 becomes possible.
[0226] The waveform connectors 15 and 15 A can be applied to not only a Hi-Fi video apparatus, but also various other apparatuses handling audio signals. As such apparatuses, there are for example CD audio signal players, MD players, DVD players, cellular phones, 8 mm video apparatuses, and audio signal communication devices.
[0227] When the present invention is applied to such apparatuses, even if there is noise or skips due to scratches or dust on the magnetic tape, noise or skips due to scratches or dust on the magnetic disk, noise or skips due to scratches or dust on the optical disk, noise or skips due to scratches or dust on the analog record disk, noise or signal loss occurring in the air or apparatus, etc., the influence of them can be eliminated and the incongruity in sound can be reduced.
[0228] Further, the present invention is not limited to the Hi-Fi video apparatuses explained above and can be applied to the signal processing of an anomaly caused when reproducing an audio signal recorded on a magnetic tape or a rotary recording medium such as a magnetic disk.
[0229] Digital Video Signal Recording and/or Reproducing Apparatus
[0230] As another embodiment of the present invention, a digital video signal recording and/or reproducing apparatus will be explained. The explanation of the processing in the Hi-Fi video apparatuses also applies to a digital video signal recording and/or reproducing apparatus, but a Hi-Fi video apparatus and digital video signal recording and/or reproducing apparatus have the following differences.
1. A digital video signal recording and/or reproducing apparatus is controlled to follow a track by a dynamic tracking head even at the time of high speed reproduction, so skips occur also in units of tracks. 2. A digital video signal recording and/or reproducing apparatus can easily judge a track skip since an ID is recorded at the track head.
[0233] FIG. 23 is a view of the configuration of a digital video signal recording and/or reproducing apparatus 2 taking into account the above conditions.
[0234] The digital video signal recording and/or reproducing apparatus 2 has a not illustrated rotary drum with rotary heads An and B mounted thereon, a digital signal demultiplexer 21 , a track skip detector 22 , and a waveform connector 23 .
[0235] FIG. 24 is a view of the track structure of the recording surface of a consumer-use digital video tape, and FIG. 25 is a view of the head scanning trace at the time of high speed reproduction.
[0236] In this example, the tracks are read skipping one out of three tracks.
[0237] The rotary heads An and B are arranged facing each other at 180 degrees in the same way as illustrated in FIG. 2 , but the digital video signal recording and/or reproducing apparatus is controlled to scan along a track by a not illustrated auto tracking control mechanism.
[0238] The digital signal demultiplexer 21 reads a recording signal comprised by insert and track information (ITI), an audio signal, a video signal, and a sub code and demultiplexes the same as the digital data.
[0239] The digital signal demultiplexer 21 transmits the video signal to a not illustrated usual video processor and transmits the audio signal to the waveform connector 23 .
[0240] The digital signal demultiplexer 21 inputs the head signal to the track skip detector 22 .
[0241] The track skip detector 22 detects the ID number of the track from the head signal, compares the same with the ID number of the track reproduced immediately before that, and determines the existence of a track skip. The track skip detector 22 sets “0” when the ID numbers continue, while sets “1” when they do not continue, and transmits a track skip pulse S 22 to the waveform connector 23 .
[0242] The waveform connector 23 has a similar configuration to that of the waveform connector 15 illustrated in FIG. 9 as illustrated in FIG. 26 .
[0243] The waveform connector 23 is configured by a signal buffer 231 and a signal processor 232 . The signal processor 232 is configured by a buffer controller 2321 , an anomaly deleter 2322 , a waveform connector 2323 , a pseudo waveform generator 2324 , a time discrepancy storage 2325 , and a pseudo waveform detector 2326 .
[0244] The signal buffer 231 of the waveform connector 23 corresponds to the signal buffer 152 of the waveform connector 15 . The signal processor 232 of the waveform connector 23 corresponds to the signal processor 155 of the waveform connector 15 . The buffer controller 2321 , anomaly deleter 2322 , waveform connector 2323 , pseudo waveform generator 2324 , time discrepancy storage 2325 , and pseudo waveform detector 2326 correspond to the buffer controller 1551 , anomaly deleter 1552 , waveform connector 1553 , pseudo waveform generator 1554 , time discrepancy storage 1555 , and pseudo waveform detector 1556 .
[0245] Note that the digital video signal recording and/or reproducing apparatus 2 performs digital signal processing, so the A/D converter 151 and the D/A converter 154 are not provided.
[0246] The signal buffer 231 receives as input a digital audio signal S 21 A detected and demultiplexed at the digital signal demultiplexer 21 .
[0247] The buffer controller 2321 performs processing equivalent to the decision processing at step 33 of FIG. 11 when the track skip pulse S 22 is “1”.
[0248] The buffer controller 2321 , anomaly deleter 2322 , waveform connector 2323 , pseudo waveform generator 2324 , time discrepancy storage 2325 , and pseudo waveform detector 2326 perform similar processing to that of the buffer controller 1551 , anomaly deleter 1552 , waveform connector 1553 , pseudo waveform generator 1554 , time discrepancy storage 1555 , and pseudo waveform detector 1556 explained above.
[0249] As explained above, the digital video signal recording and/or reproducing apparatus 2 can repair an audio signal having an anomaly due to a track skip or the like even in the case of high speed reproduction in the same way as a Hi-Fi video apparatus.
[0250] 8 mm Video Apparatus
[0251] The present invention can also be easily applied to an 8 mm video apparatus.
[0252] The track structure of an 8 mm video tape is shown in FIG. 27 .
[0253] An audio signal is digitally recorded on the magnetic tape by a rotary head as a PCM audio signal. An FM modulated analog signal (in the same way as a Hi-Fi signal) is recorded multiplexed on the video signal.
[0254] When the 8 mm video apparatus uses an FM audio signal using a dynamic tracking head, the processing is the same as in a Hi-Fi video apparatus. Further, when the 8 mm video apparatus uses a PCM audio track using the dynamic tracking head, a similar configuration to that of the case of the digital video apparatus is employed.
[0255] In this way, the 8 mm video apparatus can utilize the audio signal of a PCM or FM track at the time of high speed reproduction.
[0256] Magnetic Disk Apparatus
[0257] The data skip in the case of a magnetic disk apparatus has the following characteristic features unlike a track skip in a Hi-Fi video apparatus or a digital video signal recording and/or reproducing apparatus explained above.
1. The random accessibility of the data is high, so a skip due to limitations of physical arrangement of the tracks on a tape does not occur. 2. Rather, at the time of high speed reproduction, there are data segments which are intentionally not read so as to keep the data within the readable speed.
[0260] FIG. 28 is a view of the hardware configuration of a magnetic disk apparatus taking into account the above circumstances.
[0261] The magnetic disk apparatus 3 has an address controller 31 , a fixed disk drive 32 , and a waveform connector 33 .
[0262] The fixed disk drive 32 stores the audio signal and the video signals as digital data. At the time of reproduction, the data is read according to the address designated by the address controller 31 and input to the waveform connector 33 .
[0263] The address controller 31 compares the reproduction speed designated by the user and the reading speed of the fixed disk, determines the data read segments and the nonread segments so as to be within the range of the read speed, and designates the read addresses to the fixed data drive 32 accordingly. Further, it generates a data skip signal at the end of continuous read segments (immediately before a nonread segment) and inputs the same to the waveform connector 33 .
[0264] FIG. 29 is a graph of the operation timing of the magnetic disk apparatus 3 .
[0265] For convenience, assume that successive recording data ( FIG. 29A ) given numbers D 1 to D 15 are recorded in the fixed disk drive 32 .
[0266] At the time of reproduction, assume that the address controller determines the read segments and the nonread segments as illustrated in FIG. 29B . At that time, the data actually read from the fixed disk drive 32 become as illustrated in FIG. 29C , and discontinuity of data occurs between D 5 and D 8 and between D 12 and D 15 . The data skip signal generated by the address controller 31 detecting such discontinuity becomes as shown in FIG. 29D .
[0267] The waveform connector 33 has the equivalent circuit configuration to the waveform connector 23 illustrated in FIG. 26 .
[0268] Accordingly, the waveform connector 33 receiving the data skip signal from the address controller 31 performs repair processing similar to that explained above for the audio signal input from the fixed disk drive 32 .
[0269] As explained above, the present invention is not limited to the high speed reproduction of an audio signal recorded on a recording medium like a magnetic tape and can be applied to also the high speed reproduction of an audio signal recorded on a random access type recording medium such as a magnetic disk and an optical disk.
[0270] Further, the present invention is not limited to the embodiments explained above. The present invention can be applied to various other types of audio signal processing apparatuses. As such audio signal processing apparatuses, there are the compact disk players, MD players, DVD players, etc.
[0271] The present invention can not only be applied to apparatuses such as Hi-Fi video apparatuses, digital video signal recording and/or reproducing apparatuses, 8 mm video apparatuses, and magnetic disk apparatuses, but also can use elements configuring these apparatuses alone.
[0272] For example, the waveform connectors 15 , 23 , and 33 shown in the various embodiments are not limited to the waveform connection of the audio signals explained above, but can also be applied to other signal processing.
[0273] Summarizing the effects of the present invention, the audio signal processing method and the audio signal processing apparatus of the present invention delete the audio signal in the noise segment due to shot noise superposed on the signal, signal skip, and discontinuity and smoothly connect the waveform before and after the deletion. Particularly, it can keep the time discrepancy from the original audio signal to a minimum level by inserting a pseudo waveform into the signal.
[0274] The audio signal processing apparatuses such as Hi-Fi video apparatuses, digital video signal recording and/or reproducing apparatuses, 8 mm video apparatuses, and magnetic disk apparatuses can reproduce a high quality audio signal with little incongruity by eliminating the influence of the sound skip (skip) occurring at the time of high speed reproduction, the noise at the switching of the heads, etc.
[0275] As a result, for example, in a Hi-Fi video apparatus, even when trying to save time while fully viewing and listening to the content by reproduction at 1.2× speed, a high quality audio signal can be reproduced. In a magnetic disk apparatus, it becomes possible to obtain a greater margin in the access time and therefore perform time division processing with other tasks without exceeding the limit of the access time.
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An audio signal processing method for repairing an anomalous state such as noise, a discontinuity, and a break of sound, comprising detecting the anomalous state of an audio signal, deleting the audio signal in the anomalous segment, deducing the correct audio signal by referring to the waveform of the audio signal before and after the deleted segment, generating a repair signal for repairing the signal in the deleted segment based on the deduced result, inserting the repair signal into the deleted segment, and connecting it to the audio signal before and after the deleted segment.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a straddle-type four wheeled all terrain vehicle, and more particularly to an intake structure of a cooling air for a straddle-type four wheeled all terrain vehicle in which a belt converter is mounted to an engine.
[0003] 2. Description of the Related Art
[0004] In the straddle-type four wheeled all terrain vehicle, a belt converter is sometimes mounted to an engine. The belt converter is mounted between a crank shaft of the engine and a transmission to facilitate a speed change operation of a vehicle.
[0005] The belt converter is accommodated in a case. Since the belt converter generates heat by an operation thereof, an air is introduced from outside into the case, thereby cooling the belt converter to prevent an increase in temperature in the case.
[0006] An example of the intake structure of the cooling air into the belt converter is that a box-shaped space opened at a front and closed at a periphery thereof is provided in a lower portion of a tip end portion of a front fender and an air passage reaching the belt converter is opened in this space (see Japanese Patent No. 2963052).
[0007] However, in this structure, when the vehicle is traveling, foreign substances such as trash, mud, water as well as fresh air from front, sometimes enter the intake port. For this reason, there is a need for an improved intake structure of the cooling air into the belt converter.
SUMMARY OF THE INVENTION
[0008] The present invention addresses the above-described problem, and an object of the present is to provide a straddle-type four wheeled all terrain vehicle having an intake structure of a cooling air into a belt converter that is capable of preventing the entry of foreign substances such as water and mud with a simple constitution.
[0009] According to the present invention, there is provided a straddle-type four wheeled all terrain vehicle comprising: a vehicle body; a straddle-type seat provided on an upper portion of the vehicle body; a bar-type handle having a steering haft and provided forward of the seat; a vehicle body cover covering a portion of the vehicle body including the steering shaft from above, the steering shaft penetrating through the vehicle body cover; and a belt converter, wherein an opening of the vehicle body cover through which the steering shaft passes is an intake port of a cooling air into the belt converter.
[0010] With this constitution, since the intake port through which the cooling air is taken into the belt converter from outside is provided at the middle in the longitudinal direction of the vehicle boy and at a high position of the vehicle body, the water, mud or the like hardly enters the intake port. Besides, since the opening of the vehicle body cover through which the steering shaft passes is utilized, the intake port can be structured very simply. Also, the intake port is formed around the steering shaft of the handle and just before the rider, and therefore, if the intake port is clogged with the foreign substances or the like, they can be immediately found and removed.
[0011] Preferably, in the straddle-type four wheeled all terrain vehicle, a relay chamber may be formed inside of the vehicle body cover such that the relay chamber communicates with the opening, and a cooling air intake port of the belt converter may be opened in the relay chamber.
[0012] Thereby, the cooling air intake passage from the opening of the vehicle body cover to the belt converter can be easily constituted.
[0013] Preferably, in the straddle-type four wheeled all terrain vehicle, a portion of the vehicle body cover around the opening may be raised to be formed into a swelled portion, and the relay chamber may be structured to have a chamber wall including one part constituted by a portion of the swelled portion including the opening and the other part through which the steering shaft and a cooling air intake duct having the cooling air inlet port of the belt converter that is opened in the relay chamber penetrate.
[0014] Thereby, the intake port through which the cooling air is taken into the belt converter can be formed at a high position because of the swelled portion. In addition, since the swelled portion is utilized as part of the chamber wall, the relay chamber can be easily constituted.
[0015] Preferably, in the straddle-type four wheeled all terrain vehicle, a portion of the other part of the chamber wall through which at least the steering shaft and the cooling air intake duct of the belt converter penetrate may be comprised of a flexible plate member.
[0016] Since the flexible plate member is flexible, steering shaft, the cooling air intake duct, or the like can be easily made to penetrate through the corresponding through holes even if some positional difference occurs between these members and the through holes.
[0017] Preferably, in the straddle-type four wheeled all terrain vehicle, the swelled portion may be configured such that front and side portions around the opening is raised and the swelled portion extends rearwardly, the relay chamber may be structured such that a portion of the swelled portion defines one part of the chamber wall of the relay chamber, a front wall member, a pair of side wall members, a flexible plate member, and a seal structure define the other part of the chamber wall, the front wall member and the pair of side wall members are downwardly protruded at a front end portion and side end portions of the swelled portion that is located forward and side of the opening in an inner face of the vehicle body cover such that the front wall member and the side wall members form an enclosure, the flexible plate member substantially defines a bottom and a rear of a space covered by the portion of the swelled portion that is located forward and side of the opening, the seal structure is formed between a front end of the flexible member and a lower end of the front wall member, and the steering shaft and the cooling air intake duct of the belt converter may penetrate through the flexible plate member.
[0018] With this constitution, a wide relay chamber can be formed. Besides, since the bottom wall and the rear wall of the relay chamber can be formed by one flexible member, its structure can be simplified. Further, since the seal structure is provided at the front lower portion of the relay chamber that tends to splashed with mud or water, the entry of the mud, water, or the like into the relay chamber can be prevented.
[0019] Preferably, in the straddle-type four wheeled all terrain vehicle, the seal structure may be formed such that a support member being a frame member of the vehicle body extends along a lower end of the front wall member as having a clearance between the front wall member and the support member, a cushion member may be provided on the support member to fill the clearance, and a front end of the flexible plate member may be connected to the support member.
[0020] Thereby, the seal structure can be easily formed.
[0021] The above and further objects and features of the invention will be more fully be apparent from the following detailed description with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1 is a left side view showing an entire configuration of a straddle-type four wheeled all terrain vehicle according to an embodiment of the present invention;
[0023] [0023]FIG. 2 is a front view showing the entire configuration of the straddle-type four wheeled all terrain vehicle according to the embodiment;
[0024] [0024]FIG. 3 is a plan view showing the entire configuration of the straddle-type four wheeled all terrain vehicle according to the embodiment;
[0025] [0025]FIG. 4 is a lateral perspective view of a vehicle body main part showing an intake passage of a belt converter and an air cleaner utilizing a relay chamber of FIGS. 1 - 3 and an engine coolant circulating passage;
[0026] [0026]FIG. 5 is a partially enlarged cross-sectional view showing a detailed structure of the relay chamber of FIGS. 1 - 3 ;
[0027] [0027]FIG. 6 is a cross-sectional view taken in the direction of the arrow VI-VI of FIG. 5;
[0028] [0028]FIG. 7 is a view taken from the direction of the arrow A of FIG. 5; and
[0029] [0029]FIG. 8 is a plan view showing a shape of a flexible plate member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Hereinafter, an embodiment of the present invention will be described with reference to drawings.
[0031] [0031]FIG. 1 is a left side view showing an entire configuration of a straddle-type four wheeled all terrain vehicle according to an embodiment of the present invention, FIG. 2 is a front view thereof, and FIG. 3 is a plan view thereof.
[0032] Referring now to FIGS. 1 - 3 , a straddle-type four wheeled all terrain vehicle 1 comprises a steering bar handle 4 mounted to a vehicle body frame (partially shown in FIGS.) 2 , right and left front wheels 8 , and right and left rear wheels 9 . The straddle-type four wheeled all terrain vehicle 1 further comprises a straddle-type seat 6 placed rearward of the handle 4 and apart a certain distance therefrom, and foot boards 10 provided on opposite sides forward and downward of the seat 6 , rearward of the handle 4 , and at positions substantially as high as an axle of the front wheels 8 and the rear wheels 9 . The vehicle 1 is provided with a V-type engine 11 between the right and left foot boards 10 such that a lower end of the engine 11 is substantially as high as the foot boards 10 . In the V-type engine 11 , two cylinders are respectively inclined forward and rearward. A carburetor 32 is provided between these inclined cylinders for supplying a fuel-air mixture to the respective cylinders. An air cleaner 21 is provided immediately above the carburetors 32 for cleaning an air used in the engine 11 . The air cleaner 21 is positioned between the handle 4 and the seat 6 . Thus, in this embodiment, a vehicle body structure in which the air cleaner 21 is placed between the handle 4 and the seat 6 is realized by using the V-type engine 11 and by inclining the two cylinders forward and rearward.
[0033] A front fender 35 is provided as generally covering a portion of the vehicle body that is located forward of the handle 4 from above. An air cleaner cover 5 and a side cover 34 are provided rearward of the front fender 35 such that these covers generally cover a portion of the vehicle body located between the handle 4 and the seat 6 from above. The air cleaner cover 5 covers a portion of the air cleaner 21 of the portion of the vehicle body located between the handle 4 and the seat 6 from above and the side cover 34 covers the other portion. A rear fender 81 is provided rearward of the side cover 34 such that it generally covers a portion of the vehicle body that is located rearward of the seat 6 other than the seat 6 . The front fender 35 , the air cleaner cover 5 , the side cover 34 , and the rear fender 81 compose the vehicle body cover 201 . A front carrier 51 is provided on the front fender 35 and a rear carrier 82 is provided on a rear portion of the rear fender 81 . An intake opening 102 is formed in a middle portion in the lateral direction of the vehicle body at a boundary portion between the front fender 35 and the side cover 34 , for introducing a fresh air into the engine or the like. A steering shaft 14 of the handle 4 passes through the intake opening 102 . A handle cover 16 provided on the handle 4 covers the intake opening 102 from above.
[0034] The front fender 35 extends substantially horizontally with a width gradually increased from its front end to its rear end. The front fender 35 is configured such that a front half portion of the intake opening 102 is formed in a middle portion of a rear end portion of the front fender 35 and a portion around the front half portion of the intake opening 102 is raised to be formed into a swelled portion 101 and right and left side portions of the rear end portion other than the swelled portion 101 extends downwardly. A front periphery and a side periphery of the front fender 35 are inwardly bent substantially at a right angle. The side cover 34 and the air cleaner cover 5 are entirely curved in the lateral direction of the vehicle body such that their central portions are ridge-shaped. The central ridge portions are substantially horizontal from the front end to the middle portion and downwardly inclined from the middle portion to the rear end in the longitudinal direction of the vehicle body. The air cleaner cover 5 is located on an opening formed at a top portion of the side cover 34 . A rear half portion of the intake opening 102 is formed in a middle portion of the front end portion of the side cover 34 , which is fitted to a rear end portion of the front fender 35 . A rear end portion of the side cover 34 is covered by the front end portion of the seat 6 , although this is not shown. In a portion of the vehicle body cover 201 that is comprised of the front fender 35 , the air cleaner cover 5 , and the side cover 34 , front and side portions around the intake opening 102 is raised from the upper surface of the front fender 35 to be formed into the swelled portion 101 , which substantially extends rearwardly over a certain length. By thus raising the portion around the intake opening 102 , the intake opening 102 can be made correspondingly higher.
[0035] A relay chamber 31 is structured such that a portion of the swelled portion 101 that is located forward and side of the intake opening 102 (hereinafter referred to as a swelled front portion) 101 a defines one part of a chamber wall thereof and a member such as a flexible plate member 33 defines the other part of the chamber wall. The relay chamber 31 serves to relay the fresh air from the intake opening 102 to the engine or the like. By thus utilizing the swelled front portion 101 a as part of the chamber wall of the relay chamber 31 , the relay chamber 31 can be easily formed.
[0036] A pair of plate-shaped inner covers 52 are provided in a middle portion of an inner space of the front fender 35 such that they extend in the longitudinal direction of the vehicle body over the whole length of the front fender 35 as being apart from each other and having a certain height. The inner covers 52 are inside covers of the front wheels 8 and constitute part of side walls of the relay chamber 31 as mentioned later.
[0037] [0037]FIG. 4 is a lateral perspective view of a vehicle body main part showing the air intake passage of the belt converter and the air cleaner utilizing the relay chamber of FIGS. 1 - 3 and an engine coolant circulating passage.
[0038] Referring to FIG. 4, a belt converter chamber (not shown) is provided on the right side of a crank chamber (not shown) of the engine 11 and covered by a belt converter cover 83 . A belt converter 54 is accommodated in the belt converter chamber. A belt converter air intake duct 55 is connected to a front end portion of the belt converter chamber. An exhaust duct (not shown) is connected to the belt converter chamber. The belt converter air intake duct 55 forwardly and upwardly extends from a portion connected to the belt converter chamber and is opened at a tip end thereof in the relay chamber 31 . An air cleaner intake duct 29 is connected to a lower portion of a front face of the air cleaner 21 . The air cleaner air intake duct 29 extends forwardly and upwardly from a portion connected to the air cleaner 21 and is opened at a tip end thereof in the relay chamber 31 . This constitution enables the belt converter 54 and the air cleaner 21 to take in the fresh air through the intake opening 102 provided at the highest position of the vehicle body through the relay chamber 31 . In this constitution, since the intake opening 102 of the vehicle body cover 201 through which the steering shaft 14 passes is utilized as the intake port through which the fresh air is taken into the belt converter 54 and the air cleaner 21 , the intake port can be simply constituted. Also, since it is not necessary to directly connect the belt converter intake duct 55 and the air cleaner intake duct 29 to the intake opening 102 , the fresh air intake passage from the intake opening 102 to the belt converter 54 and the air cleaner 21 can be easily constituted.
[0039] A radiator 56 is mounted substantially at the middle of the front end portion of the vehicle body in the vertical direction. A thermostat 85 is provided in the vicinity of a lower portion of the relay chamber 31 . A coolant hose 84 connects the radiator 56 , the thermostat 85 , and the engine 11 , thereby forming a circulating passage 202 of the engine coolant (hereinafter simply referred to as a coolant). A water pump 57 is provided on a left side portion of the lower portion of the engine 11 . An internal circulating passage (not shown) of the coolant is formed in the engine 11 such that it extends from a discharge port of the water pump 57 to an upper end portion of each cylinder of the engine 11 . Two branch hoses 84 a , 84 b of a discharge-side coolant hose 84 c of the water pump 57 (hereinafter referred to as a discharge-side coolant hose) respectively extend forwardly and upwardly from an end of the internal circulating passage of the upper end portion of each cylinder to the thermostat 85 , where these hoses meet to be formed into the discharge-side coolant hose 84 c , which substantially horizontally extends to a position above and rearward of the radiator 56 and further forwardly and downwardly extends so as to be connected to an upper end of the radiator 56 . A suction-side coolant hose 84 d rearwardly and downwardly extends from a lower end portion of the radiator 56 and is connected to a suction port of the water pump 57 . A coolant filler neck 58 is provided integrally with and adjacently to the thermostat 85 so as to communicate with the thermostat 85 , for filling the coolant into the coolant circulating passage 202 . The coolant filler neck 58 extends upwardly from the thermostat 58 and is opened at a tip end thereof in the relay chamber 31 . A cap 58 a is attached to the coolant filler neck 58 . Thereby, the filling port of the coolant is positioned at the highest position of the coolant circulating passage 202 without lessening visual appearance. Also, with this constitution, since the discharge-side coolant hose 84 c is put through the upper end of the radiator 56 obliquely from above, the air in the coolant circulating passage 202 can be easily released. It should be noted that the coolant filler neck 58 is provided with a coolant overflow pipe 59 mounted vertically downwardly from a side portion of the coolant filler neck 58 , for discharging the coolant overflowed from the coolant circulating passage 202 .
[0040] [0040]FIG. 5 is a partially enlarged cross-sectional view showing a detailed structure of the relay chamber of FIGS. 1 - 3 . FIG. 6 is a cross-sectional view taken in the direction of the arrows substantially along line VI-VI of FIG. 5. FIG. 7 is a view taken from the direction of the arrow A of FIG. 5. FIG. 8 is a plan view showing a shape of a flexible plate member. In FIG. 5, a side wall portion of the relay chamber 31 is shown as being cut out. In FIG. 5, side wall ribs 65 and the inner covers 52 thus constituting the cut-out side wall portion are indicated by imaginary lines.
[0041] As shown in FIGS. 5 - 7 , a plate-shaped front wall rib 64 is provided at a front end portion of the swelled front portion 101 a in an inner face of the front fender 35 such that it extends downwardly to a predetermined vertical position and in the lateral direction of the vehicle body over substantially the entire width of the swelled front portion 101 a . A semi-circular cut-out portion 64 a is formed at a portion located slightly leftward from the center of the lower end of the front wall rib 64 . A cross member 2 a (support member) extends along the lower end of the front wall rib 64 as having a predetermined clearance below the front wall rib 64 . The cross member 2 a constitutes part of the vehicle body frame 2 and an upper face thereof is flat. The discharge-side coolant hose 84 c penetrates through the front wall rib 64 in the cut-out portion 64 a in the longitudinal direction of the vehicle body. A cushion member 63 is provided to fill the clearance between the upper face of the cross member 2 a and the front wall rib 64 , and the discharge-side coolant hose 84 c , and the clearance between the discharge-side coolant hose 84 c and the front wall rib 64 . The cushion member 63 is, for example, made of sponge and comprised of a portion 63 a provided on the cross member 2 a and a portion 63 b wound around the discharge-side coolant hose 84 c.
[0042] A pair of side wall ribs 65 are protruded at right and left side end portions of the swelled front portion 101 a in the inner face of he front fender 35 such that these ribs extend in the longitudinal direction of the vehicle body. The inner covers 52 are respectively mounted to outer faces of the side wall ribs 65 to extend downwardly.
[0043] The side wall ribs 65 and the inner covers 52 cover a side of a space located below the space covered by the swelled front portion 101 a over the entire height from the inner face of the front fender 35 to the upper face of the cross member 2 a . Therefore, the front wall rib 64 , and the side wall ribs 65 and the inner covers 52 form an enclosure at the front end portion and the opposite side end portions of the swelled front portion 101 a.
[0044] A flexible plate member 33 substantially defines the bottom and rear of the space covered by the swelled front portion 101 a , the front wall rib 64 , the side wall ribs 65 and the inner covers 52 . The flexible plate member 33 is, for example, comprised of a rubber plate. As shown in FIG. 8, the flexible plate member 33 is comprised of a rectangular bottom wall portion 33 a and a substantially trapezoid rear wall portion 33 b formed at the rear end thereof as having a width smaller than that of the bottom wall portion 33 a . The bottom wall portion 33 a conforms in shape to the bottom of the space covered by the front wall rib 64 , the side wall ribs 65 and the inner covers 52 . A steering shaft through hole 72 , an intake duct through hole 73 for air cleaner, an intake duct through hole 74 for belt converter, and a coolant filler neck through hole 75 are formed in the bottom wall portion 33 a . Cuts 72 a and cuts 74 a are respectively formed in the steering shaft through hole 72 and the intake duct through hole 74 . These cuts make it easy that the corresponding members are inserted into the respective holes. A slit 76 is formed in the bottom wall portion 33 a from the front end to the steering shaft through hole 72 . The slit 76 allows the steering shaft mounted to the vehicle to be put through the steering shaft through hole 72 when the flexible plate member 33 is mounted to the vehicle body. Elongated holes 77 are formed on opposite sides with respect to the slit 77 . The elongated holes 77 are used in such a manner that bands are put therethrough to allow the slit 76 to be tightened to prevent it from being widened after the steering shaft is put through the steering shaft hole 72 . A wide cut-out portion 33 c is formed at a middle portion of a rear end of the rear wall portion 33 b . Small holes 71 are formed on opposite sides of the rear end portion of the rear wall portion 33 b.
[0045] As shown in FIG. 5, a front end portion of the bottom wall portion 33 a of the flexible plate member 33 is placed on the upper face of the cross member 2 a adjacently to the rear end of the cushion member 63 . The bottom wall portion 33 a horizontally extends rearwardly from the portion fixed to the cross member 2 a to the rear end of the front fender 35 , from where the rear wall potion 33 b upwardly and inwardly extends. FIG. 8 illustrates a boundary 33 d between the bottom wall portion 33 a and the rear wall portion 33 b , at which the flexible plate member 33 is bent. As shown in FIG. 7, rear peripheral portions of the front fender 35 are inwardly bent at a right angle to be formed into rear peripheral ribs 35 b and resin rivets 66 are formed at predetermined portions of outer faces of the rear peripheral ribs 35 b . As shown in FIGS. 5, 7, the rear wall portion 33 b of the flexible plate member 33 passes through between the right and left rear peripheral ribs 35 b to the outer face side thereof, from where the rear wall portion 33 b upwardly and forwardly extends along the outer face of the rear peripheral ribs 35 b to a vicinity of the intake opening 102 . In the vicinity of the opening 102 , the resin rivets 66 are inserted through the small holes 71 and with these rivets, the rear wall portion 33 b can be secured to the rear peripheral ribs 35 b . The cut-out portion 33 c of the rear wall portion 33 b serves to prevent interference with the rearwadly inclined steering shaft 14 .
[0046] As shown in FIGS. 5, 6, 8 , in this embodiment, the coolant hoses 84 a , 84 b , 84 c , the thermostat 85 , and the coolant overflow pipe 59 are placed in part of the space surrounded by the front wall rib 64 and the side wall ribs 65 , and the inner covers 52 . The bottom wall portion 33 a of the flexible plate member 33 cover these members such that these members are located outside of the relay chamber 31 . Therefore, the bottom wall portion 33 a is configured to have a swelled portion 33 e located at substantially the center in the lateral direction thereof that is slightly leftward when seen in a front view and substantially at a front half thereof when seen in a side view.
[0047] The steering shaft 14 , the air cleaner intake duct 29 , the intake duct 55 for belt converter, and the coolant injecting tube 58 respectively penetrate through the bottom wall portion 33 a in the holes 72 , 73 , 74 , 75 . By using the flexible plate member 33 as the portions of the chamber wall of the relay chamber 31 through which the members 14 , 29 , 55 , 58 such as the steering shaft or the like penetrates, these members can be easily made to penetrate through the through holes even if some positional difference occurs between the members 14 , 29 , 55 , 58 and the through holes 72 , 73 , 74 , 75 .
[0048] A coolant supply opening 61 is formed in a portion of the swelled front portion 101 a of the front fender 35 that is located above the filler neck 58 , and a lid member 62 is removably fitted to the coolant supply port 61 (see FIGS. 2, 3).
[0049] Thus, the swelled front portion 101 a , the front wall rib 64 , the cushion member 63 , the cross member 2 a , the side wall ribs 65 , the inner covers 52 , and the flexible plate member 33 constitute the chamber wall of the relay chamber 31 . This constitution provides the wide relay chamber 31 . Besides, since the bottom wall and the rear wall of the relay camber 31 are constituted by one flexible plate member 33 , the structure can be simplified.
[0050] Subsequently, how so constituted straddle-type four wheeled all terrain vehicle operates and is used will be explained.
[0051] Referring to FIGS. 1 - 5 , when the rider starts the straddle-type four wheeled all terrain vehicle 1 and the engine 11 operates, the belt converter 54 is activated, thereby causing the fresh air to be taken into the belt converter chamber through the clearance between the intake opening 102 and the steering shaft 14 , the relay chamber 31 , and the belt converter intake duct 55 . The belt converter 54 is cooled by the fresh air. Meanwhile, the fresh air to be used in the engine 11 is taken into the air cleaner 21 through the clearance between the intake opening 102 and the steering shaft 14 , the relay chamber 31 , and the air cleaner intake duct 29 and purified therein to be supplied to the engine 11 through the carburetor 32 . While the straddle-type four wheeled all terrain vehicle 1 is traveling, foreign substances such as water or mud sometimes might fly from front of the vehicle. However, since the front portion of the relay chamber 31 is closed and the intake opening 102 as the intake port of the fresh air is provided at the central portion in the longitudinal direction of the vehicle body and at a high position of the vehicle body, the foreign substances such as water or mud hardly enters the intake opening 102 . In addition, since the intake opening is formed around the steering shaft 14 of the handle 4 and located just before the rider. Therefore, if the intake opening 102 is clogged with the foreign substances, they can be found immediately and removed. In some cases, the water, mud or the like splashes up from below of the vehicle body. In such cases, the mud or water tends to splash up to the front lower comer portion of the relay chamber 31 , but since a seal structure comprised of the cushion member 63 and the cross member 2 a is formed in this portion, the entry of the water or mud into the relay chamber 31 can be prevented.
[0052] Meanwhile, when the engine 11 starts, the coolant circulates through the circulating passage 202 to cool the engine 11 . By opening/closing the control valve of the thermostat 85 , the circulation of the coolant is released or stopped. When the temperature of the coolant is increased to a certain value or more and an internal pressure is increased to cause the coolant to be overflowed, the overflowed coolant is discharged from the coolant overflow pipe 59 to a reserve tank (not shown). When the coolant is changed or the amount of the coolant is checked, the rider opens the lid member 62 of the front fender 35 and detaches the cap 58 a to fill the coolant from the upper end of the coolant filler neck 58 . In this case, since the coolant filler neck is located at the highest point of the coolant circulating path 202 , the coolant can be injected while easily releasing the air.
[0053] Alternatively, the relay chamber 31 of this embodiment may be omitted.
[0054] Also, the swelled portion 101 formed around the intake opening 102 may be dispensed with.
[0055] While the swelled portion 101 substantially extends to a position rearward of the opening, this may be formed only around the portion of the intake opening 102 .
[0056] While the relay chamber 31 extends to the below of the swelled front portion 101 a , this may be formed in one part of the swelled front portion 101 a.
[0057] While most of the bottom wall and the rear wall of the relay chamber 31 may be constituted by the flexible plate member 33 , only the portion of the chamber wall through which the other members penetrate may be constituted by the flexible plate member 33 . For example, only the bottom wall portion of the chamber wall may be constituted by the flexible plate member 33 .
[0058] Numerous modifications and alternative embodiments of the invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, the description is to be construed as illustrative only, and is provided for the purpose of teaching those skilled in the art the best mode of carrying out the invention. The details of the structure and/or function may be varied substantially without departing from the spirit of the invention and all modifications which come within the scope of the appended claims are reserved.
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A straddle-type four wheeled all terrain vehicle comprises: a bar-type handle provided forward of a straddle-type seat; a vehicle body cover covering a portion of a vehicle body including a steering shaft of the handle, the steering shaft penetrating through the vehicle body cover; and a belt converter, wherein an opening of the vehicle body cover through which the steering shaft pass is an intake port of a cooling air into the belt converter.
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[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 12/275,197, filed 20 Nov. 2008, which is incorporated by reference herein, and claims the benefit of U.S. provisional patent applications 61/081,385 filed 16 Jul. 2008, 61/097,855, filed 17 Sep. 2008, 61/376,259, filed 23 Aug. 2010, and 61/384,277, filed 19 Sep. 2010.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] This invention relates to the field of power tools, and in particular to a portable assembly that allows a power hand saw, or other cutting tool, to be used as a cross-cut or miter saw, as well as a table saw.
[0003] The cost of power tools continues to increase, as does the space and weight that is consumed by the variety of specialized tools normally used in construction projects.
[0004] It would be advantageous to allow one power tool to perform multiple purposes, and in particular, it would be advantageous to allow a power hand saw, or other cutting tool, to be used as a cross-cut saw, a miter saw, and a table saw.
[0005] These advantages, and others, can be realized by a portable assembly in which a power saw can be mounted on a rotatable plate. The plate is large enough to allow the saw to travel above a worksurface. When the plate is in a reference orientation, a workpiece on the worksurface can be cross-cut or rip-cut. When the plate is offset from the reference orientation, the workpiece can be miter-cut or rip-cut. When working with large workpieces, the plate with the power saw can be inverted, transforming the assembly into a table saw. The plate is preferably configured to allow popular sized power saws, jig saws, and routers to be mounted and used in the above manner; or, multiple plates can be provided with the assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The invention is explained in further detail, and by way of example, with reference to the accompanying drawings wherein:
[0007] FIGS. 1A-1C illustrate an example cross-cut, rip-cut, miter, table saw assembly.
[0008] FIGS. 2A-2B illustrate an example invertable and rotatable plate.
[0009] FIGS. 3A-3F illustrate an example plate with power tools.
[0010] FIGS. 4A-4B illustrate example attachment elements for attaching a power tool to the rotatable plate.
[0011] FIGS. 5A-5B illustrate an example adjustment of guides to accommodate a power tool.
[0012] FIG. 6 illustrate an example guide plate.
[0013] FIGS. 7A-7C illustrate an example support plate and fences.
[0014] FIG. 8 illustrates an example extendable assembly.
[0015] Throughout the drawings, the same reference numerals indicate similar or corresponding features or functions. The drawings are included for illustrative purposes and are not intended to limit the scope of the invention.
DETAILED DESCRIPTION
[0016] In the following description, for purposes of explanation rather than limitation, specific details are set forth such as the particular architecture, interfaces, techniques, etc., in order to provide a thorough understanding of the concepts of the invention. However, it will be apparent to those skilled in the art that the present invention may be practiced in other embodiments, which depart from these specific details. In like manner, the text of this description is directed to the example embodiments as illustrated in the Figures, and is not intended to limit the claimed invention beyond the limits expressly included in the claims. For purposes of simplicity and clarity, detailed descriptions of well-known devices, circuits, and methods are omitted so as not to obscure the description of the present invention with unnecessary detail.
[0017] FIG. 1A illustrates a perspective view of an example cross-cut, rip-cut, miter-cut, and table saw assembly 100 in accordance with aspects of this invention. FIG. 1B illustrates a rear view, and FIG. 1C illustrates a side view. Because the assembly 100 is symmetric, the user may choose which side is the ‘front’; that is, which side the user will typically face when operating the tool. Note that particular features of the assembly 100 , detailed below, are not illustrated, so as not to detract from an understanding of the basic principles of this invention. The parent application of this continuation-in-part includes details regarding similar features, and is published as USPA 2010/0011929, dated 21 Jan. 2010.
[0018] A base 110 includes a base top 115 with a circular opening 116 that is arranged to accept a circular plate 150 that is configured to guide and/or support a power tool, such as a power saw, jig saw, router, and so on. The plate 150 includes a slot 158 , and a pair of guides 155 on either side of this slot 158 . In this example, the guides 155 are configured to allow a base plate of the power tool to fit below a portion 156 of the guides 155 , as detailed further below. One of skill in the art will recognize, however, that the guides 155 could be shaped without this overlapping portion 156 . One of skill in the art will also recognize that a single guide 155 , with or without portion 156 , may be used, wherein the user guides the power tool against the guide 155 as it is pushed across the plate 150 . The example guides 155 include slots 157 for receiving a fastening element that allows for adjusting the guides 155 to accommodate particular tools, as detailed further below.
[0019] In accordance with an aspect of this invention, the plate 150 includes features that allow the power tool to be fixedly attached to the plate 150 , detailed further below. When the power tool is affixed to the plate 150 , the plate 150 with the attached power tool can be placed in the circular opening 116 in an inverted position, with the operational element (saw blade, router bit, etc.) facing up. This inverting capability allows the assembly 100 to be used as a table-saw, a routing table, and so on. Advantageously, in this inverted configuration, large workpieces can be accommodated. For ease of understanding, the term ‘table-saw’ is used to identify the configuration wherein the operational element is facing up, regardless of the particular type of power tool being supported by the plate 150 . In like manner, the term ‘blade’ is used to identify the operational element, regardless of the particular type of operational element (saw blade, router bit, etc.).
[0020] FIG. 1B illustrates example electrical connections for providing power to the tool. In this example, an outlet box 180 is configured to include a male plug 181 for receiving an extension cord that is plugged into a source of power, and a female outlet 182 for receiving the plug of the power cord of the tool. The plug 181 and outlet 182 are preferably coupled via a power switch 185 . To facilitate emergency shut-off, the power switch 185 is preferably a push-pull switch, wherein when it is pushed in power is shut off, when it is pulled out, power is provided to the outlet 182 . Other configurations for providing power will be evident to one of skill in the art.
[0021] FIG. 2A illustrates a top view of the assembly 100 when a power tool 210 is atop the support 150 , in the non-inverted configuration, herein termed the ‘blade-down’ position. FIG. 2B illustrates a top view of the assembly 100 when the power tool 210 is attached to the support 150 and the support 150 is in the inverted, table-saw configuration.
[0022] Returning to FIGS. 1A-1C , the example assembly 100 includes a removable workpiece support 120 , and workpiece openings 112 that allow the workpiece to be placed beneath the plate 150 when the plate 150 is used in the blade-down position. The support 120 is supported by rails 125 . The example workpiece support 120 is illustrated with a circular kerf opening 126 that allows the blade of the power tool to extend below the workpiece. In a preferred embodiment, a variety of kerf plates may also be provided for placement in the opening 126 , to optimize support for the workpiece for particular tasks. For example, if the assembly is being used to perform cross-cuts while in a reference orientation (e.g. normal to the front of the assembly 100 ), a kerf plate with a single kerf slot that extends from front to rear may be used. In accordance with an aspect of this invention, the assembly 100 also includes openings 114 that allows the workpiece to travel from front to rear of the assembly for performing rip cuts while the plate 150 is in this same reference position, using this same kerf plate.
[0023] The workpiece support 120 is also preferably configured to support a fence, not illustrated, for orienting or guiding the workpiece beneath the plate 150 . Preferably, two types of fences are provided. For cross-cuts and miter-cuts, wherein the workpiece is introduced via the side openings 112 , a pair of removable fence portions are attached to either the support 120 or the aforementioned kerf plate on either side of the kerf slot or opening, parallel to the front of the assembly 100 . For rip-cuts wherein the workpiece is introduced via the front or back openings 114 , a movable fence that extends from front to rear of the assembly 100 is used. Such a fence may be structured to clamp to the front and rear surfaces of the base 110 , at the lower edge of the openings 114 , as detailed below.
[0024] The opening 126 in the support 120 also provides clearance for the power tool when the assembly 100 is used in the table-saw configuration, in most cases. If the power tool does not fit within the opening 126 , the support 120 can be removed.
[0025] In a preferred embodiment, the assembly 100 also includes a removable drawer 130 . This draw 130 advantageously collects the saw dust or other waste material produced while working on the workpiece. This drawer 130 may also include covered partitions for storing small tools, preferably outside the region where most of the waste will fall. The drawer 130 may also include a hose attachment at the rear, for coupling to a shop-vac or other waste collecting device.
[0026] In operation, the assembly 100 will generally be used in the blade-down configuration for cutting lumber and boards, and in the table-saw configuration for cutting sheet material. Rip cutting can be performed in either configuration, depending upon the width of the workpiece and the width of the rip. It is envisioned that this invention will be embodied in at least two sizes, an all-purpose size, and a smaller utility size. To accommodate a variety of tool in the table-saw configuration, the base unit 110 in each size will be about 8″ tall.
[0027] In the all-purpose size, because common board sizes extend up to 2″× 12 ″ (1½″×11½″ finished), the size of the openings 112 and 114 is preferably at least 2″×12″; for ripping, the board may be offset, so the front and rear openings 114 are preferably wider than 12″. That is, assuming that the saw blade is in the center, an opening 114 of 23″ will allow the 12″ (11½″) board to be ripped on either side of the blade. In like manner, power saw blades are typically 8″ in diameter; accordingly, the length of the slot 158 is preferably at least 24″ (8″ start location of saw, 12″ travel, 4″ end location of saw). Thus, the base unit of the all-purpose size will be in the order of 30″×30″.
[0028] The smaller utility size is designed for the most common applications, using, for example, 2″×8″ as the largest board size that should be accommodated. In this case, the openings 112 are preferably 2″×8″, and the openings 114 are preferably 2″×16″. The slot 158 may be 20″ long (8″ start+8″ travel+4″ end), although a shorter length may be sufficient due to the fact that the full width/diameter of the blade does not extend below the saw, and the nominal 8 ″ board is 7½″ wide). In a preferred embodiment of the utility size embodiment, the slot 158 is about 3″ wide and 18″ long. Thus, the base unit of the all-purpose size will be in the order of 24″×24″.
[0029] FIGS. 3A-3F illustrate a variety of example configurations of different power tools with respect to the support 150 .
[0030] FIGS. 3A-3B illustrate a power saw 310 in the non-inverted, blade-down configuration, and in the inverted, table-saw configuration. FIGS. 3C-3D illustrate a router 320 in the non-inverted, blade-down configuration, and in the inverted, table-saw configuration. FIGS. 3E-3F illustrate a jig-saw 330 in the non-inverted, blade-down configuration, and in the inverted, table-saw configuration. In the table-saw configuration, a fastening device 350 affixes the tool 310 , 320 , 330 to the support plate 150 .
[0031] FIG. 4A illustrates an example attachment of a router 320 to the plate 150 . In this embodiment, the router is attached via mounting holes 435 in the plate 430 of the router 320 . A thumbscrew 410 extends into receptors 415 in the plate 150 . In a preferred embodiment, the receptors 415 are situated in tracks that allow them to be spaced appropriately to align with the holes 435 in the plate 430 .
[0032] FIG. 4B illustrates another example attachment of the router 320 to the plate 150 via fastening devices 350 . As in the example of FIG. 4A , a thumbscrew 410 extends into receptors 415 in the plate 150 . Referring to FIG. 1 , these receptors 415 may be placed below the center slots 157 in the guides 155 , allowing the tool to be fastened to the plate 150 without removing the guides 155 . As illustrated in FIG. 4B , the fastening device 350 includes a U-shaped element 420 that is configured to apply pressure to the base 430 of the router 320 when the thumbscrew 410 is tightened. One of skill in the art will recognize that other tool attachment techniques, common in the art, may alternatively be used.
[0033] FIGS. 5A-5B illustrates the use of the guides 155 when a power saw 310 is used in the blade-down configuration of the assembly 100 . In these examples, thumbscrews 510 extend into receptors 515 in the plate 150 , through the slots 157 ( FIG. 1 ) in the guides 155 . As noted above, the slots 157 allow the guides to be adjusted to accommodate the particular size of the plate 530 of the power saw 310 . When the guides are in the appropriate locations, the thumbscrews 510 are tightened to hold the guides in their proper place, The overlapping portions 156 of the guides 155 are shaped to overlay the plate 530 , yet allow the saw 310 to be pushed along the guides 155 by the user. As also noted above, these overlapping portions 156 are optional, as is the use of two guides 155 .
[0034] As illustrated in FIG. 5B , the opening 158 in the support plate 150 is sized sufficiently to allow the power saw 310 to be tilted, thereby allowing for angled cuts as well as compound-miter cuts.
[0035] In a preferred embodiment of this invention, spacers may be provided to elevate the guides 155 above the surface of the plate 150 , allowing for different thicknesses of plates 530 .
[0036] As will be evident to one of skill in the art, some tools may not have a plate that is suitable for use with the guides 155 , or suitable for use with the fastening device 350 ( FIG. 3 ). In a preferred embodiment of this invention, a guide plate may be provided to facilitate the use of a variety of tools.
[0037] FIG. 6 illustrates an example guide plate 610 . The guide plate 610 is illustrated as having tongues 655 that fit within the guides 155 , and a thicker region 650 that supports the tool and allows it to extend above the guides 155 , as required. Preferably, the plate will be made of a workable material, such as plastic, so that the user can form the appropriate cutouts and attachment holes. A plurality of guide plates 610 may be provided with the assembly 100 so that the user can attach the plates 610 to a variety of tools. In this manner, if each guide plate is the same width, adjustments to the guide rails for different tools will not be required.
[0038] FIG. 7A illustrates an example support plate 150 with cutouts 758 that facilitate viewing of the workpiece (not illustrated) while it is placed in position along a set of removable fences 710 . The fences 710 are removable in order to allow the workpiece to be introduced from the front or rear for rip-cuts, without rotating the saw. The guides 155 are not illustrated in this figure, so as not to obscure the figure, but they would be positioned on the surface on either side of the slot 158 .
[0039] Also illustrated in FIG. 7A are detents 720 that facilitate positioning of the support plate 150 on the top surface 115 of the assembly 100 . In this example embodiment, the top 115 includes a ledge 715 that supports the rotatable plate 150 . FIG. 7B illustrates a cross section view of the top 115 with the plate 150 situated on the ledge 715 . To facilitate adjustment of the rotatable plate 150 , the ledge 715 includes bearings 725 at the locations of the detents 720 . As the plate 150 is rotated, it will either be rotatably supported by these bearings 725 , or fixedly supported as the bearings 725 engage the detects 720 . The detents 720 are situated on both sides of the plate 150 , so that they can engage the bearings in both the non-inverted blade-down configuration and the inverted table-saw configuration.
[0040] The detents 720 are illustrated as being spaced at 45° around the support plate 150 , although other spacings may be used as well. In this manner, the plate 150 can be easily placed at the reference orientation for crosscuts and ripcuts and a 45° orientation for mitered corner cuts. At other angles, one or more receptors 730 are situated on the top 115 , near the perimeter of the plate 150 . As in FIG. 4 , a fastening device 350 , comprising a thumbscrew 410 and U-shaped element 420 can be used to apply pressure to the plate 150 to hold it at the desired angle. Not illustrated in FIG. 7A , the plate 150 or the top 115 is preferably labeled or engraved with graduation marks around at least a section of the perimeter of the plate, indicating the relative angle of the plate 150 with respect to the top 115 , and, correspondingly, relative to the fence 710 . Also in a preferred embodiment of this invention, linear graduation marks are places along the edges of the top 115 , to facilitate measuring and marking the workpiece without a separate measuring device.
[0041] FIG. 7C illustrates a fence 770 that can be used on the top 115 when the assembly 100 is in the blade-up table-saw configuration, or on the support 120 when ripping in the blade-down configuration. The fence 770 includes a rear flange 772 that includes a lip for wrapping around the edge of the top 115 , or the rear support rail 125 for the support 120 ( FIG. 1 ). The fence 770 also includes a front flange 774 with a thumbscrew that can apply pressure to the front edge of the top 115 , or the edge of the front support rail 125 .
[0042] To support large workpieces, such as plywood sheets, FIG. 8 illustrates an assembly with extendable supports 810 . In this example embodiment, a pair of telescopic rods 820 allows the support 810 to be extended to an appropriate width so that the upper surface 815 of the support 810 is able to support the workpiece. Also illustrated in FIG. 8 , the support 810 includes notches 812 that facilitate the use of the example fence 770 in FIG. 7 . As compared to the example of FIG. 1 , the example of FIG. 8 illustrates a thinner support wall 830 , allowing for wider workpieces at the lower worksurface 120 .
[0043] The foregoing merely illustrates the principles of the invention. It will thus be appreciated that those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the invention and are thus within its spirit and scope. For example, the example embodiments include a circular support plate that facilitates miter cuts, although one of skill in the art will recognize that a simpler embodiment may provide for cross-cuts, rip-cuts, and table-saw features, without the miter feature, obviating the need for a circular support plate. Because such an embodiment would not necessarily require symmetry, the aspect ratio of the assembly could be optimized for a particular set of tasks. For example, a long and narrow assembly could provide the length needed for cross cutting wide boards when the blade is parallel to the long dimension, and with the blade perpendicular to the long dimension, could provide the width needed to support wide sheet material in the table-saw configuration. Also, an alternative for the cutouts in the support plate is the use of a relatively transparent material to form the support plate, such as glass, plexiglas, or other polycarbonates. The top of the base may also comprise transparent material. These and other system configuration and optimization features will be evident to one of ordinary skill in the art in view of this disclosure, and are included within the scope of the following claims.
[0044] In interpreting these claims, it should be understood that:
[0045] a) the word “comprising” does not exclude the presence of other elements or acts than those listed in a given claim;
[0046] b) the word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements;
[0047] c) any reference signs in the claims do not limit their scope;
[0048] d) several “means” may be represented by the same item or hardware or software implemented structure or function;
[0049] e) each of the disclosed elements may be comprised of hardware portions (e.g., including discrete and integrated electronic circuitry), software portions (e.g., computer programming), and any combination thereof;
[0050] f) hardware portions may include a processor, and software portions may be stored on a non-transient computer-readable medium, and may be configured to cause the processor to perform some or all of the functions of one or more of the disclosed elements;
[0051] g) hardware portions may be comprised of one or both of analog and digital portions;
[0052] h) any of the disclosed devices or portions thereof may be combined together or separated into further portions unless specifically stated otherwise;
[0053] i) no specific sequence of acts is intended to be required unless specifically indicated; and
[0054] j) the term “plurality” of an element includes two or more of the claimed element, and does not imply any particular range of number of elements; that is, a plurality of elements can be as few as two elements, and can include an immeasurable number of elements.
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A portable assembly is provided in which a power tool can be mounted on a rotatable plate. The plate is large enough to allow the saw to travel above a worksurface. When the plate is in a reference orientation, a workpiece on the support surface below the plate can be cross-cut or rip-cut. When the plate is offset from the reference orientation, the workpiece can be miter-cut, compound-miter cut, or rip-cut. When working with large workpieces, the plate with the power tool can be inverted, transforming the assembly into a table saw. The plate is preferably configured to allow popular sized power saws, jig saws, and routers to be mounted and used in the above manner. Multiple standard width guide plates can be provided with the assembly, to minimize the need to adjust the guide rails.
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FIELD OF THE INVENTION
The present invention relates to a method and an apparatus for the use of carbon-isotope monoxide in labeling synthesis. More specifically, the invention relates to a method and apparatus for producing an [ 11 C]carbon monoxide enriched gas mixture from an initial [ 11 C]carbon dioxide gas mixture, and using the produced gas mixture in labeling synthesis by photo-initiated carbonylation. Radiolabeled acids are provided using alkyl or aryl iodides as precursors, as well as sulfoxides and triethylamine.
BACKGROUND OF THE INVENTION
Tracers labeled with short-lived positron emitting radionuclides (e.g. 11 C, t 1/2 =20.3 min) are frequently used in various non-invasive in vivo studies in combination with positron emission tomography (PET). Because of the radioactivity, the short half-lives and the submicromolar amounts of the labeled substances, extraordinary synthetic procedures are required for the production of these tracers. An important part of the elaboration of these procedures is development and handling of new 11 C-labelled precursors. This is important not only for labeling new types of compounds, but also for increasing the possibility of labeling a given compound in different positions.
During the last two decades carbonylation chemistry using carbon monoxide has developed significantly. The recent development of methods such as palladium-catalyzed carbonylative coupling reactions has provided a mild and efficient tool for the transformation of carbon monoxide into different carbonyl compounds.
Carbonylation reactions using [ 11 C]carbon monoxide has a primary value for PET-tracer synthesis since biologically active substances often contain carbonyl groups or functionalities that can be derived from a carbonyl group. The syntheses are tolerant to most functional groups, which means that complex building blocks can be assembled in the carbonylation step to yield the target compound. This is particularly valuable in PET-tracer synthesis where the unlabelled substrates should be combined with the labeled precursor as late as possible in the reaction sequence, in order to decrease synthesis-time and thus optimize the uncorrected radiochemical yield.
When compounds are labeled with 11 C, it is usually important to maximize specific radioactivity. In order to achieve this, the isotopic dilution and the synthesis time must be minimized. Isotopic dilution from atmospheric carbon dioxide may be substantial when [ 11 C]carbon dioxide is used in a labeling reaction. Due to the low reactivity and atmospheric concentration of carbon monoxide (0.1 ppm vs. 3.4×10 4 ppm for CO 2 ), this problem is reduced with reactions using [ 11 C]carbon monoxide.
The synthesis of [ 11 C]carbon monoxide from [ 11 C]carbon dioxide using a heated column containing reducing agents such as zinc, charcoal or molybdenum has been described previously in several publications. Although [ 11 C]carbon monoxide was one of the first C-labelled compounds to be applied in tracer experiments in human, it has until recently not found any practical use in the production of PET-tracers. One reason for this is the low solubility and relative slow reaction rate of [ 11 C]carbon monoxide which causes low trapping efficiency in reaction media. The general procedure using precursors such as [ 11 C]methyl iodide, [ 11 C]hydrogen cyanide or [ 11 C]carbon dioxide is to transfer the radioactivity in a gas-phase, and trap the radioactivity by leading the gas stream through a reaction medium. Until recently this has been the only accessible procedure to handle [ 11 C]carbon monoxide in labeling synthesis. With this approach, the main part of the labeling syntheses with [ 11 C]carbon monoxide can be expected to give a very low yield or fail completely.
There are only a few examples of practically valuable 11 C-labelling syntheses using high pressure techniques (>300 bar). In principal, high pressures can be utilized for increasing reaction rates and minimizing the amounts of reagents. One problem with this approach is how to confine the labeled precursor in a small high-pressure reactor. Another problem is the construction of the reactor. If a common column type of reactor is used (i.e. a cylinder with tubing attached to each end), the gas-phase will actually become efficiently excluded from the liquid phase at pressurization. The reason is that the gas-phase, in contracted form, will escape into the attached tubing and away from the bulk amount of the liquid reagent.
The cold-trap technique is widely used in the handling of 11 C-labelled precursors, particularly in the case of [ 11 C]carbon dioxide. The procedure has, however, only been performed in one single step and the labeled compound was always released in a continuous gas-stream simultaneous with the heating of the cold-trap. Furthermore, the volume of the material used to trap the labeled compound has been relative large in relation to the system to which the labeled compound has been transferred. Thus, the option of using this technique for radical concentration of the labeled compound and miniaturization of synthesis systems has not been explored. This is especially noteworthy in view of the fact that the amount of a 11 C-labelled compound usually is in the range 20-60 nmol.
Recent technical development for the production and use of [ 11 C]carbon monoxide has made this compound useful in labeling synthesis. WO 02/102711 describes a system and a method for the production and use of a carbon-isotope monoxide enriched gas-mixture from an initial carbon-isotope dioxide gas mixture. [ 11 C]carbon monoxide may be obtained in high radiochemical yield from cyclotron produced [ 11 C]carbon dioxide and can be used to yield target compounds with high specific radioactivity. This reactor overcomes the difficulties listed above and is useful in synthesis of 11 C-labelled compounds using [ 11 C]carbon monoxide in palladium or selenium mediated reaction. With such method, a broad array of carbonyl compounds can be labeled (Kilhlberg, T.; Långström, B. J., Org. Chem. 1999, 9201-9205). The use of transition metal mediated reactions is, however, restricted by problems related to the competing β-hydride elimination reaction, which excludes or at least severely restricts utilization of organic electrophiles having hydrogen in β-position. Thus, a limitation of the transition metal mediated reactions is that most alkyl halides could not be used as substrates due to the β-hydride elimination reaction. One way to circumvent this problem is to use free-radical chemistry based on light irradiation of alkyl halides. We earlier succeeded in using free-radical chemistry for the carbonylation of alkyl iodides using amines to yield labeled amides.
However, the attempt to yield labeled esters and acids in an analogous way (using water as a reactant instead of amines) is challenged by dissimilar solubility of water and alkyl or aryl iodides in solvents due to very different polarities of the reactants. Another problem of this approach is the low reactivity of water in these reaction conditions (typically the yields of esters and acids compared to those of amides are lower by 10 to 100 times). Therefore, there is a need for a method in order to use photo-induced free radical carbonylation to overcome the problems of weakly reacting water and dissimilar solubility of water and alkyl or aryl iodides and provide target structures with high yield to further increase the utility of [ 11 C]carbon monoxide in preparing useful PET tracers.
Discussion or citation of a reference herein shall not be construed as an admission that such reference is prior art to the present invention.
SUMMARY OF THE INVENTION
The present invention provides a method for labeling synthesis, comprising:
(a) providing a UV reactor assembly comprising a high pressure reaction chamber with a gas inlet and a liquid inlet, a UV spot light source with a light guide, wherein the light guide is used to provide photo irradiation of a reaction mixture through a window in the reaction chamber,
(b) dissolving triethylamine (TEA) and a sulfoxide in a solvent,
(c) adding an alkyl or aryl iodide to the solution of step (b) to give a reagent volume to be labeled,
(d) introducing a carbon-isotope monoxide enriched gas-mixture into the reaction chamber of the UV reactor assembly via the gas inlet,
(e) introducing at high-pressure said reagent volume into the reaction chamber via the liquid inlet,
(f) turning on the UV spot light source and waiting a predetermined time while the labeling synthesis occur, and
(g) collecting labeled acid from the reaction chamber.
The present invention also provides a system for labeling synthesis, comprising: a UV reactor assembly comprising a high pressure reaction chamber with a gas inlet and a liquid inlet, a UV spot light source with a light guide, wherein a light guide is used to provide photo irradiation of the reaction mixture through a window in the reaction chamber thereof, wherein the photo irradiation from the light source, which stands at the distance from the reaction chamber, is delivered through the window of the reaction chamber.
The present invention further provides a method for the synthesis of labeled acids, using photo-initiated carbonylation with [ 11 C]carbon monoxide using alkyl or aryl iodides, TEA and a sulfoxide, preferably dimethysulfoxide (DMSO).
In another embodiment, the invention also provides [ 11 C]-labeled acids, and pharmaceutically acceptable salts and solvates thereof. In yet another embodiment, the invention provides kits for use as PET tracers comprising effective amount of [ 11 C]-labeled acids, or pharmaceutically acceptable salts and solvates thereof. In still another embodiment, the invention provides a method for conducting PET of a subject comprising administering to the subject a kit of the instant invention and measuring distribution within the subject of the [ 11 C]-labeled acids by PET.
Other features and advantages of the present invention will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples while indicating preferred embodiments of the invention are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a flow chart over the method according to the invention
FIG. 2 is a schematic view of a carbon-isotope monoxide production and labeling-system according to the invention.
FIG. 3 is the cross-sectional view of the reaction chamber.
FIG. 4 is a view of the UV spot light source.
FIG. 5 shows how the reaction chamber, magnetic stirrer, and the UV spot light source are arranged into the UV reactor assembly.
FIGS. 6 a and 6 b show alternative embodiments of a reaction chamber according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
The main advantage of the present invention is to overcome the limitations of transition metal-mediated reaction and provide a simple approach to synthesize 11 C-labeled acids under very mild conditions using alkyl/aryl iodides as precursors. The levels of specific radioactivity are high compared with alternative methods such as the use of Grignard reactions for preparation of [carbonyl- 11 C]esters and acids. Iodides used in this invention have a formula RI, where R is linear or cyclic alkyl or substituted alkyl, aryl or substituted aryl, and may contain fluoro, ester and carboxyl groups, which are separated by at least one carbon atom from the carbon atom bearing the iodide atom. Sulfoxides are defined as compounds having the structure R′ 2 S═O, wherein R′ is a lower (less than 10 carbons) alkyl or aryl. Examples of sulfoxides include DMSO and diphenylsulfoxide (Ph 2 S═O).
The resultant labeled acids have a formula
wherein R is defined as above. They and their pharmaceutically acceptable salts and/or solvates thereof provide valuable PET tracers in various PET studies.
It is to be clear that the present invention includes pharmaceutically acceptable salts and solvates of labeled compounds of the instant invention, and mixtures comprising two or more of such labeled compounds, pharmaceutically acceptable salts of the labeled compounds and pharmaceutically acceptable solvates of labeled compounds.
The term “pharmaceutically acceptable” means compatible with the treatment of animals, in particular, humans.
The term “pharmaceutically acceptable salt” refers to salt forms that are pharmacologically suitable for or compatible with the treatment of patients.
If the inventive compound is a base, the desired pharmaceutically acceptable salt may be prepared by an suitable method available in the art, for example, treatment of the free base with an inorganic acid, such as hydrochloric acid, hydrobromic acid, sulfuric acid, nitric acid, phosphoric acid and the like, or with an organic acid, such as acetic acid, maleic acid, succinic acid, mandelic acid, fumaric acid, malonic acid, pyruvic acid, oxalic acid, glycolic acid, salicylic acid, a pyranosidyl acid, such as glucuronic acid or galacturonic acid, an α-hydroxy acid, such as citric acid or tartaric acid, an amino acid, such as aspartic acid or glutamic acid, an aromatic acid, such as benzoic acid or cinnamic acid, a sulfonic acid, such as p-toluenesulfonic acid or ethanesulfonic acid, or the like.
If the inventive compound is an acid, the desired pharmaceutically acceptable salt may be prepared by any suitable method, for example, treatment of the free acid with an inorganic or organic base, such as an amine (primary, secondary or tertiary), an alkali metal hydroxide or alkaline earth metal hydroxide, or the like. Illustrative examples of the suitable salts include organic salts derived from amino acids, such as glycine and arginine, ammonia, primary, secondary, and tertiary amines, and cyclic amines, such as piperidine, morpholine and piperazine, and inorganic salts derived from sodium, calcium, potassium, magnesium, manganese, iron, copper, zinc, aluminum and lithium.
The term “solvate” as used herein means a compound of the invention, wherein molecules of a suitable solvent are incorporated in the crystal lattice. A suitable solvent is physiologically tolerable at the dosage administered. Examples of suitable solvents are ethanol, water and the like. When water is the solvent, the molecule is referred to as a “hydrate”.
General reaction scheme for the synthesis of labeled acids are as illustrated below:
wherein R and sulfoxide are as defined above. * indicates the 11 C-labeled position.
The radiolabelled compounds, or pharmaceutically acceptable salts and solvates thereof, of the invention are suitably formulated into pharmaceutical or radiopharmaceutical compositions for administration to human subjects in a biologically compatible form suitable for administration in vivo. Accordingly, in another aspect, the present invention provides a pharmaceutical composition comprising a radiolabelled compound or pharmaceutically acceptable salts and solvates thereof, of the invention in admixture with a suitable diluent or carrier.
The term an “effective amount” as used herein is that amount sufficient to effect desired results, including clinical results, and, as such, an “effective amount” depends upon the context in which it is being applied.
The term “subject” as used herein includes all members of the animal kingdom including human. The subject is preferably a human.
In preferred embodiment of the present invention, it provides kits for use as PET tracers comprising an effective amount of carbon isotope-labeled esters and acids, or pharmaceutically acceptable salts and solvates thereof.
Such kits are designed to give sterile products suitable for human administration, e.g. direct injection into the bloodstream. Suitable kits comprise containers (e.g. septum-sealed vials) containing the adrenergic interfering agent and precursor of the adrenergic imaging agent.
The kits may optionally further comprise additional components such as radioprotectant, antimicrobial preservative, pH-adjusting agent or filler.
By the term “radioprotectant” is meant a compound which inhibits degradation reactions, such as redox processes, by trapping highly-reactive free radicals, such as oxygen-containing free radicals arising from the radiolysis of water. The radioprotectants of the present invention are suitably chosen from: ascorbic acid, para-aminobenzoic acid (i.e. 4-aminobenzoic acid), gentisic acid (i.e. 2,5-dihydroxybenzoic acid) and salts thereof.
By the term “antimicrobial preservative” is meant an agent which inhibits the growth of potentially harmful micro-organisms such as bacteria, yeasts or moulds. The antimicrobial preservative may also exhibit some bactericidal properties, depending on the dose. The main role of the antimicrobial preservative(s) of the present invention is to inhibit the growth of any such micro-organism in the pharmaceutical composition post-reconstitution, i.e. in the radioactive diagnostic product itself. The antimicrobial preservative may, however, also optionally be used to inhibit the growth of potentially harmful micro-organisms in one or more components of the kit of the present invention prior to reconstitution. Suitable antimicrobial preservatives include: the parabens, i.e., ethyl, propyl or butyl paraben or mixtures thereof; benzyl alcohol; phenol; cresol; cetrimide and thiomersal. Preferred antimicrobial preservative(s) are the parabens.
The term “pH-adjusting agent” means a compound or mixture of compounds useful to ensure that the pH of the reconstituted kit is within acceptable limits (approximately pH 4.0 to 10.5) for human administration. Suitable such ph-adjusting agents include pharmaceutically acceptable buffers, such as tricine, phosphate or TRIS [i.e. tris(hydroxymethyl)aminomethane], and pharmaceutically acceptable bases such as sodium carbonate, sodium bicarbonate or mixtures thereof. When the ligand conjugate is employed in acid salt form, the pH-adjusting agent may optionally be provided in a separate vial or container, so that the user of the kit can adjust the pH as part of a multi-step procedure.
By the term “filler” is meant a pharmaceutically acceptable bulking agent which may facilitate material handling during production and lyophilisation. Suitable fillers include inorganic salts such as sodium chloride, and water soluble sugars or sugar alcohols such as sucrose, maltose, mannitol or trehalose.
The present invention also includes a method for conducting positron emission tomography of a subject comprising administering to the subject an effective amount of a radiolabelled compound, or pharmaceutically acceptable salts and solvates thereof, of the instant invention and measuring the distribution within the subject of the compound by PET. In a preferred embodiment, the invention provides a method for conducting PET of a subject comprising administering to the subject a kit of the instant invention and measuring distribution within the subject of the [ 11 C]-labeled esters or acids by PET.
In accordance with the methods of the invention, the radiolabeled compounds of the invention may be administered to a patient in a variety of forms depending on the selected route of administration, as will be understood by those skilled in the art. The compositions of the invention are preferably administered by intravenous administration, and the radiopharmaceutical compositions formulated accordingly, for example together with any physiologically and radiologically tolerable vehicle appropriate for administering the compound systemically.
In a preferred embodiment of the instant invention, it provides a method and system is that nearly quantitative conversion of carbon-isotope monoxide into labeled products can be accomplished.
There are several other advantages with the present method and system. The high-pressure technique makes it possible to use low boiling solvents such as diethyl ether at high temperatures (e.g. 200° C.). The use of a closed system consisting of materials that prevents gas diffusion, increases the stability of sensitive compounds and could be advantageous also with respect to Good Manufacturing Practice (GMP).
Still other advantages are achieved in that the resulting labeled compound is highly concentrated, and that the miniaturization of the synthesis system facilitates automation, rapid synthesis and purification, and optimization of specific radioactivity through minimization of isotopic dilution.
Most important is the opening of completely new synthesis possibilities, as exemplified by the present invention.
Embodiments of the invention will now be described with reference to the figures.
The term carbon-isotope that is used throughout this application preferably refers to 11 C, but it should be understood that C may be substituted by other carbon-isotopes, such as 13 C and 14 C, if desired.
FIG. 1 shows a flow chart over the method according to the invention, which firstly comprises production of a carbon-isotope monoxide enriched gas-mixture and secondly a labeling synthesis procedure. More in detail the production part of the method comprises the steps of:
Providing carbon-isotope dioxide in a suitable carrier gas of a type that will be described in detail below. Converting carbon-isotope dioxide to carbon-isotope monoxide by introducing said gas mixture in a reactor device which will be described in detail below. Removing traces of carbon-isotope dioxide by flooding the converted gas-mixture through a carbon dioxide removal device wherein carbon-isotope dioxide is trapped but not carbon-isotope monoxide nor the carrier gas. The carbon dioxide removal device will be described in detail below. Trapping carbon-isotope monoxide in a carbon monoxide trapping device, wherein carbon-isotope monoxide is trapped but not said carrier gas. The carbon monoxide trapping device will be described in detail below. Releasing said trapped carbon-isotope monoxide from said trapping device, whereby a volume of carbon-isotope monoxide enriched gas-mixture is achieved.
The production step may further comprise a step of changing carrier gas for the initial carbon-isotope dioxide gas mixture if the initial carbon-isotope dioxide gas mixture is comprised of carbon-isotope dioxide and a first carrier gas not suitable as carrier gas for carbon monoxide due to similar molecular properties or the like, such as nitrogen. More in detail the step of providing carbon-isotope dioxide in a suitable second carrier gas such as He, Ar, comprises the steps of:
Flooding the initial carbon-isotope dioxide gas mixture through a carbon dioxide trapping device, wherein carbon-isotope dioxide is trapped but not said first carrier gas. The carbon dioxide trapping device will be described in detail below. Flushing said carbon dioxide trapping device with said suitable second carrier gas to remove the remainders of said first carrier gas. Releasing said trapped carbon-isotope dioxide in said suitable second carrier gas.
The labeling synthesis step that may follow the production step utilizes the produced carbon-isotope dioxide enriched gas-mixture as labeling reactant. More in detail the step of labeling synthesis comprises the steps of:
Providing a UV reactor assembly comprising a UV spot light source and a high pressure reaction chamber having a liquid reagent inlet and a labeling reactant inlet in a bottom surface thereof. In a preferred embodiment, the UV reactor assembly further comprises a magnetic stirrer and a magnetic stirring bar. In another preferred embodiment, the UV reactor assembly further comprises a protective housing and a bench where the reaction chamber, UV spot light guide and the magnetic stirrer can be mounted. The UV reactor assembly and the reaction chamber will be described in detail below. Providing a reagent volume that is to be labeled. The reagent volume can be prepared in following steps: 1. Dissolve TEA and a sulfoxide in a solvent; 2. Add alkyl or aryl iodide to the solution of step 1 to form a reagent volume as late as possible before being introduced into the high pressure reaction chamber. Definition and examples of sulfoxides are provided above. In a preferred embodiment, a sulfoxide is a DMSO. Solvent can be any organic solvent or water. Introducing the carbon-isotope monoxide enriched gas-mixture into the reaction chamber via the labeling reactant inlet. Introducing, at high pressure, said liquid reagent into the reaction chamber via the liquid reagent inlet. Turning on the UV spot light source and waiting a predetermined time while the labeling synthesis occurs. Collecting the solution of labeled acid from the reaction chamber.
The step of waiting a predetermined time may further comprise adjusting the temperature of the reaction chamber such that the labeling synthesis is enhanced.
FIG. 2 schematically shows a [ 11 C]carbon dioxide production and labeling-system according to the present invention. The system is comprised of three main blocks, each handling one of the three main steps of the method of production and labeling:
Block A is used to perform a change of carrier gas for an initial carbon-isotope dioxide gas mixture, if the initial carbon-isotope dioxide gas mixture is comprised of carbon-isotope dioxide and a first carrier gas not suitable as carrier gas for carbon monoxide. Block B is used to perform the conversion from carbon-isotope dioxide to carbon-isotope monoxide, and purify and concentrate the converted carbon-isotope monoxide gas mixture. Block C is used to perform the carbon-isotope monoxide labeling synthesis.
Block A is normally needed due to the fact that carbon-isotope dioxide usually is produced using the 14N(p,α) 11 C reaction in a target gas containing nitrogen and 0.1% oxygen, bombarded with 17 MeV protons, whereby the initial carbon-isotope dioxide gas mixture comprises nitrogen as carrier gas. However, compared with carbon monoxide, nitrogen show certain similarities in molecular properties that makes it difficult to separate them from each other, e.g. in a trapping device or the like, whereby it is difficult to increase the concentration of carbon-isotope monoxide in such a gas mixture. Suitable carrier gases may instead be helium, argon or the like. Block A can also used to change the pressure of the carrier gas (e.g. from 1 to 4 bar), in case the external system does not tolerate the gas pressure needed in block B and C. In an alternative embodiment the initial carbon-isotope dioxide gas mixture is comprised of carbon-isotope dioxide and a first carrier gas that is well suited as carrier gas for carbon monoxide, whereby the block A may be simplified or even excluded.
According to a preferred embodiment ( FIG. 2 ), block A is comprised of a first valve V 1 , a carbon dioxide trapping device 8 , and a second valve V 2 .
The first valve V 1 has a carbon dioxide inlet 10 connected to a source of initial carbon-isotope dioxide gas mixture 12 , a carrier gas inlet 14 connected to a source of suitable carrier gas 16 , such as helium, argon and the like. The first valve V 1 further has a first outlet 18 connected to a first inlet 20 of the second valve V 2 , and a second outlet 22 connected to the carbon dioxide trapping device 8 . The valve V 1 may be operated in two modes A, B, in mode A the carbon dioxide inlet 10 is connected to the first outlet 18 and the carrier gas inlet 14 is connected to the second outlet 22 , and in mode B the carbon dioxide inlet 10 is connected to the second outlet 22 and the carrier gas inlet 14 is connected to the first outlet 18 .
In addition to the first inlet 20 , the second valve V 2 has a second inlet 24 connected to the carbon dioxide trapping device 8 . The second valve V 2 further has a waste outlet 26 , and a product outlet 28 connected to a product inlet 30 of block B. The valve V 2 may be operated in two modes A, B, in mode A the first inlet 20 is connected to the waste outlet 26 and the second inlet 24 is connected to the product outlet 28 , and in mode B the first inlet 20 is connected to the product outlet 28 and the second inlet 24 is connected to the waste outlet 26 .
The carbon dioxide trapping device 8 is a device wherein carbon dioxide is trapped but not said first carrier gas, which trapped carbon dioxide thereafter may be released in a controlled manner. This may preferably be achieved by using a cold trap, such as a column containing a material which in a cold state, (e.g. −196° C. as in liquid nitrogen or −186° C. as in liquid argon) selectively trap carbon dioxide and in a warm state (e.g. +50° C.) releases the trapped carbon dioxide. (In this text the expression “cold trap” is not restricted to the use of cryogenics. Thus, materials that trap the topical compound at room temperature and release it at a higher temperature are included). One suitable material is porapac Q®. The trapping behavior of a porapac-column is related to dipole-dipole interactions or possibly Van der Waal interaktions. The said column 8 is preferably formed such that the volume of the trapping material is to be large enough to efficiently trap (>95%) the carbon-isotope dioxide, and small enough not to prolong the transfer of trapped carbon dioxide to block B. In the case of porapac Q® and a flow of 100 ml nitrogen/min, the volume should be 50-150 μl. The cooling and heating of the carbon dioxide trapping device 8 may further be arranged such that it is performed as an automated process, e.g. by automatically lowering the column into liquid nitrogen and moving it from there into a heating arrangement.
According to the preferred embodiment of FIG. 2 block B is comprised of a reactor device 32 in which carbon-isotope dioxide is converted to carbon-isotope monoxide, a carbon dioxide removal device 34 , a check-valve 36 , and a carbon monoxide trapping device 38 , which all are connected in a line.
In the preferred embodiment the reactor device 32 is a reactor furnace comprising a material that when heated to the right temperature interval converts carbon-isotope dioxide to carbon-isotope monoxide. A broad range of different materials with the ability to convert carbon dioxide into carbon monoxide may be used, e.g. zinc or molybdenum or any other element or compound with similar reductive properties. If the reactor device 32 is a zinc furnace it should be heated to 400° C., and it is important that the temperature is regulated with high precision. The melting point of zinc is 420° C. and the zinc-furnace quickly loses it ability to transform carbon dioxide into carbon monoxide when the temperature reaches over 410° C., probably due to changed surface properties. The material should be efficient in relation to its amount to ensure that a small amount can be used, which will minimize the time needed to transfer radioactivity from the carbon dioxide trapping device 8 to the subsequent carbon monoxide trapping device 38 . The amount of material in the furnace should be large enough to ensure a practical life-time for the furnace (at least several days). In the case of zinc granulates, the volume should be 100-1000 μl.
The carbon dioxide removal device 34 is used to remove traces of carbon-isotope dioxide from the gas mixture exiting the reactor device 32 . In the carbon dioxide removal device 34 , carbon-isotope dioxide is trapped but not carbon-isotope monoxide nor the carrier gas. The carbon dioxide removal device 34 may be comprised of a column containing Ascarite® (i.e. sodium hydroxide on silica). Carbon-isotope dioxide that has not reacted in the reactor device 32 is trapped in this column (it reacts with sodium hydroxide and turns into sodium carbonate), while carbon-isotope monoxide passes through. The radioactivity in the carbon dioxide removal device 34 is monitored as a high value indicates that the reactor device 32 is not functioning properly.
Like the carbon dioxide trapping device 8 , the carbon monoxide trapping device 38 , has a trapping and a releasing state. In the trapping state carbon-isotope monoxide is selectively trapped but not said carrier gas, and in the releasing state said trapped carbon-isotope monoxide is released in a controlled manner. This may preferably be achieved by using a cold trap, such as a column containing silica which selectively trap carbon monoxide in a cold state below −100° C., e.g. −196° C. as in liquid nitrogen or −186° C. as in liquid argon, and releases the trapped carbon monoxide in a warm state (e.g. +50° C.). Like the porapac-column, the trapping behavior of the silica-column is related to dipole-dipole interactions or possibly Van der Waal interactions. The ability of the silica-column to trap carbon-isotope monoxide is reduced if the helium, carrying the radioactivity, contains nitrogen. A rationale is that since the physical properties of nitrogen are similar to carbon monoxide, nitrogen competes with carbon monoxide for the trapping sites on the silica.
According to the preferred embodiment of FIG. 2 , block C is comprised of a first and a second reaction chamber valve V 3 and V 4 , a reagent valve V 5 , an injection loop 70 and a solvent valve V 6 , and the UV reactor assembly 51 which comprises a UV lamp 91 , a concave mirror 92 and a reaction chamber 50 .
The first reaction chamber valve V 3 has a gas mixture inlet 40 connected to the carbon monoxide trapping device 38 , a stop position 42 , a collection outlet 44 , a waste outlet 46 , and a reaction chamber connection port 48 connected to a gas inlet 52 of the reaction chamber 50 . The first reaction chamber valve V 3 has four modes of operation A to D. The reaction chamber connection port 48 is: in mode A connected to the gas mixture inlet 40 , in mode B connected to the stop position 42 , in mode C connected to the collection outlet 44 , and in mode D connected to the waste outlet 46 .
FIG. 3 shows the reaction chamber 50 (micro-autoclave) which has a gas inlet 52 and a liquid inlet 54 , which are arranged such that they terminate at the bottom surface of the chamber. Gas inlet 52 may also be used as product outlet after the labeling is finished. During operation the carbon-isotope monoxide enriched gas mixture is introduced into the reaction chamber 50 through the gas inlet 52 , where after the liquid reagent at high pressure enters the reaction chamber 50 through the liquid inlet 54 . FIGS. 6 a and 6 b shows schematic views of two preferred reaction chambers 50 in cross section. FIG. 6 a is a cylindrical chamber which is fairly easy to produce, whereas the spherical chamber of FIG. 6 b is the most preferred embodiment, as the surface area to volume-ratio of the chamber is further minimized. A minimal surface area to volume-ratio optimizes the recovery of labeled product and minimizes possible reactions with the surface material. Due to the “diving-bell construction” of the reaction chamber 50 , both the gas inlet 52 and the liquid inlet 54 becomes liquid-filled and the reaction chamber 50 is filled from the bottom upwards. The gas-volume containing the carbon-isotope monoxide is thus trapped and given efficient contact with the reaction mixture. Since the final pressure of the liquid is approximately 80 times higher than the original gas pressure, the final gas volume will be less than 2% of the liquid volume according to the general gas-law. Thus, a pseudo one-phase system will result. In the instant application, the term “pseudo one-phase system” means a closed volume with a small surface area to volume-ratio containing >96% liquid and <4% gas at pressures exceeding 200 bar. In most syntheses the transfer of carbon monoxide from the gas-phase to the liquid phase will probably not be the rate limiting step. After the labeling is finished the labeled volume is nearly quantitatively transferred from the reaction chamber by the internal pressure via the gas inlet/product outlet 52 and the first reaction chamber valve V 3 in position C.
In a specific embodiment, FIG. 3 shows a reaction chamber made from stainless steel (Valco™) column end fitting 101 . It is equipped with sapphire window 102 , which is a hard material transparent to short wavelength UV radiation. The window is pressed between two Teflon washers 103 inside the drilled column end fitting to make the reactor tight at high pressures. Temperature measurement can be accomplished with the thermocouple 104 attached by solder drop 105 to the outer side of the reactor. A magnet stirrer (not shown) drives small Teflon coated magnet stirring bar 106 placed inside the reaction chamber. The magnetic stirrer can be attached against the bottom of the reaction chamber. Distance between the magnet stirrer and the reactor should be minimal.
FIG. 4 shows a commercial UV spot light source 110 (for example, Hamamatsu Lightningcure™ LC5), which is an example of UV spot light sources that can be used in the instant invention. Light source 110 has necessary means of operating and controlling the photo irradiation that is produced, of the light source is available from the manufacturer (Hamamatsu Photonics K. K. Thus intensity and time duration of the photo irradiation are easily adjusted by an operator. Light source 110 may be externally controlled by a computer, providing a possibility for automating the reactor assembly. The photo irradiation is delivered to the reaction vessel through a flexible light guide, which is an accessory of Hamamatsu Lightningcure™ LC5. Thus light source 110 may be placed at the distance from the reaction chamber providing the possibility to save precious space inside a sheltered hot-cell, where the radiolabeling syntheses are carried out. Light source 110 complies with the existing industrial safety standards. Further, optional accessories (e.g. changeable lamps, optical filters) are provided which may be advantageously used for adjusting the properties of the photo irradiation.
FIG. 5 shows the reaction chamber 50 situated a magnetic stirrer 201 , with gas inlet/product outlet 52 and liquid inlet 54 facing the magnetic stirrer 201 . Top of the reaction chamber 50 is connected through the flexible light guide 202 to the UV spot light source (not shown).
Referring back to FIG. 2 , the second reaction chamber valve V 4 has a reaction chamber connection port 56 , a waste outlet 58 , and a reagent inlet 60 . The second reaction chamber valve V 4 has two modes of operation A and B. The reaction chamber connection port 56 is: in mode A connected to the waste outlet 58 , and in mode B it is connected to the reagent inlet 60 .
The reagent valve V 5 , has a reagent outlet 62 connected to the reagent inlet 60 of the second reaction chamber valve V 4 , an injection loop inlet 64 and outlet 66 between which the injection loop 70 is connected, a waste outlet 68 , a reagent inlet 71 connected to a reagent source, and a solvent inlet 72 . The reagent valve V 5 , has two modes of operation A and B. In mode A the reagent inlet 71 is connected to the injection loop inlet 64 , and the injection loop outlet 66 is connected to the waste outlet 68 , whereby a reagent may be fed into the injection loop 70 . In mode B the solvent inlet 72 is connected to the injection loop inlet 64 , and the injection loop outlet 66 is connected to the reagent outlet 62 , whereby reagent stored in the injection loop 70 may be forced via the second reaction chamber valve V 4 into the reaction chamber 50 if a high pressure is applied on the solvent inlet 72 .
The solvent valve V 6 , has a solvent outlet 74 connected to the solvent inlet 72 of the reagent valve V 5 , a stop position 76 , a waste outlet 78 , and a solvent inlet 80 connected to a solvent supplying HPLC-pump (High Performance Liquid Chromatography) or any liquid-pump capable of pumping organic solvents at 0-10 ml/min at pressures up to 400 bar (not shown). The solvent valve V 6 , has two modes of operation A and B. In mode A the solvent outlet 74 is connected to the stop position 76 , and the solvent inlet 80 is connected to the waste outlet 78 . In mode B the solvent outlet 74 is connected to the solvent inlet 80 , whereby solvent may be pumped into the system at high pressure by the HPLC-pump.
Except for the small volume of silica in the carbon monoxide trapping devise 38 , an important difference in comparison to the carbon dioxide trapping device 8 , as well as to all related prior art, is the procedure used for releasing the carbon monoxide. After the trapping of carbon monoxide on carbon monoxide trapping devise 8 , valve V 3 is changed from position A to B to stop the flow from the carbon monoxide trapping devise 38 and increase the gas-pressure on the carbon monoxide trapping devise 38 to the set feeding gas pressure (3-5 bar). The carbon monoxide trapping devise 38 is then heated to release the carbon monoxide from the silica surface while not significantly expanding the volume of carbon monoxide in the carrier gas. Valve V 4 is changed from position A to B and valve V 3 is then changed from position B to A. At this instance the carbon monoxide is rapidly and almost quantitatively transferred in a well-defined micro-plug into the reaction chamber 50 . Micro-plug is defined as a gas volume less than 10% of the volume of the reaction chamber 50 , containing the topical substance (e.g. 1-20 μL). This unique method for efficient mass-transfer to a small reaction chamber 50 , having a closed outlet, has the following prerequisites:
A micro-column 38 defined as follows should be used. The volume of the trapping material (e.g. silica) should be large enough to efficiently trap (>95%) the carbon-isotope monoxide, and small enough (<1% of the volume of a subsequent reaction chamber 50 ) to allow maximal concentration of the carbon-isotope monoxide. In the case of silica and a reaction chamber 50 volume of 200 μl, the silica volume should be 0.1-2 μl. The dead volumes of the tubing and valve(s) connecting the silica column and the reaction chamber 50 should be minimal (<10% of the micro-autoclave volume). The pressure of the carrier gas should be 3-5 times higher than the pressure in the reaction chamber 50 before transfer (1 atm.).
In one specific preferred embodiment specifications, materials and components are chosen as follows. High pressure valves from Valco®, Reodyne® or Cheminert® are used. Stainless steel tubing with o.d. 1/16″ is used except for the connections to the porapac-column 8, the silica-column 38 and the reaction chamber 50 where stainless steel tubing with o.d. 1/32″ are used in order to facilitate the translation movement. The connections between V 1 , V 2 and V 3 should have an inner diameter of 0.2-1 mm. The requirement is that the inner diameter should be large enough not to obstruct the possibility to achieve the optimal flow of He (2-50 ml/min) through the system, and small enough not to prolong the time needed to transfer the radioactivity from the porapac-column 8 to the silica-column 38. The dead volume of the connection between V 3 and the autoclave should be minimized (<10% of the autoclave volume). The inner diameter (0.05-0.1 mm) of the connection must be large enough to allow optimal He flow (2-50 ml/min). The dead volume of the connection between V 4 and V 5 should be less than 10% of the autoclave volume.
The porapac-column 8 preferably is comprised of a stainless steel tube (o.d.=⅛″, i.d.=2 mm, l=20 mm) filled with Porapac Q® and fitted with stainless steel screens. The silica-column 38 preferably is comprised of a stainless steel tube (o.d= 1/16″, i.d.=0.1 mm) with a cavity (d=1 mm, h=1 mm, V=0.8 μl) in the end. The cavity is filled with silica powder (100/80 mesh) of GC-stationary phase type. The end of the column is fitted against a stainless steel screen.
It should be noted that a broad range of different materials could be used in the trapping devices. If a GC-material is chosen, the criterions should be good retardation and good peak-shape for carbon dioxide and carbon monoxide respectively. The latter will ensure optimal recovery of the radioactivity.
Below a detailed description is given of a method of producing carbon-isotope using an exemplary system as described above.
Preparations of the system are performed by the steps 1 to 5:
1. V 1 in position A, V 2 in position A, V 3 in position A, V 4 in position A, helium flow on with a max pressure of 5 bar. With this setting, the helium flow goes through the porapac column, the zinc furnace, the silica column, the reaction chamber 50 and out through V 4 . The system is conditioned, the reaction chamber 50 is rid of solvent and it can be checked that helium can be flowed through the system with at least 10 ml/min. UV lamp 91 is turned on. 2. The zinc-furnace is turned on and set at 400° C. 3. The porapac and silica-columns are cooled with liquid nitrogen. At −196° C., the porapac and silica-column efficiently traps carbon-isotope dioxide and carbon-isotope monoxide respectively. 4. V 5 in position A (load). The injection loop (250 μl), attached to V 5 , is loaded with the reaction mixture. 5. The HPLC-pump is attached to a flask with freshly distilled THF (or other high quality solvent) and primed. V 6 in position A.
Production of carbon-isotope dioxide may be performed by the steps 6 to 7:
6. Carbon-isotope dioxide is produced using the 14N(p,α) 11 C reaction in a target gas containing nitrogen (AGA, Nitrogen 6.0) and 0.1% oxygen (AGA. Oxygen 4.8), bombarded with 17 MeV protons. 7. The carbon-isotope dioxide is transferred to the apparatus using nitrogen with a flow of 100 ml/min.
Synthesis of carbon-isotope may thereafter be performed by the steps 8 to 16
8. V 1 in position B and V 2 in position B. The nitrogen flow containing the carbon-isotope dioxide is now directed through the porapac-column (cooled to −196° C.) and out through a waste line. The radioactivity trapped in the porapac-column is monitored. 9. When the radioactivity has peaked, V 1 is changed to position A. Now a helium flow is directed through the porapac-column and out through the waste line. By this operation the tubings and the porapac-column are rid of nitrogen. 10. V 2 in position A and the porapac-column is warmed to about 50° C. The radioactivity is now released from the porapac-column and transferred with a helium flow of 10 ml/min into the zinc-furnace where it is transformed into carbon-isotope monoxide. 11. Before reaching the silica-column (cooled to −196° C.), the gas flow passes the ascarite-column. The carbon-isotope monoxide is now trapped on the silica-column. The radioactivity in the silica-column is monitored and when the value has peaked, V 3 is set to position B and then V 4 is set to position B. 12. The silica-column is heated to approximately 50° C., which releases the carbon-isotope monoxide. V 3 is set to position A and the carbon-isotope monoxide is transferred to the reaction chamber 50 within 15 s. 13. V 3 is set to position B, V 5 is set to position B, the HPLC-pump is turned on (flow 7 ml/min) and V 6 is set to position B. Using the pressurised THF (or other solvent), the reaction mixture is transferred to the reaction chamber 50 . When the HPLC-pump has reached its set pressure limit (e.g 40 Mpa), it is automatically turned off and then V 6 is set to position A. 14. UV spot light source 110 , magnetic stirrer 201 and magnet stirring bar 106 in reaction chamber 50 are turned on. 15. After a sufficient reaction-time (usually 5 min), V 3 is set to position C and the content of the reaction chamber 50 is transferred to a collection vial. 16. The reaction chamber 50 can be rinsed by the following procedure: V 3 is set to position B, the HPLC-pump is turned on, V 6 is set to position B and when maximal pressure is reached V 6 is set to position A and V 3 is set to position 3 thereby transferring the rinse volume to the collection vial.
With the recently developed fully automated version of the reaction chamber 50 system according to the invention, the value of [ 11 C]carbon monoxide as a precursor for 11 C-labelled tracers has become comparable with [ 11 C]methyl iodide. Currently, [ 11 C]methyl iodide is the most frequently used 11 C-precursor due to ease in production and handling and since groups suitable for labeling with [ 11 C]methyl iodide (e.g. hetero atom bound methyl groups) are common among biologically active substances. Carbonyl groups, which can be conveniently labeled with [ 11 C]carbon monoxide, are also common among biologically active substances. In many cases, due to metabolic events in vivo, a carbonyl group may even be more advantageous than a methyl group as labeling position. The use of [ 11 C]carbon monoxide for production of PET-tracers may thus become an interesting complement to [ 11 C]methyl iodide. Furthermore, through the use of similar technology, this method will be applicable for synthesis of 13 C and 14 C substituted compounds.
EXAMPLES
The invention is further described in the following examples which are in no way intended to limit the scope of the invention.
Example 1
Precursors and Resultant Products
Precursors that were used to label acids are shown in List. 1.
List 1. Iodides Used as Precursors in the Synthesis of Labeled Acids
The following experiments illustrate the present invention. Radical carboxylation using submicromolar amounts of [ 11 C]carbon monoxide is performed yielding labeled with the acids shown in Table 1 as target compounds.
TABLE 1
Radiochemical yields for 11 C-labelled acids
11 CO
Isolated
Base
conv.
Yield b
Yield
Labelled compound a
Solvents
(mmol)
(%)
(%)
(%)
DMSO
TEA
25
N/A
34
DMSO
TEA
82
64
50
DMSO DMSO/THF (1:9)
TEA TEA
81 74
69 67
59 58
C 16 H 33 [ 11 C]O 2 H
DMSO/THF (2:3)
TEA
86
67
N/A
a The position of 11 C label is denoted by * and 13 C substitution by †.
b Decay-corrected radiochemical yield determined by LC.
Example 2
Experimental Setup
[ 11 C]Carbon dioxide production was performed using a Scanditronix MC-17 cyclotron at Uppsala Imanet. The 14 N(p,α) 11 C reaction was employed in a gas target containing nitrogen (Nitrogen 6.0) and 0.1% oxygen (Oxygen 4.8), that was bombarded with 17 MeV protons.
[ 11 C]Carbon monoxide was obtained by reduction of [ 11 C]carbon dioxide as described previously (Kihlberg, T.; Långström, B. Method and apparatus for production and use of [ 11 C]carbon monoxide in labeling synthesis. Swedish Pending Patent Application No. 0102174-0).
Liquid chromatographic analysis (LC) was performed with a gradient pump and a variable wavelength UV-detector in series with a β + -flow detector. An automated synthesis apparatus, Synthia (Bjurling, P.; Reineck, R.; Westerberg, G.; Gee, A. D.; Sutcliffe, J.; Långström, B. In Proceedings of the VIth workshop on targetry and target chemistry ; TRIUMF: Vancouver, Canada, 1995; pp 282-284) was used for LC purification of the labelled products.
Radioactivity was measured in an ion chamber. Xenon-mercury lamp was used as a photo-irradiation source.
In the analysis of the 11 C-labeled compounds, isotopically unchanged reference substances were used for comparison in all the LC runs.
NMR spectra were recorded at 400 MHz for 1 H and at 100 MHz for 13 C, at 25° C. Chemical shifts were referenced to TMS via the solvent signals.
LC-MS analysis was performed with electrospray ionization.
Solvents: THF was distilled under nitrogen from sodiuni/benzophenone; all other solvents were commercial grade, The solvents were purged with helium.
Alkyl iodides were commercially available or otherwise prepared from commercial allyl bromides by the Finkelstein reaction.
Example 3
Preparation of [carboxyl- 11 C] Acids
General procedure. Triethylamine (25 μL) was placed in a capped vial (1 mL, flushed beforehand with nitrogen to remove oxygen) and dissolved in DMSO (500 μL). An alkyl or aryl iodide (0.1 mol) was added to the solution ca. 7 min before the start of the synthesis. The resulting mixture was pressurized (over 40 MPa) into the micro-autoclave (270 μL), pre-charged with [ 11 C]carbon monoxide (10 −8 -10 −9 mol) mixed with He. The mixture was irradiated with a UV source for 6 min with stirring at 35° C. The crude reaction mixture was then transferred from the autoclave to a capped vial, held under reduced pressure. After measurement of the radioactivity the vial was purged with nitrogen and the radioactivity was measured again. The crude product was diluted with acetonitrile or methanol (0.6 mL) and injected on the semi-preparative LC. Analytical LC and LC-MS were used to assess the identity and radiochemical purity of the collected fraction.
Specific Embodiments
Citation of References
The present invention is not to be limited in scope by specific embodiments described herein. Indeed, various modifications of the inventions in addition to those described herein will become apparent to these skilled in the art from the foregoing description and accompanying figures. Such modifications are intended to fall within the scope of the appended claims.
Various publications and patent applications are cited herein, the disclosures of which are incorporated by reference in their entireties.
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Methods and reagents for photo-initiated carbonylation with carbon-isotope labeled carbon monoxide using alkyl/aryl iodides with sulfoxides and triethylamine are provided. The resultant carbon-isotope labeled acids, and pharmaceutical acceptable salts and solvates are useful as radiopharmaceuticals, especially for use in Positron Emission Tomography (PET). Associated kits and method for PET studies are also provided.
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TECHNICAL FIELD
[0001] This disclosure relates to flexible and printable nonwoven substrates having high air- and steam-permeability, heat stability, and bacterial impermeability, for use in forming packages for instruments, devices, appliances and the like that require sterilization by various methods including heat, ethylene oxide and gamma radiation, and related methods of manufacture.
BACKGROUND OF INVENTION
[0002] Many types of instruments, devices, appliances and the like including, for example, surgical and other medical instruments (collectively “instruments”) must be sterilized prior to use. Typically, such instruments are packaged, sealed and sterilized in disposable packaging so they can be safely transported and stored until they are used. Several sterilization techniques are known in the art, including gamma radiation, steam, dry heat and ethylene oxide sterilization techniques. In general, a sterilizing gas, vapor or liquid flows through pores in the disposable packaging and sterilizes the instruments contained therein. The sterilizing gas, vapor or liquid dissipates from the package also through the package's pores.
[0003] To form such a disposable package, an instrument may be placed between two layers of paper or plastic substrate, at least one of the layers being impervious to bacteria and debris while also being permeable to gases or steam, and the layers are sealed together to form a bag or pouch. A pouch or bag may also be formed from a paper or plastic substrate prior to inserting an instrument therein with a flap at or near an opening in the pouch such that the flap may be folded over and sealed to the pouch with an adhesive or other type of known sealing method. Alternatively, an instrument may be placed in a paper or plastic tray, sometimes molded to the shape of the instrument, and then covered and sealed with at least one layer of paper or plastic substrate that is both impervious to bacteria and debris, and permeable to gases or steam.
[0004] Substrates useful to form such packaging should exhibit sufficient airflow through the material to relieve pressure in the package during sterilization, high steam permeability, resistance to high temperatures, and should provide a significant barrier to penetration by bacteria and debris. It is also desirable that a substrate for this purpose be flexible, strong, printable, and sealable to itself and thermoplastic films and substrates. Other desired characteristics depend on the particular product disposed within the packaging.
[0005] An example of a commonly used medical packaging material is a high strength barrier nonwoven composed entirely of flash-spun polyolefin (usually high density polyethylene) sold under the trademark TYVEK® by E.I. DuPont De Nemours & Co. and described in U.S. Pat. No. 3,169,898 to Steuber. Although TYVEK® fabric is micro-porous and acts as a barrier to particulate matter that is sub-micron in size, TYVEK® fabric has very low air and gas permeability (i.e., high resistance to air and gas permeation), making the penetration of ethylene oxide and steam, and their subsequent off-gassing difficult and time consuming. TYVEK® fabric also has poor printability due to its inherent low surface energy and suppleness, and must be treated and/or coated to improve printability. Further, TYVEK® fabric has a relatively low melting point (approximately 130° C.) and will severely deform and shrink under high temperature sterilization techniques such as steam, which is typically conducted at temperatures greater than 135° C.
[0006] Barrier fabrics have been developed using wet-laid processing techniques, and often include 100% wood pulp, which is wet-laid on a Fourdrinier machine, saturated with latex and highly calendered. In the medical industry, these barrier fabrics are commonly referred to as “medical packaging paper.” Wet-laid barrier fabrics made from other fibers are disclosed in U.S. Publication No. US 2010/0272938 A1, published Oct. 28, 2010. However, wet-laid nonwovens typically do not have sufficient barrier properties to prevent bacteria and debris from penetrating through the fabric, and also lack sufficient strength for packaging instruments.
[0007] Barrier properties of a porous packaging material (i.e., the ability to resist the passage of microorganisms) are measured using ASTM Standard F1608, “Standard Test Method for Microbial Ranking of Porous Packaging Materials (Exposure Chamber Method),” and result in a “Log Reduction Value” for a material. The higher the Log Reduction Value, the more effective a material is at filtering out bacteria. For example, medical grade TYVEK® fabric has a Log Reduction Value of 5. Wet-laid nonwovens and papers typically have a Log Reduction Value between 1 and 2.5. Wet-laid nonwoven fabrics containing cellulosic fibers can improve their barrier properties by using highly refined pulps, calendering and/or selecting shorter and thinner walled hardwood fibers, but these modifications also weaken the physical strength (i.e., tear strength) of the fabric, reduce opacity and increase stiffness. Cellulosic fibers also tend to weaken and discolor during certain sterilization techniques such as steam and ethylene oxide sterilization.
[0008] It is therefore an object of this disclosure to overcome the foregoing difficulties such as those associated with TYVEK® medical grade fabric and cellulosic wet-laid nonwovens and papers, and provide a nonwoven substrate that exhibits high strength and that can withstand higher temperatures than TYVEK® medical grade fabric, is steam sterilizable, has sufficient airflow to relieve pressure in the package during sterilization, provides a significant barrier to penetration by bacteria and debris, is sealable to itself and thermoplastic films and substrates, and is printable.
SUMMARY OF INVENTION
[0009] The foregoing purposes, as well as others that will be apparent, are achieved generally by providing a nonwoven substrate in the form of a wet-laid fibrous sheet comprising a low porosity top layer for barrier and printing properties and a high strength bottom layer. The top layer comprises nanofibrillated lyocell fibers. The bottom layer comprises a blend of microfibers, fibers having a flat, rectangular cross-section, binder fibers, first polymeric fibers having a first linear density and a first length and second polymeric fibers having a second linear density and a second length both greater than the first linear density and first length of the first polymeric fibers. In a preferred embodiment, the top layer further comprises microfibers; and, in another preferred embodiment, the top layer further comprises fibers having a flat, rectangular cross-section.
[0010] The fibers having a flat, rectangular cross-section are preferably splittable conjugated fibers, which have an ultra-fine structure that provides improved strength, tear resistance, and barrier properties. The splittable conjugated fibers are synthetic (preferably polyester and nylon), and are characterized by high melting points, allowing them to be sterilizable at high temperatures and, in particular, allows for steam sterilization. Preferred splittable conjugated fibers have a sectional cross-section that splits into ribbon-like fibers after fibrillation, mimicking some cellulosic fibers, and, more particularly, have a sectional cross section that is generally rectangular in shape. Such fibers are generally extruded in a cylindrical shape and split into ribbon-like fibers with varying widths and slightly curved ends.
[0011] After formation of the substrate or sheet by a wet-laid process, the sheet may be fused using a thru-air drier, an infrared drier, a gas oven, or a thermally heated calender. If a thermally heated calender is used, temperatures of approximately 150° C. and pressures of approximately 500 to 1500 pounds per square inch can sufficiently fuse the web. The advantage of a thermally heated calender to fuse the binder fibers is that it provides greater compaction of the sheet (i.e., improved barrier) compared to other methods. The fused and dried sheet is then subjected to treatment with an aqueous binder composition preferably comprising a styrenated acrylic having a glass transition temperature between 20° C. and 40° C.
[0012] Preferred blends of fibers include: (i) a bottom layer of 10 to 30% by weight of polyester microfibers, 0 to 20% by weight of splittable conjugated fibers, 5 to 15% by weight of binder fibers having a melt temperature greater than 140° C., 0 to 20% by weight of the first polymeric fiber, and 10 to 40% by weight of the second fiber; and (ii) a top layer of 40 to 80% by weight of fibrillated lyocell fibers and 20 to 60% by weight of either polyester microfiber or splittable conjugated fibers.
[0013] The nonwoven substrate may have a total weight of about 65 to about 113 grams per square meter, and should be sufficiently porous to allow the appropriate permeability to air, gas and steam while maintaining resistance to undesirable contaminants such as bacteria and debris. The average pore size of a layer or layers depends on the overall basis weight and spatial density of the substrate, the composition of fiber morphologies (shape and coarseness) making up the substrate and relative ratio of the weight of the top phase to the weight of the bottom phase, bearing in mind that the size of bacteria is generally from 0.5 to 5 micron (or micrometers, μm), and is preferably in the range of 0.25 to 11 micrometers. The average pore size may be measured using a capillary flow porometer (such as those available from Porous Materials, Inc., Ithaca, N.Y.).
[0014] Strength, porosity and permeability characteristics are imparted to the nonwoven substrates disclosed herein by the combination of synthetic fibers employed in the fiber blend. For example, the substrate has a preferred combination of properties including Gurley porosity value of at least 13 seconds per 100 milliliters and Elmendorf tear strength of greater than 400 grams in both the cross direction and machine direction. The substrate also exhibits a Log Reduction Value greater than 2 and dry process tensile strengths of at least about 10,000 grams per 25 millimeters in the machine direction and at least about 6,000 grams per 25 millimeters in the cross direction.
[0015] Preferred fiber blends maintain balance between strength, barrier properties and cost. For example, increasing the amount of lyocell fibers in the blend generally increases the resulting substrate's barrier properties, and increasing the amount of microfibers or splittable conjugated fiber in the blend generally increases the substrate's strength and dimensional stability.
[0016] Additional fibers, materials and layers may be added to the nonwoven substrate to impart other properties. Other objects, features and advantages of the present disclosure will be apparent when the detailed description of preferred embodiments is considered in conjunction with the following drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0017] FIG. 1 is a scanning electron micrograph (or SEM) of the top surface of a first embodiment of an untreated exemplary nonwoven substrate with 425 times magnification.
[0018] FIG. 2 is an SEM of the top surface of a second embodiment of an untreated exemplary nonwoven substrate with 385 times magnification.
[0019] FIG. 3A is an illustration of an apparatus for forming an aqueous suspension of fibers for use in manufacturing a wet-laid nonwoven substrate.
[0020] FIG. 3B is an illustration of an alternative apparatus for forming an aqueous suspension of fibers for use in manufacturing a wet-laid nonwoven substrate.
[0021] FIG. 4A is an illustration of an apparatus for manufacturing a wet-laid nonwoven substrate.
[0022] FIG. 4B is an illustration of an alternative apparatus for manufacturing a wet-laid nonwoven substrate.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] Preferred nonwoven substrates that exhibit the desired characteristics of improved strength, bacterial barrier, tear resistance, flexibility, printability, stability during steam sterilization, air and steam permeability, heat resistance, sealability and high melting point comprise at least two layers and are produced via a wet-laid process on an inclined wire (or combination of inclined wire and Fourdrinier as in a twin wire process shown in FIG. 3A ), dried and fused (optionally using a heated calender for added compaction), and treated with an aqueous binder composition. A top layer comprises nanofibrillated lyocell fibers. A bottom layer comprises a blend of microfibers, fibers having a flat, rectangular cross-section, binder fibers, first polymeric fibers having a first linear density and a first length and second polymeric fibers having a second linear density and a second length both greater than the first linear density and first length of the first polymeric fibers.
[0024] The top layer further comprises either microfibers or fibers having a flat, rectangular cross-section. FIGS. 1 and 2 are SEMs of two preferred top layers of the substrate. FIG. 1 shows a top layer comprising nanofibrillated lyocell fibers 12 and fibers having a flat, rectangular cross-section 14 . FIG. 2 shows a top layer comprising nanofibrillated lyocell fibers 12 and microfibers 16 .
[0025] The fibers selected for use in preferred nonwoven substrates disclosed herein are synthetic fibers. As used in this application, the term “synthetic fibers” are fibers that are formed through a melt extrusion process (i.e., fiber pellets are dissolved and extruded as a continuous filament) to permit control of the length, shape and morphology of the extruded fiber. Synthetic fibers include lyocell fibers, but do not include natural cotton, wool or pulp fibers. Preferred nonwoven substrates disclosed herein comprise 100% synthetic fibers.
[0026] The diameter or linear density of a fiber may be measured in units of micron or denier per filament. The unit micron is equivalent to the unit micrometer, and represents one-millionth of a meter (or 1/1000 of a millimeter or 0.001 mm). Denier per filament (or dpf) is the denier of a fiber divided by the number of filaments in the fiber. Denier is the weight in grams of 9,000 meters of fiber. Linear density may also be measured in Decitex (or dtex), which is the weight in grams of 10,000 meters of fiber. To convert from dtex to denier, the following formula may be used: denier=0.9×dtex. The ratio of fiber length to fiber diameter is referred to as the “aspect ratio” of the fiber.
[0027] The term “microfibers”, as used herein, refers to fibers having a diameter less than 5 micron and a length of less than 3 millimeters. Preferred microfibers 16 are polyester (PET) microfibers having a non-splittable, cylindrical cross-section, and act as a processing aid in the wet-laid forming process, permitting processing of 100% synthetic compositions without specialized handling or processing equipment and also providing wet strength. A preferred microfiber 16 is a PET microfiber available from Eastman, Kingsport, Tenn., having a 2 to 4 micron (micrometer) diameter and length of about 1.5 millimeters. The Eastman PET microfibers are extruded “islands-in-the-sea” (IS) fibers made from a proprietary water dispersible polyester resin. They are available in diameters of 2 to 4 micron and can be chopped to desired length between 1.5 and 3 millimeter, and then processed to dissolve the sea portion of the fibers and leave the islands portion of the fibers.
[0028] As an alternative, polyvinyl alcohol (PVA) binder fibers can be used as a processing aid and to provide wet strength instead of the microfibers. For example, a PVA fiber available from Kuraray Co., Ltd., Osaka, Japan under the designation PV105-2 may be used to perform a similar processing function. However, use of a microfiber of similar polymer chemistry permits forming a substrate with a homogeneous fiber matrix, which may be useful for recycling at end of use.
[0029] In preferred embodiments, microfibers should be present in the bottom layer in an amount of about 10% to 30% by weight of the bottom layer. Weight measurements throughout this specification are measured in the dry state. When microfibers 16 are used in the top layer, they should be present in an amount of about 20% to 60% by weight of the top layer.
[0030] Fibers having a flat, rectangular cross-section 14 are useful in wet-laid nonwovens because their flat surfaces permit such fibers to cover holes resulting from the forming process, and thus improve barrier properties of nonwoven substrate. It has been found that increasing the amount of such flat, rectangular fibers 14 in a fabric results in increased barrier properties (relative to the use of other short cut staple fiber synthetic fibers). Preferred flat fibers are splittable conjugated fibers or standard flat polyester fibers. Conjugated fibers are those that have two different polymers within the fiber. A conjugated fiber is splittable when the two different polymers have little cohesion between the fibers. Preferred Splittable conjugated fibers 14 have a sectional cross-section that splits into multiple ribbon-like fibers (mimicking some cellulosic fibers). See FIG. 1 . For example, a conjugated fiber of nylon and polyester is easily separated and useful in the preferred nonwoven substrates. Such splittable conjugated fibers have an ultrafine structure that, after fibrillation, provides good barrier properties similar to refined pulp, but also imparts improved strength, dimensional stability, and good drainage. Fibrillation of the splittable conjugated fiber occurs during the wet-laid process from shearing forces resulting from the mechanical action (or turbulence) under dilute conditions, which are sufficient to spontaneously split the conjugate fibers during the wet-laid process.
[0031] In preferred embodiments, conjugated fibers 14 should be present in the bottom layer in an amount of about 0% to 20% by weight of the bottom layer. When conjugated fibers 14 are used in the top layer, they should be present in an amount of about 20% to 60% by weight of the top layer.
[0032] A preferred conjugated polyester/nylon short-cut fiber is available from Kuraray Co., Ltd., Osaka, Japan under the trade name WRAMP, Solid Core Type, which has a linear density of 3.3 dtex (2.97 denier) before split and length of 3-10 millimeters. The linear density after split is approximately 0.3 dtex (0.27 denier). The WRAMP fiber has a split number of 11 (6 polyester/5 nylon). WRAMP fibers provide substrates with high tear factor, low air permeability, smaller pore size, high luster and high folding capacity. Kuraray WRAMP splittable conjugated fibers also have a high melting temperature, which makes them steam sterilizable.
[0033] Binder fibers useful in the bottom layer should have a high melting temperature, 140° C. or higher, and may be formed from polyacrylate, styrene-butadiene copolymer, polyvinyl chloride, ethylene-acrylate copolymer, vinyl acetate-acrylate copolymer and coPET binders. Preferred binder fibers are bi-component fibers of the type having an outer sheath and a core. An example of such a bi-component binder fiber is the high temperature copolyester binder fibers (copolyester/polyester), Type TJ04BN supplied by Teijin Fibers Limited, Osaka, Japan having linear density of 1.7-3 dtex (1.53-2.7 denier), length of 5-15 millimeters, and sheath melting temperature of about 150° C. Other examples of binder fibers that may be used include Type 7080 crystalline bicomponent coPET/PET fibers, available from Unitika Fibers Ltd., Osaka, Japan, having a linear density of 2.0 denier, a length of 5 mm and a sheath melt temperature of 160° C.) and Kuraray Type N720H (melting temperature 150° C.). In preferred embodiments, binder fibers should be present in the bottom layer in an amount of about 5% to 15% by weight (in dry state) of the bottom layer.
[0034] Preferred nanonfibrillated lyocell fibers 12 used in the substrate are fibers formed by dissolving and extruding naturally occurring cellulosic materials, such that the chemical nature of the naturally occurring cellulosic material is retained after the fiber formation process, and the length, diameter and morphology of the extruded fiber may be controlled. Therefore, preferred lyocell fibers are synthetic fibers as defined herein.
[0035] During fiber formation, lyocell fibers 12 typically fibrillate, or form micro-fibrils or nano-fibrils on the fiber surface, and fill in gaps in the top layer left by the conjugated fibers 14 or microfibers 16 during wet-laid processing, as shown in FIGS. 1 and 2 . A preferred lyocell fiber is a nano-fibrillated fiber available from Engineered Fibers Technology in Longmeadow, Mass. under the trademark EFTec 010-4. Other nano-fibrillated lyocell fibers may also be used. In preferred embodiments, lyocell fibers 12 should be present in the top layer in an amount of about 40% to 80% by weight of the top layer.
[0036] The remaining fibers in the fiber blend of the bottom layer are preferably polymeric fibers of varying linear density and length. For example, a first fiber may be a short-cut polyester fiber having a liner density of 1.7 dtex (1.53 denier) and a length of about 5-15 mm, such as a 10 millimeter 100% Post Consumer recycled polyester fiber (“EcoPET”) from Teijin Fibers Limited, Type TA4 may be used, or alternatively a 10 millimeter Kuraray EP303, or Teijin's virgin 10 mm TA04N fiber may be used. Such a fiber may be present in the amount of about 0% to 20% of the bottom layer. A second polymeric fiber used in the bottom layer may be a standard polyester fiber having a linear density of 1.5-6.0 dtex (1.35-5.4 denier) and length of 15-25 millimeters. For example, a polyester fiber from William Barnet & Sons, LLC, Product No. P50FM may be used (a High Tenacity fiber 5.2 dtex/19 millimeter). Such a fiber may be present in the amount of about 10% to 40% of the bottom layer.
[0037] The weight of the top layer is preferably in the range of about 10 to 25 grams per square meter, and the weight of the bottom layer is preferably in the range of about 40 to 60 grams per square meter. The bottom layer is typically heavier than the top layer by about 2 to 3 times. Preferably, the weight ratio of top layer to bottom layer is about 1 to 2.5. A higher weight ratio of top layer to bottom layer, or using a more massive top layer for a given bottom layer, will produce a more closed and higher barrier substrate. If the weight ratio of top layer to bottom layer is changed, without changing the total basis weight of the combined layers, increasing the ratio will decrease the strength of the substrate and improve barrier properties. To increase strength properties, the weight of the bottom layer should be increased.
[0038] A first exemplary fiber blend for a two-layer nonwoven substrate in accordance with the foregoing disclosure is set forth in TABLE I, and referred to herein as Example 1.
[0000]
TABLE I
Fiber Composition of Two-Layer Structure - 10242011-1B
Aspect
Diameter or
Length
Weight
Ratio
Component
Brand
Linear Density
(mm)
(%)
(L/D)
TOP LAYER (Weight - 20 gsm):
PET/Nylon
Kuraray
3.3 dtex (2.97
5
40
893
Conjugated
WRAMP
denier)
Fiber
(before split)
Fibrillated
EFTec
nanofibrillated
4
60
Lyocell
010-04
BOTTOM LAYER (Weight - 44 gsm):
PET
Eastman
1.5 micron
1.5
20
1000
Microfiber
Microfiber
PET/Nylon
Kuraray
3.3 dtex (2.97
5
10
893
Conjugated
WRAMP
denier)
Fiber
(before split)
CoPET/PET
Teijin
2.2 dtex (1.98
5
10
357
Binder Fiber
TJ04BN
denier)
Polyester
Teijin TA4
1.7 dtex (1.53
10
20
12000
Fiber
denier)
Polyester
Barnet
5.2 denier
19
40
712
Fiber
P50FM -
High
tenacity
[0039] A second exemplary fiber blend is set forth in TABLE II, and referred to herein as Example 2.
[0000]
TABLE II
Fiber Composition of Two-Layer Structure - 10242011-2B
Aspect
Diameter or
Length
Weight
Ratio
Component
Brand
Linear Density
(mm)
(%)
(L/D)
TOP LAYER (Weight - 20 gsm):
PET
Eastman
1.5 micron
1.5
40
1000
Microfiber
Microfiber
Fibrillated
EFTec
4
60
Lyocell
010-04
BOTTOM LAYER (Weight - 44 gsm):
PET
Eastman
1.5 micron
1.5
20
1000
Microfiber
Microfiber
PET/Nylon
Kuraray
3.3 dtex (2.97
5
10
893
Conjugated
WRAMP
denier)
Fiber
(before split)
CoPET/PET
Teijin
2.2 dtex (1.98
5
10
357
Binder Fiber
TJ04BN
denier)
Polyester
Teijin TA4
1.7 dtex (1.53
10
20
12000
Fiber
denier)
Polyester
Barnet
5.2 denier
19
40
712
Fiber
P50FM -
High
tenacity
[0040] The specific ratio of fibers in the fiber blends of preferred nonwoven substrates varies depending on what specific material properties are required. Employing the appropriate mix of synthetic fibers permits tuning the fiber matrix to the desired porosity and barrier characteristics, while taking into account cost considerations. In general, a double layer substrate is more cost effective because it allows a thinner, but higher concentration of fine fibers (higher barrier) within a layer, thus using fewer specialty fibers. If a high barrier property is required (i.e., bacterial barrier), greater amounts of lyocell fibers should be used, while substituting conjugate or microfiber fibers for lyocell fibers will render a slightly more porous sheet. However, too much lyocell makes it difficult for water to drain from the substrate during production and will require slower production speeds. Tuning the amount of lyocell fibers within the ranges set forth in this application will prevent this problem, and represents a level of good runnability (i.e., faster processing speeds and fewer breaks) and performance.
[0041] If the nonwoven substrate is produced in a two-layer structure, one layer can be designed specifically for barrier properties and the other layer can be designed to provide strength. This type of construction permits one to minimize fiber costs.
[0042] Although preferred embodiments are described as a double-layer construction, the nonwoven substrate is not limited to the use of only two layers. The grammage and characteristics of the various sheets may be adjusted according to the general teachings of the present disclosure. For example, a three-layer substrate may be formed having a high barrier central layer that is not as strong and two outer layers that exhibit strength, or a high barrier central layer may be sandwiched between an outer layer with good sealing properties and an outer layer with high printability.
[0043] Nonwoven substrates that exhibit the desired characteristics of improved strength, bacterial barrier, tear resistance, flexibility, printability, stability during steam sterilization, air (and steam) permeability, heat resistance, sealability and high melting point, may be produced by conventional wet-laid processes, preferably using an inclined wire machine.
[0044] Referring to FIGS. 3A and 3B , at least two suspensions of fibers are prepared by filling hydropulpers 20 , 22 with warm water, agitating the water, adding a blend of fibers as set forth above, and further agitating the mixture for approximately 2 to 20 minutes to mix the fibers and create a fiber slurry. For example, the fibers used for bottom layer are mixed in hydropulper 20 and the fibers used for the top layer are mixed in hydropulper 22 . Each of the fiber slurries is then transported to a mixing chest 24 , 26 to further mix the fibers of each blend, and then to a blending chest to dilute the fiber slurry to the desired consistency of 0.2% to 0.4%. Fibrillation of the splittable conjugated fiber occurs in this part of the wet-laid process. The hydropulpers 20 , 22 and mixing chests 24 , 26 apply sufficient shearing forces resulting from the mechanical action (or turbulence) under dilute conditions to spontaneously split the conjugate fibers. Heating the water to about 40-80° C. and/or hydroentanglement may also aid in splitting the fibers, but are not necessary.
[0045] When the fiber slurries are sufficiently mixed and diluted, each of fiber slurries is transported to a headbox 28 , 30 for delivery to the web-forming machine, where the fiber slurries are dewatered on an inclined wire forming line 32 to form a multi-layer sheet. Referring to FIG. 3A , the top layer may be formed on a separate wire 34 (which, in this twin wire configuration, could alternatively be a Fourdrinier style former), and then placed on top of the bottom layer while the bottom layer is traveling up the inclined wire forming line 32 . Alternatively, the bottom layer and top layer may be placed onto the inclined wire forming line 32 successively, as shown in FIG. 3B . Thus, each layer may be formed separately on a wire and then combined to form the substrate, or the bottom layer may be formed on the wire, and the top layer may be formed directly on the bottom layer.
[0046] After the substrate is formed from the fiber blends, the formed sheet may be dried and fused as shown, for example, in the process lines of FIGS. 4A and 4B . FIG. 4A shows a process of using a heated calendering step for fusing and consolidation. FIG. 4B shows a process of using a thru air drier 48 for fusing the binder fibers instead of the heated precalender 38 shown in FIG. 4A . Other means of fusing the fibers may also be used, such as infrared, or gas ovens.
[0047] In the case of FIG. 4A , a calendering process may be introduced to fuse the sheath of the bicomponent binder fibers to the other synthetic fibers, to render the surface smooth, decrease its permeability (via densification) to the desired target, and achieve a porosity value lower than 20 L/min/100 cm 2 as measured by the testing method described in TAPPI T251 (before treatment). This test measures the air permeability of a square centimeter of fabric, or the volume of air that flows through the fabric per minute. The calender section may have single or multiple nip configurations for web consolidation. Calendering may be done on-line or off-line, but it is preferable to have it in-line. The calendering process should minimize any disruption or degradation of the bottom surface of the bottom layer. This can be accomplished by exposing only the top of the sheet to heat and pressure, and the bottom of the sheet only to pressure. For example, a heated steel roll and a non-heated rubber lower roll can be employed. Preferred calendering pressures vary between 300 and 2,000 pounds per square inch, preferably 500-1,500 pounds per square inch. Preferred temperatures of the top roll vary between 250-350° F., preferably 295° F., depending on the type of fibers that are used in the fiber blend.
[0048] Referring to FIG. 4A , the formed substrate sheets may be transferred from the inclined wire forming line 32 to a first drying section comprising a series of drying cans 36 to remove water. Then, the formed substrate sheets may be transferred to a heated precalender section 38 for fusing the binder fiber.
[0049] Various binders may then be applied to the formed sheet in aqueous form to further improve strength and barrier properties. The aqueous binder treatment is preferably applied after calendering the sheet, and may be provided on-line or off-line, to further enhance final product properties, such as increasing the density of the sheet, developing inter-fiber bonding and strength. A saturating size press 40 or other conventional means may be used to apply the binder.
[0050] Acceptable aqueous binders include, but are not limited to: styrenated acrylic (for example, BASF nx-4787), coPET (for example, Eastman 1200), acrylic (for example, Eco 100 Dow), polyurethane (for example, Permax 202), styrene-butadiene copolymer (for example, GenFlo 3060), acrylic copolymer (for example, BASF 4612), or combination there of (either sequentially added to the web or as a single mixture). The binder should have a glass transition temperature in the range of about +20° C. to +40° C. The aqueous binder is used in combination with the binder fibers to develop interfiber bonding and strength. Additionally, the aqueous binder boosts strength and ties down the fibers to limit the amount of fibers raised above the surface of the substrate.
[0051] The aqueous binder may be applied as an add-on to the substrate in an amount equal to about 15 to 28 grams per square meter. In the exemplary embodiments shown above, about 18 grams per square meter of aqueous binder were applied, but the application amount could range from between 15% to 36% add-on depending on the basis weight of each layer of the substrate. The total weight of the nonwoven substrates in this disclosure, including the aqueous binder treatment, will be about 65 to about 113 grams per square meter
[0052] Water may then be removed from the calendered sheet by passing the sheet through a second drying section 42 comprising drying cans or a through-air dryer to permit the aqueous binder treatment to cure. Additional soft calendering 44 may be applied to further smooth the surface, decrease its permeability (via densification) to the desired target, and achieve a porosity value of less than 5 L/min/100 cm 2 as measured by the testing method described in TAPPI T251 (after treatment). This test measures the air permeability of a square centimeter of fabric, or the volume of air that flows through the fabric per minute. The calender section may have a single or multiple nip configurations for web consolidation. Calendering may be done on or off-line, but it is preferable to have it in-line. The post calendering process should again minimize any disruption or degradation of the bottom surface of the bottom layer fiber matrix. This can be accomplished by exposing only the top of the sheet to heat and pressure, and the bottom of the sheet only to pressure. For example, a heated steel roll and a non-heated rubber lower roll can be employed. Preferred calendering pressures vary between 300 and 1,500 pounds per square inch, preferably 500-1,000 pounds per square inch. Preferred temperatures of the top roll vary between 200-300° F., preferably 250° F., depending on the type of binder(s) used in the aqueous binder treatment.
[0053] Post treatment soft calendering is beneficial, but is not required. The calendered substrates may then be further processed (for example, slitting) and wound to a roll in the rewind section 46 .
[0054] In an alternative process shown in FIG. 4B , a thru air drier 48 may be used for fusing the binder fibers instead of the heated precalender 38 shown in FIG. 4A . In this embodiment, the binder fibers in the formed substrate sheets are fused and the sheets are then dewatered in the first drying section 36 . One advantage of this process is that it is immediately adaptable to production lines (inclined wire) currently using through-air dryers, infrared, or gas ovens for binder fiber fusing. Most production lines do not use thermal calendering for fusing or densification purposes.
[0055] The nonwoven substrates described above exhibit improved porosity, strength and barrier properties as compared to TYVEK® and commercially available wet-laid medical papers. For example, preferred substrates have a Log Reduction Value of 2 or greater, as measured in accordance with ASTM Standard F1608, but also have improved airflow permeation resistance and strength. Airflow permeation resistance is measured by a Gurley densometer in accordance with TAPPI T460 standard test method, and measures the amount of time it takes (in seconds) for 100 milliliters of air to pass through a sample. For barrier applications, it is better for airflow permeation resistance to be higher. Elmendorf tear strength measures the force it takes to tear a 4 by 2 inch sample of a material in grams in accordance with TAPPI T414 standard test method. Higher values represent stronger substrates. Nonwoven substrates according the present disclosure have an airflow permeation resistance of at least 13 seconds per 100 milliliters and Elmendorf tear strength of at least 400 grams in both machine direction and cross direction. Preferred substrates also have a dry process tensile strength of at least about 10,000 grams per 25 meters in the machine direction and at least about 6,000 grams per 25 millimeters in the cross direction, as measured by TAPPI T494 standard test method.
[0056] The nonwoven substrates disclosed herein are also able to withstand higher temperatures than TYVEK® and are more durable than conventional medical packaging paper, such as the medical packaging paper available from Kimberly Clark as 52# Medical Packaging Paper, Type S-60857 (“KC S-60857”). The physical properties of Examples 1 and 2 compared to similar physical properties of TYVEK® and KC S-60857 are shown in Table III.
[0000]
TABLE III
Physical Properties
TYVEK ®
KC
Properties
Units
Test Method
Example 1
Example 2
1074B
S-60857
Basis Weight
g/m 2
82.3
83.5
74
85
Ta2 Thickness
Microns
TAPPI T411
220
203
185
105
Airflow
S/100 ml
TAPPI T460
13
20
22
7
Permeation
(Gurley
Resistance
Densometer)
MD Dry
g/25 mm
TAPPI T494
12000
12500
12500
12000
Tensile
Strength
CD Dry
g/25 mm
TAPPI T494
7800
7600
14200
9000
Tensile
Strength
MD Elmendorf
g
TAPPI T414
723
712
380
100
Tear Strength
CD Elmendorf
g
TAPPI T414
650
646
430
150
Tear Strength
MD Elongation
%
TAPPI T494
19
18
24
8
CD Elongation
%
TAPPI T494
18
18
26
12
LRV
Log
ASTM F1608
2.9
N/A
5.3
2
[0057] Tests of the porosity of the top layer of Examples 1 and 2 prior to calendering show that greater than 17 liters of air flow through a square centimeter sample of the top layers per minute, as measured by the standard test method of TAPPI T251. The top layer in Example 1 has a porosity of 17.71/m/100 cm2 and the top layer in Example 2 has a porosity of 20.7 l/m/100 cm2 (untreated). This shows that the top layers provide good barrier properties even without binder treatment.
[0058] The data shows that nonwoven substrates manufactured as set forth herein are steam sterilizable and sufficiently porous to allow gases to escape, while providing adequate bacterial protection and strength. In addition to the foregoing properties, because the nonwoven substrates do not include any wood pulp, the substrates will not yellow during sterilization or ultraviolet exposure. The substrates also have good uniformity and are printable via flexographic, lithographic, offset and gravure printing methods without the need for expensive ink drying accelerants to cure the ink onto the surface. It is believed this results from the use of fibers that have inherently higher surface energy than high-density polyethylene used in TYVEK® products.
[0059] The above disclosure, embodiments and examples are illustrative only and should not be interpreted as limiting. Modifications and other embodiments will be apparent to those skilled in the art, and all such modifications and other embodiments are intended to be within the scope of the present invention as defined by the claims.
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Sterilizable and printable, wet-laid non-woven substrate exhibiting high-strength and temperature resistance above 140° C., providing sufficient airflow to relieve pressure in a package formed from the substrate during sterilization, providing a significant barrier to penetration by bacteria and debris, and which is sealable to itself and to thermoplastic films, comprises blends of nanofibrillated lyocell fibers, microfibers, fibers having a flat, rectangular cross-section and binder fibers.
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BACKGROUND OF THE INVENTION
The present invention is generally related to steam generators with lance type water cannons for cleaning heat transfer surfaces. More particularly, the present invention is directed to a method and system for controlling the positioning of the water cannon lance by measuring the angular displacements of the lance with respect to the wall on which the water cannon is mounted.
Large steam generators such as boilers have a combustion chamber and heat transfer surfaces on which soot and ash deposits build up as a result of the combustion process. The soot and ash buildup form a contamination layer on the heat transfer surfaces that reduces the heat exchange efficiency of the boiler. Some of the negative impacts of the thermal efficiency of these boilers are: (1) added fuel consumption in order to maintain the proper steam conditions that are required by the downstream processes; and (2) an increase in boiler flue gas temperature leading to increased fouling and plugging of the gas passages requiring the boiler to be taken off line to be cleaned.
In order to combat the buildup of ash, boilers are fitted with automatic cleaning devices known as soot blowers. There are many types of soot blowers based on boiler design as well as the area of the boiler that needs to be cleaned. In the case of boilers burning fossil fuels such as coal or heavy oil, there also is a need to clean the walls of the boiler in the area known as the lower furnace or hearth.
In this area of the boiler, the walls are comprised of tubes that are positioned side by side to form a box type shape. Fuel such as coal or oil is introduced into the cavity of this box (hearth) where it is burned. High pressure water flows through the inside of the tubes and is used to absorb the heat. In doing so, the water eventually picks up enough heat to be converted into steam.
Some of the residue of combustion adheres to the walls of the hearth inhibiting the transfer of heat. There are three methods in the prior art that have been used for cleaning the furnace wall: (1) traditional soot (wall) blowers containing a lance tube, and introduced through an opening in the boiler wall, eject steam/air back towards the wall; (2) water blowers that eject water back towards the wall; and (3) water cannons that eject water toward opposing or adjacent side walls.
Lance-type water cannons inserted through a front wall of the generator are used to direct a stream of fluid to clean the heat transfer surfaces. However, not all heat transfer surfaces develop an ash buildup at the same rate. Ash can accumulate more in one corner than in another. Likewise, more contamination by ash and soot can occur in one zone of a generator wall than in another zone of the same wall because of temperature differentials during the combustion process. The temperatures in some zones are higher than in others. The zones in which contaminants such as ash and soot build up more quickly require more frequent cleaning in order to retain heat exchange efficiency of the steam generator. Often sensors are installed in the furnace walls that measure the temperature or heat flux in order to determine the cleanliness of the heating surface that the water cannon is intended to keep in a clean condition. The information provided by the sensors is used in a control system to determine whether and where the water cannon shall clean.
SUMMARY OF THE INVENTION
The present invention provides a more efficient method for controlling the blower used in cleaning the ash and soot contamination off the zones where the buildup is the worst. It does this by a process of determining the appropriate angles with respect to the horizontal and to the cannon wall that correspond to the X, Y, Z coordinates of the points that bound the zone to be cleaned. The angles are measured by angular resolvers positioned at a cardan joint supporting the water cannon lance at the blower end.
The present invention provides a technique that maps any location in space to the appropriate angles that relate to the inclination of the lance with respect to the horizontal as well as the cannon wall. The angle made with the horizontal is further corrected to account for the gravitational effects on the trajectory of the water jet. In some instances both angles may have to be not only corrected for gravity but also for the influence of gas side turbulence. In this case the turbulence in the ambient flue gas deflects the jet away from the intended target. Those two angles represent the feedback provided by the X and Y resolvers for the cannon. The X and Y resolvers are positioned at the cardan joint that attaches the water cannon to the lance tube. The prior art used methods, particularly encoders, for measuring displacements in the x and y directions that related the position in space to a position on the motion wall.
In one exemplary embodiment, a method for controlling the positioning of a stream of pressurized fluid against a surface zone of a steam generator to clean contaminants is provided. The coordinates of the boundary points of the surface zone (i.e., defined area of a wall of the steam generator) to be cleaned are first determined. The coordinates are measured with respect to a fixed coordinate system such as the Cartesian coordinate system with origin point at the location where the water cannon lance penetrates the cannon wall of the steam generator. The determined boundary points are converted into corresponding angles with respect to the horizontal plane and the cannon wall (i.e., the wall of the steam generator or boiler through which the water cannon lance penetrates. These angles can be used directly to control the position of the cannon, or they can be translated into corresponding points on a motion plane defined by the prior art encoders with respect to the fixed coordinate system. The stream of pressurized fluid is directed against the surface zone in a predetermined pattern by monitoring and controlling the angle of the lance.
DESCRIPTION OF THE DRAWINGS
The invention is better understood by reading the following detailed description of an exemplary embodiment in conjunction with the accompanying drawings.
FIG. 1 illustrates a prior art example of a soot-removal blower in which encoders are used to determine distances traveled by a lance tube based on actuation of associated spindles.
FIG. 2 illustrates the placement of resolvers to measure the angular rotation of the lance tube with respect to a pair of axes.
FIG. 3 illustrates an isometric sketch of a layout for a water cannon positioned on the cannon wall while aimed at a point in space.
DETAILED DESCRIPTION OF THE INVENTION
The water cannon lance is mounted in a cardan-type (universal) joint on the cannon wall as illustrated in the prior art FIG. 1 . This particular drawing is from U.S. Pat. No. 5,882,430, which is commonly-owned with the present invention. The disclosure of this patent, in its entirety, is incorporated by reference herein. This drawing will be used as a basis for explaining the novelty of the present invention, which uses axial resolvers instead of encoders. An advantage of measuring the angles directly by resolvers is that measuring angles actually provides the state of the lance tube, whereas using the encoders of the prior art, an indirect determination of the state of the lance tube was obtained by measuring the x and y displacements.
As shown in FIG. 1 , lance 1 of the water lance blower is mounted to the opening in the steam generator wall via wall box 2 that, in turn, is attached to the wall of the combustion chamber. The lance 1 is secured in cover 2 by a universal joint 3 . The other end of lance 1 slides axially in and out of second universal joint 4 . The second universal joint 4 is attached to an alignment sleeve 5 that slides along a spindle 6 . The spindle 6 is driven by braking motor 7 . The ends of the spindle slide back and forth along two parallel spindles 8 . Braking motor 9 drives one spindle 8 directly and the other spindle 8 by way of chain 10 . The rotation of spindle 6 vertically displaces alignment sleeve 5 along with second universal joint 4 . Lance 1 will sweep along a horizontal axis, and the jet leaving lance 1 will be shifted vertically. This vertical displacement is measured by Y-encoder 14 mounted on spindle 6 . The rotation of parallel spindles 8 will similarly generate horizontal motion of spindle 6 and of the second universal joint 4 mounted thereon. Lance 1 will accordingly swing around a vertical axis, and the jet leaving lance 1 will move horizontally. This horizontal displacement is measured by X-encoder 16 mounted on one of the two spindles 8 as shown in FIG. 1 .
FIG. 2 shows a cross-sectional view of second universal joint 4 at the end of lance 1 . The present invention provides X-resolver 20 and Y-resolver 18 , which directly measure the angular rotation of the lance 1 about the horizontal and vertical axes, respectively. X-resolver 20 and Y-resolver 18 replace the X-encoder 16 and Y-encoder 14 of FIG. 1 . The housing accommodation 10 on vertical spindle 6 supports a cardan-shaped cage 11 . In its interior portion, the cage 11 can be designed as a sleeve 12 that holds the lance 1 , in an axially shiftable manner.
Resolvers measure the angular rotation of the lance. The resolvers are positioned a fixed distance from the cannon wall and measure the angle of rotation of the lance with respect to the X-Y and X-Z planes, respectively. In directing the stream of fluid against the zone to be cleaned, various patterns can be developed to cover the zone. In one exemplary embodiment, a zone is covered by following a zigzag pattern from the left edge of the zone to right edge of the zone at the highest elevation of the top boundary points and then right edge to left edge at an angle depressed a fixed amount from the initial angle, etc. until the entire zone has been covered. Regions in a zone can be excluded such as, for example, the door of the boiler, by mapping out the boundary points of the door in X, Y, Z space.
FIG. 3 shows an isometric sketch of a layout for a cannon positioned at location O on the cannon wall while being aimed at some point P′ in space. The cross section of the boiler is 2L×2W. The coordinates of the point P′ are (X p′ , Y p′ , Z p′ ). The angle that the lance makes with respect to the horizontal is β, while the angle it makes with respect to the cannon wall is θ. To compensate for the effects of gravity one would increase the value of β depending on the relative position of the target point in relation to the origin as well as the velocity of the jet at the nozzle exit. In addition to gravitational effects the trajectory of the jet can be influenced by the turbulence of the flue gas flow in the boiler. Further corrections to the inclination of the lance can be done by using the signals of the wall sensors as a feedback for the impingement location of the jet on the wall. If the effects of gravity and gas side turbulence were to be neglected, OP′ represents the path of the jet between the cannon nozzle and point P′. Point P (X p , Y p , Z p ) represents the location where line OP′ intersects with the opposite wall.
Also shown in the figure is an inclined wall representing part of the boiler nose. This wall is inclined at an angle γ with respect to the opposite wall. If necessary, point P′ could be such that OP′ never intersects the opposite wall, but instead intersects a point on either the inclined nose wall or one of the side walls of the boiler. If the inclined wall shown in the figure were facing downwards, it would represent a hopper wall.
The following represents the vector analysis for a boiler wall. Vector {overscore (OP)} represent the line of sight (water jet) from the lance tip to point P on the opposite wall.
{overscore (OP)}=X p ī+Y p {overscore (j)}+Z p {overscore (k)} (1)
ī, {overscore (j)}, and {overscore (k)} are the unit vectors, in the direction of the three axes X, Y and Z, respectively. Point E represents the location of the normal from point P to the horizontal X-Z plane. Therefore, vector {overscore (OE)} is:
{overscore (OE)}=X p ī+Z p {overscore (k)} (2)
Taking the dot product between these two vectors gives,
Cos β = OP _ · OE _ OP _ OE _ ( 3 )
Substituting equations (1) and (2) in equation (3) provides:
β = ArcCos X P 2 + Z P 2 X P 2 + Y P 2 + Z P 2 ( 4 )
In the front wall, Z p =2W, the angle β represents measurements made by the Y-axis resolver for the water cannon.
In order to determine the angle θ measured between the plane OPE and the Y-Z plane, the dot product between vector {overscore (OE)} and {overscore (OX)}={overscore (k)} is taken. The result is
Cos θ = OE _ · OZ _ OE _ ( 5 )
Substituting for {overscore ( OE )} and {overscore ( OZ )} in equation (5) gives the angle measured by the X-axis resolver for the water cannon.
θ = ArcCos ( Z P X P 2 + Z P 2 ) ( 6 )
In the case of the front wall, Z p =2W while for the side wall X p =L.
The following represents the vector analysis for the motion plane. The motion plane of the cannon is a plane parallel to the cannon plane set back by a distance of ‘b’ on the Z-axis. The equation of the motion plane is:
Z M =−b (7)
The parametric form of vector {overscore (OP)} is given by:
X=X p t, Y=Y p t and Z=Z p t (8)
If E 1 (X M , Y M , Z M ) represents the point of intersection of the vector {overscore (OP)} with the motion plane then, Z p t=−b or t=−b/Z p . Therefore,
X M = X P ( - b / Z P ) , Y M = Y P ( - b / Z P ) and Z M = - b ( 9 )
In the case of the front wall Z p =2W . Substituting this value into the above expressions yields
X M / X P = - b / 2 W and ( 10 ) Y M / Y P = - b / 2 W ( 11 )
Consider a point P on the side wall where Y p =±L If Z′ is the projection of point E′ on the OZ axis then,
Cot θ = Z P X P = ± Z P L ( 12 )
Substituting Z p from equation (12) in equation (9) provides:
X M L = - b L Cot θ ( 13 )
and
Y M Y P = - b L Cot θ ( 14 )
The angle θ has already been derived in equation (6).
As examples of the use of the invention for determining the angular rotation of the lance to direct a stream of fluid to a point in the steam generator, consider a boiler whose dimensions are 2L=150′ and 2W=100′. A water cannon is placed on the front wall at an elevation 40′ below the inclined surface of the nose. In the following examples, three cases are considered wherein a point P (X p , Y p , Z p ) lies on the boiler rear wall, side wall and inclined surface of the nose, respectively. The examples determines the angles that represent the inclination of the lance with respect to the horizontal and the boiler wall so that the lance points in the direction of point P.
Case 1—Boiler Rear Wall
Let Point P lie on the boiler rear wall where X p =−50′, Y p =25′ and Z p =2W=100′. Therefore the inclination of the lance tube β with respect to the X-Z plane is:
β = ArcCos 50 2 + 100 2 50 2 + 25 2 + 100 2 = 13 °
The angle θ made by the lance tube and the Y-Z plane is:
θ = ArcCos ( 100 50 2 + 100 2 ) = 27 °
Case 2—Boiler Side Wall
Point P lies on the side wall where X p =−75′, Y p =25′ and Z p =90′. Once again angles β and θ are calculated according to equations (4) and (6) to yield:
β = 75 2 + 90 2 75 2 + 25 2 + 90 2 = 12 ° and ,
θ = ArcCos ( 90 75 2 + 90 2 ) = 40 °
Case 3—Boiler Nose
Consider a point P that lies on the lower inclined surface of the boiler nose. The coordinates for point P are as follows: X p =50′, Y p =65′, and Z p =92′. Note that the boiler rear wall is at a distance 2W=100′. The inclinations of the lance, to the X-Z and Y-Z planes respectively, are:
β = ArcCos 50 2 + 92 2 50 2 + 65 2 + 92 2 = 32 ° and ,
θ = ArcCos ( 92 50 2 + 92 2 ) = 29 °
Those skilled in the art will appreciate that many modifications to the exemplary embodiments of the present invention are possible without departing from the spirit and scope of the present invention. In addition, it is possible to use some of the features of the present invention without the corresponding use of the other features. Accordingly, the foregoing description of the exemplary embodiments are provided for the purpose of illustrating principles of the present invention and not in limitation thereof, since the scope of the present invention is defined solely by the appended claims.
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A method for controlling the positioning of a stream of pressurized fluid against a surface zone of a stream generator to clean contaminants. The coordinates of a plurality of points of the surface zone to be cleaned are first determined. The coordinates are measured with respect to a fixed coordinate system with origin point at the location where the lance water cannon penetrates the cannon wall of the steam generator. The determined boundary points are converted into corresponding angles with respect to the horizontal plane and the cannon wall. These angles are then used directly to control the position of the lance with respect to the fixed coordinate system. The stream of pressurized fluid is directed against the surface zone in a predetermined pattern by monitoring and controlling the angle of the lance through axial resolvers.
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This is a continuation of application Ser. No. 08/298,981 filed on Aug. 31, 1994, now abandoned.
The present invention relates to production of nitrosamine-free silicone articles. More particularly, it is concerned with production of nitrosamine-free silicone articles by means of post baking in an atmosphere substantially oxygen free.
BACKGROUND OF THE INVENTION
Several reports have been published describing the presence of volatile N-nitrosamines in various rubber products. The present concern about the occurrence of volatile N-nitrosamines in baby bottle rubber nipples and the possible migration of these compounds into infant formula was prompted by a report of Preussmann et al., (1981) Am. Chem. Soc. Symp. Ser. 174, American Chemical Society, Washington, DC, p. 217.
A method was described for the estimation of volatile N-nitrosamines in the rubber nipples of babies bottles. In study of rubber nipples from one manufacturer, N-nitrosopiperidine were determined by gas chromatography, using a thermal energy analyser, and their presence was confirmed by mass spectrometry with average levels of individual nitrosamines ranging from 22 to 281 ppb. When the nipples were sterilized in a conventional sterilizer together with milk or infant formula the three nitrosamines migrated into the milk or formula. Storing a bottle of milk with a rubber nipple invertied in it for 2 hr at room temperature or overnight in a refrigerator after sterilization resulted in an 8-13% average increase in the nitrosamine levels migrating into the milk. On repeated sterilization of a single nipple, the quantities of nitrosamines migrating into milk from rubber nipples declined steadily, but after seven sterilizations, nitrosamines were still readily detectable in the milk. Nitrosamine levels were higher in rubber nipples after sterilization, indicating the presence of nitrosamine precursors in the nipples. No nitrosamines were found in raw, uncured rubber. Chemical accelerators and stabilizers added during the vulcanization process are the source of the amine precursors in rubber nipples.
On Jan. 1, 1984, the U.S. Food and Drug Administration (hereinafter "FDA") established an action level of 60 ppb total N-nitrosamines in rubber nipples. The action level was reduced to 10 ppb on Jan. 1, 1985.
A collaborative study was conducted on the FDA dichloromethane extraction method for determining volatile N-nitrosamines in baby bottle rubber nipples. Following dichloromethane extraction, N-nitrosamines were determined by gas chromatography-thermal energy analysis. Six pairs of blind duplicate rubber nipple samples representing 6 lots were analyzed by 11 collaborating laboratories. All samples were portions taken from equilibrated composites of cut-up rubber nipples obtained from manufacturers in the United States. Recoveries of the internal standard (N-nitrosodipropylamine) at approximately 20 ppb ranged from 10 to 120%. Reproducibility relative standard deviations (RSD) were between 35 and 45% for N-nitrosamine levels from 10 to 20 ppb. However, when data from laboratories with recoveries less than 75% were excluded (this is now specified in the method), RSD, values were between 11 and 32% for N-nitrosamine levels from 6 to 26 ppb. Values were consistent with or better than those reported for other analytical techniques designed to quantitate trace contaminants at the low ppb level, e.g., aflatoxin in food. The method has been adopted official first action for the quantitation of volatile N-nitrosamines in baby bottle rubber nipples. See Gas Chromatographic-Thermal Energy Analysis Method for Determination of Volatile N-Nitrosamines in Baby Bottle Rubber Nipples: Collaborative Study, by Gray & Stachiw, J. Assoc. Off. Anal. Chem. (1987) 70, March Issue.
Although research in the rubber industry has been devoted to lowering or eliminating nitrosamines, none of these studies have included silicone rubber materials. Silicone elastomeric compositions, in contrast to synthetic rubber compounds, are usually prepared from a vinyl-containing polydiorganosiloxane, an organohydrogensilicone crosslinker, and a platinum catalyst. The compositions of this type are desirable for many reasons. For instance, they cure without by-products. They can cure at room temperature or at elevated temperatures. They can be stabilized for storage at room temperature by utilization of a platinum catalyst inhibitor. And, they can be made from high and low viscosity polymers. These compositions utilize components that are low enough in viscosity that they are easily pumpable or extrudable as well as have a fast cure time. These compositions also provide cured silicone elastomers which are characterized by high strength and high durometer.
Cross-linked silicone polymers with their particularly low intermolecular interactions have low tensile strengths. Only with the addition of reinforcing fillers can high-strength silicone polymers be obtained. Particularly suitable are fumed silicas with BET surface areas of 150 to 400 m 2 /g which increase the tensile strength about 20 fold to 10-12 MPa. At the same time, viscosity is considerably increased because fumed silicas have a strong thickening effect. This effect is caused by formation of agglomerates of the primary silica particles. These agglomerates build a three-dimensional network (tertiary structure) via hydrogen bonds so that the bulk density of the fumed silica is only about 50 g/l. To produce a mixture of 40 parts silica, in 100 parts polymer therefore requires addition of 8 volume parts of filler for 1 volume part of polymer. These ratios dearly indicate the necessity of using treating agents which reduce interactions between filler agglomerates as much as possible. The most effective and most commonly used treating agents is hexamethyldisilazane (hereinafter "HMDZ"). The fillers treated with HMDZ have a considerably reduced thickening effect and therefore are particularly suitable for the use in liquid silicone rubbers.
Since silicone elastomer are entirely different polymers, these silicones became leading candidates to replace the synthetic rubber compounds, Analysis of the cured silicone elastomers showed no presence of nitrosamines. However, to applicants' surprise, upon post-baking as required by FDA, the presence of nitrosamines was detected. For silicones to serve these FDA regulated markets, a method of removing the nitrosamines must be found.
SUMMARY OF THE INVENTION
There is provided by the present invention a method for making nitrosamine-free silicone articles which comprises mixing (A) vinyl-containing organopolysiloxane; (B) silicon hydride siloxane; (C) filler and (D) a catalytic amount of a platinum group metal compound or a peroxide, and post baking the mixture in an inert atmosphere.
The critical feature that led to this invention is based on the discovery that if the post baking is carried out in an atmosphere substantially oxygen free, the resultant part is substantially free of nitrosamine.
DETAILED DESCRIPTION OF THE INVENTION
Component (A), the vinyl-containing organopolysiloxanes, generally has a viscosity of from 5,000 to 1,000,000 centipoise at 25° C. The preferred vinyl-containing organopolysiloxanes are be vinyl-stopped polymer having the general formula M Vi D x M Vi , vinyl-on-chain copolymers such as MD Vi x D y M, vinyl-stopped, vinyl-on-chain copolymers such as M Vi D x D Vi y M Vi , vilyl and trimethylsilyl-stopped copolymers such as MD x M Vi , or a mixture thereof, wherein Vi represents a vinyl radical, M represents a trimethylsiloxy radical, M Vi represents dimethylvinylsiloxy, D is dimethylsiloxy. Such polymers are taught by U.S. Pat. Nos 5,082,886, 4,340,709, 3,884,866 issued to Jeram et al., U.S. Pat. No. 5,331,075 issued to Sumpter et al., U.S. Pat. No. 4,162,243 issued to Lee et al., U.S. Pat. No. 4,382,057 issued to Tolentino, and U.S. Pat. No. 4,427,801 issued to Sweet, hereby incorporated by reference.
Component (B), the silicon hydride siloxane or silicon hydride siloxane fluid used in the invention can have about 0.04 to about 1.4% by weight of chemically combined hydrogen attached to silicon. One form of the silicon hydride siloxane is a "coupler" having the formula, ##STR1## where R 1 is selected from C 1-13 monovalent hydrocarbon radicals free of olefinic unsaturation and n is an integer having a value sufficient to provide the "coupler" with a viscosity of 1 to 500 centipoises at 25° C. and from about 3 to 9 mole percent of chain-stopping diorganohydride siloxy units, based on the total moles of chemically combined siloxy units in the silicon hydride siloxane fluid.
In addition fo the silicone hydride coupler of formula (1), the silicon hydride siloxane fluid used in the heat curable organopolysiloxane compositions of the present invention also can include silicon hydride resins consisting essentially of the following chemically combined units, ##STR2## chemically combined with SiO 2 units, where the R 2 +H to Si ratio can vary from 1.0 to 2.7. Silicon hydride resin also can have units of the formula, ##STR3## chemically combined with SiO 2 units and (R 4 ) 2 SiO units, where the R 3 +R 4 +H to Si ratio can vary from 1.2 to 2.7, where R 2 , R 3 and R 4 are C 1-13 monovalent hydrocarbon radicals free of olefinic unsaturation selected from R 1 radicals.
The silicon hydride siloxane fluid also can include linear hydrogen containing polysiloxane having the formula, ##STR4## where R 5 is a C 1-13 monovalent hydrocarbon radical free of olefinic unsaturation, selected from R 1 radicals, and p and q are integers having values sufficient to provide a polymer having a viscosity of from 1 to 1,000 centipoises at 25° C.
In formulas (1) and (2) and the chemically combined units described above, R 1 , R 2 , R 3 , R 4 and R 5 can be the same or different radicals selected from the group consisting of alkyl radicals of 1 to 8 carbon atoms, such as methyl, ethyl, propyl, etc.; cycloalkyl radicals such as cyclohexyl, cycloheptyl, etc.; aryl radicals such as phenyl, tolyl, xylyl, etc.; and haloalkyl radicals such as 3,3,3-trifuloropropyl.
Component (C), the filler is any reinforcing or extending filler known in the prior art. In order to get the high tensile strength, for example, a reinforcing filler is incorporated. Illustrative of the many reinforcing fillers which can be employed are titanium dioxide, lithopone, zinc oxide, zirconium silicate, silica aerogel, iron oxide, diatomaceous earth, calcium carbonate, fumed silica, silazane treated silica, precipitated silica, glass fibers, magnesium oxide, chromic oxide, zirconium oxide, aluminum oxide, alpha quartz, calcined clay, asbestos, carbon, graphite, cork, cotton, synthetic fibers, etc.
Preferably, the filler is either a fumed or precipitated silica that has been treated. The treating process may be done in accordance with the teachings of U.S. Pat. No. 4,529,774 issued to Evans et al., U.S. Pat. No. 3,635,743 issued to Smith, U.S. Pat. No. 3,847,848 issued to Beers; hereby incorporated by reference, Alternatively, and most preferably, the filler is treated in-situ; that is the untreated silica filler and the treating agents are added to the silicone elastomer composition separately, and the treatment process is accomplished simultaneously with the mixture of the filler into the elastomer. This in-situ process is taught by Evans in U.S. Pat. No. 4,529,774; hereby incorporated by reference.
Alternatively, the fillers can be replaced by the vinyl treated silica filler of U.S. Pat. No. 4,162,243 issued to Lee et al.; and U.S. Pat. No. 4,427,801 issued to Sweet; hereby incorporated by reference.
Component (D), the catalyst, is any compound that promotes the hydrosilation reaction between a silicon hydride and an ethylenically unsaturated polyorganosiloxane. Typically, it is a precious metal compound; usually platinum. Such catalysts are well known in the art. Preferred catalysts are taught by in U.S. Pat. Nos. 3,917,432, 3,197,433 and 3,220,972 issued to Lamoreaux, U.S. Pat. Nos. 3,715,334 and 3,814,730 issued to Karstedt, and U.S. Pat. No. 4,288,345 issued to Ashby et al., hereby incorporated by reference.
Alternatively, the catalyst can be a peroxide or it can be a combination of peroxides comprising a low temperature peroxide and a high temperature peroxide.
Since mixtures containing Components A, B, and C with the catalyst, Component D, may begin to cure immediately on mixing at room temperature, it may be desirable to inhibit the action of the catalyst at room temperature with a suitable inhibitor if the composition is to be stored before molding. Platinum catalyst inhibitors are used to retard the catalytic activity of the platinum at room temperature, but allow the platinum to catalyze the reaction between Components A, B and C at elevated temperature.
One suitable type of platinum catalyst inhibitor is described in U.S. Pat. No. 3,445,420 issued to Kookootsedes et al. which is hereby incorporated by reference to show certain acetylenic inhibitors and their use. A preferred class of acetylenic inhibitors are the acetylenic alcohols, especially 2-methyl-3-butyn-2-ol.
A second type of platinum catalyst inhibitor is described in U.S. Pat. No. 3,989,667 issued to Lee et al. which is hereby incorporated by reference to show certain olefinic siloxanes, their preparation and their use as platinum catalyst inhibitors.
A third type of platinum catalyst inhibitor is a polymethylvinylcyclosiloxane having three to six methylvinylsiloxane units per molecule.
The optimum concentration of platinum catalyst inhibitor is that which will provide the desired storage stability at ambient temperature without excessively prolonging the time interval required to cure the compositions at elevated temperatures. This amount will vary widely and will depend upon the particular inhibitor that is used, the nature and concentration of platinum-containing catalyst and the nature of the organohydrogensiloxane.
Compositions of the present invention can be used in a liquid injection molding process in which the composition is injected into light weight molds under low pressures, such as 600 kPa cylinder pressure. Such compositions can be cured very rapidly in a hot mold and removed without cooling the mold. The type of molding, extruding or curing process used is not narrowly critical and can include those known in the art. An advantage of the compositions of this inventions is the extrudability which makes it adaptable to molding processes such as liquid injection molding at low pressures. The prepared compositions have a viscosity such that at least 45 grams per minute can be extruded through a 3.175 millimeter orifice under a pressure of 620 kilopascals. Preferably, the viscosity is such that at least 50 grams per minute can be extruded.
The silicone elastomeric compositions can readily be prepared in conventional mixing equipment because of its fluid nature. The order of mixing is not critical if the composition is to be used immediately. However, it is preferable to combine (A), (C) and (D) and thereafter add (B). This permits the small amount of (D) to become well dispersed in (A) and (C) prior to the beginning of any curing reaction. Suitable two package composition can be made using such as technique. For example, a convenient two package composition can be prepared by mixing part of (A), part of (C) and all of (D) in one package and the remainder of (A) and (C) and all of (B) in a second package such that equal amounts of package one and package two can be mixed to produce the compositions of this invention. Single package compositions can be prepared by mixing (A),(B), (C), (D), and a platinum catalyst inhibitor. These inhibited compositions can be stored for extended periods of time without curing, but the compositions will still cure when heated above 70° C., preferably when heated above 100° C. to shorten the cure time.
The cured silicone elastomers obtained from the compositions are then post baked in an atmosphere substantially oxygen free. What is meant by substantially oxygen free is that the atmosphere is generally less than 15% oxygen and preferably less than 10%. In one embodiment, the cured silicone elastomers are post baked in an inert atmosphere comprises He, N 2 , argon, CO 2 , CH 4 and a mixture thereof. Alternatively, the cured silicone elastomers are post baked in a vacuum system. The cured silicone elastomers are post baked at temperatures from 300° to 450° F. for 0.3 to 5 hours, preferably 325° to 425° F. for 0.5 to 4 hours, and most preferably at 400° F. for 1 hour.
In order to demonstrate various features of this invention, the following examples are submitted. They are for illustrative purposes and are not intended to limit in any way the scope of this invention.
EXAMPLE 1 Test Specimen Preparation
A silicone LIM base compound was prepared according to the teachings of this invention using the formulation of Table I.
TABLE I______________________________________64.5 pts 40,000 cps vinyl chainstopped polydimethylsiloxane polymer25 pts 325 m.sup.2 /gm octamethylcyclotetrasiloxane treated fumed silica1 pt vinyltriethoxysiloxane6 pts hexamethyldisilazane6 pts water4 pts 500 cps vinyl chainstopped, polydimethyl, methylvinyl copolymer4 pts 500 cps trimethylsilyl and dimethylvinyl chainstopped polydi- methylsiloxane polymer2.5 pts MQ resin______________________________________
The 40,000 cps vinyl chainstopped polymer, water and hexamethyldisfiazane were mixed together in a cooled mixer. The 325 m 2 /gm D 4 treated filler was added slowly into the mixture and mixed until it was completely incorporated. The vinyltriethoxysfiane was added into the mixture and mixed well. The mixer was sealed and heated for one hour at 70°-80° C. The batch was stripped at 140° C. under full vacuum to remove all the filler treating reaction by products. The mixture was 80° C. and added the two 500 cps vinyl containing copolymers and mixed well. 2.5 parts of the MQ resin release agent was added. Pulled vacuum to deair the batch.
Component A was prepared by adding sufficient amount of Karstedt platinum organosiloxane complex to obtain 20-40 ppm Pt as platinum. Component B was prepared by adding approximately 330 ppm H of hydride crosslinker (M H D x D y H M H ) and approximately 0.4 parts methyl butynol, mixed until well dispersed. A LIM composition was prepared by mixing 100 parts of component A with 100 parts of component B in a static mixer with no air being introduced. The A/B mixture was then molded 20 seconds at 375° F. into 3"×5"×0.070" sheets. The as molded sheet has less than 1.0 ppb DMNA.
EXAMPLE 2 Post Baking in Air
Sheet #1 was post baked for one hour @ 400° in an air circulating oven and cooled to room temperature. The sample was referred to as PBO. Sheet #2 was wrapped in aluminum foil and post baked under the same conditions. The sample was referred to as PBS. The results are shown below:
______________________________________ Sheet #1 Sheet #2 PBO PBS 1 hr @ 400° F. 1 hr @ 400° F.______________________________________Standard Formulation (Control) 4.0 ppb DMNA 42.8 ppb DMNAPost Baked in Air______________________________________ DMNA = dimethyl nitrosamine
The results clearly indicate that there was no nitrosamines in molded LIM compositions. The nitrosamine only occurred when post baked in air at 400° F. for an hour. The nitrosamines generated were volatilized when post baked open and trapped when post baked sealed.
EXAMPLE 3 Post Baking in Helium Atmosphere
Same components A and B were mixed as described in the above Example 2, except the post bake 1 hr @ 400° F. was performed in a Helium atmosphere oven.
______________________________________ PBO PBS 1 hr @ 400° F. 1 hr @ 400° F.______________________________________Standard Formulation (Control) <1.0 ppb DMNA 2.9 ppb DMNA*Post Baked in He Environment______________________________________ *The low 2.9 ppb DMNA is probably due to some air that may have been trapped in the sealed sample.
The results indicate that post baking in He essentially eliminates the DMNA.
EXAMPLE 4 Post Baking in Nitrogen Atmosphere
Same components A and B were mixed as described in the above Example 2, except the post bake 1 hr @ 400° F. was performed in a nitrogen atmosphere oven.
______________________________________ PBO PBS 1 hr @ 400° F. 1 hr @ 400° F.______________________________________Standard Formulation (Control) <1 ppb DMNA <1 ppb DMNAPost Baked in nitrogen Environment______________________________________
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The present invention relates to a method for making nitrosamine-free silicone articles by post baking in an inert atmosphere.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation-in-part of:
(a) U.S. patent application Ser. No. 12/983,409, filed Jan. 3, 2011, which is a continuation of U.S. patent application Ser. No. 12/052,788, filed Mar. 21, 2008, now abandoned, which is a divisional of U.S. patent application Ser. No. 11/349,020, filed Feb. 7, 2006, now U.S. Pat. No. 7,561,919, which is a continuation-in-part of U.S. patent application Ser. No. 10/783,113, filed Feb. 20, 2004, now U.S. Pat. No. 7,117,033; and
(b) U.S. patent application Ser. No. 13/849,673, filed Mar. 25, 2013, which is a divisional of U.S. patent application Ser. No. 13/223,929, filed Sep. 1, 2011, now U.S. Pat. No. 8,406,869, which is a divisional of U.S. patent application Ser. No. 11/465,381, filed Aug. 17, 2006, now U.S. Pat. No. 8,055,347, which claims the benefit of U.S. Provisional Patent Application 60/709,734, filed Aug. 19, 2005.
All of the above-mentioned patent applications are assigned to the assignee of the present application and are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to medical procedures and devices, e.g., electrical devices. More specifically, the invention relates to the use of electrical devices for implantation in the head, for example, in the nasal cavity, and/or to the use of stimulation for treating medical conditions.
BACKGROUND OF THE INVENTION
The blood-brain barrier (BBB) is a unique feature of the central nervous system (CNS) which isolates the brain from the systemic blood circulation. To maintain the homeostasis of the CNS, the BBB prevents access to the brain of many substances circulating in the blood.
The BBB is formed by a complex cellular system of endothelial cells, astroglia, pericytes, perivascular macrophages, and a basal lamina. Compared to other tissues, brain endothelia have the most intimate cell-to-cell connections: endothelial cells adhere strongly to each other, forming structures specific to the CNS called “tight junctions” or zonula occludens. They involve two opposing plasma membranes which form a membrane fusion with cytoplasmic densities on either side. These tight junctions prevent cell migration or cell movement between endothelial cells. A continuous uniform basement membrane surrounds the brain capillaries. This basal lamina encloses contractile cells called pericytes, which form an intermittent layer and probably play some role in phagocytosis activity and defense if the BBB is breached. Astrocytic end feet, which cover the brain capillaries, build a continuous sleeve and maintain the integrity of the BBB by the synthesis and secretion of soluble growth factors (e.g., gamma-glutamyl transpeptidase) essential for the endothelial cells to develop their BBB characteristics.
PCT Publication WO 01/85094 and U.S. Pat. Nos. 7,120,489 and 7,190,998 to Shalev and Gross, which are assigned to the assignee of the present patent application and are incorporated herein by reference, describe apparatus for modifying a property of a brain of a patient, including electrodes applied to a sphenopalatine ganglion (SPG) or a neural tract originating in or leading to the SPG. A control unit drives the electrodes to apply a current capable of inducing (a) an increase in permeability of a blood-brain barrier (BBB) of the patient, (b) a change in cerebral blood flow of the patient, and/or (c) an inhibition of parasympathetic activity of the SPG.
U.S. Pat. No. 6,853,858 to Shalev, which is assigned to the assignee of the present application and is incorporated herein by reference, describes apparatus for delivering a Non Steroidal Anti-Inflammatory Drug (NSAID) supplied to a body of a subject for delivery to at least a portion of a central nervous system (CNS) of the subject via a systemic blood circulation of the subject. The apparatus includes a stimulator adapted to stimulate at least one site of the subject, so as to cause an increase in passage of the NSAID from the systemic blood circulation across a blood brain barrier (BBB) of the subject to the portion of the CNS, during at least a portion of the time that the NSAID is present in the blood, the site selected from the list consisting of: a sphenopalatine ganglion (SPG), an anterior ethmoidal nerve, a posterior ethmoidal nerve, a communicating branch between an anterior ethmoidal nerve and a retro-orbital branch of an SPG, a communicating branch between a posterior ethmoidal nerve and a retro-orbital branch of an SPG, a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, a nasopalatine nerve, a posterior nasal nerve, an infraorbital nerve, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve.
US Patent Application Publication 2004/0220644 to Shalev et al, which is assigned to the assignee of the present application and is incorporated herein by reference, describes a method for treating a subject, comprising positioning at least one electrode at at least one site of the subject for less than about 3 hours, applying an electrical current to the site of the subject, and configuring the current to increase cerebral blood flow (CBF) of the subject, so as to treat a condition of the subject. The site is selected from the list consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve. Also described is an apparatus comprising an elongated support element having a length of between about 1.8 cm and about 4 cm, and having a proximal end and a distal end; one or more electrodes fixed to the support element in a vicinity of the distal end thereof; a receiver, fixed to the support element in a vicinity of the proximal end thereof; and a control unit, adapted to be coupled to the receiver, and adapted to drive the electrodes to apply an electrical current to tissue of the subject, and configure the current to have a pulse frequency of between about 10 Hz and about 50 Hz, an amplitude of between about 0.2 V and about 10 V, a pulse width of between about 50 microseconds and about 5 milliseconds, and, in alternation, on periods of between about 1 second and about 2 minutes, and off periods of between about 1 second and about 2 minutes.
The following patent application publications, all of which are assigned to the assignee of the present application and are incorporated herein by reference, may be of interest: WO 03/090599, WO 03/105658, WO 04/044947, WO 04/043217, WO 04/043334, and WO 05/030118.
US Patent Application Publication 2003/0176898 to Gross et al., which is assigned to the assignee of the present application and is incorporated herein by reference, describes apparatus for treating a condition of an eye of a subject, comprising a stimulator adapted to stimulate at least one site of the subject, such as the SPG, so as to treat the eye condition.
US Patent Application Publication 2005/0159790 to Shalev, which is assigned to the assignee of the present application and is incorporated herein by reference, describes a method for facilitating a diagnosis of a condition of a subject, including applying a current to a site of the subject, such as the SPG, and configuring the current to increase conductance of molecules from brain tissue of the subject through a blood brain barrier (BBB) of the subject into a systemic blood circulation of the subject. The method also includes sensing a quantity of the molecules from a site outside of the brain of the subject, following initiation of application of the current.
US Patent Application Publication 2005/0266099 to Shalev, which is assigned to the assignee of the present application and is incorporated herein by reference, describes a method for modifying a property of a brain of a patient includes presenting an odorant to an air passage of the patient, the odorant having been selected for presentation to the air passage because it is such as to increase conductance of molecules from a systemic blood circulation of the patient through a blood brain barrier (BBB) of the brain into brain tissue of the patient. The molecules are selected from the group consisting of: a pharmacological agent, a therapeutic agent, an endogenous agent, and an agent for facilitating a diagnostic procedure.
PCT Publication WO 04/010923 to Gross et al., which is assigned to the assignee of the present application and is incorporated herein by reference, describes a chemical agent delivery system, including a chemical agent supplied to a body of a subject for delivery to a site in a central nervous system of said subject via blood of said subject; and a stimulator for stimulating parasympathetic fibers associated with the SPG, thereby rendering a blood brain barrier (BBB) of said subject permeable to said chemical agent during at least a portion of the time that said chemical agent is present in said blood.
PCT Publication WO 04/043218 to Gross et al., which is assigned to the assignee of the present application and is incorporated herein by reference, describes apparatus for treating a subject, including (a) a stimulation device, adapted to be implanted in a vicinity of a site selected from the list consisting of: a SPG and a neural tract originating in or leading to the SPG; and (b) a connecting element, coupled to the stimulation device, and adapted to be passed through at least a portion of a greater palatine canal of the subject.
PCT Publication WO 04/045242 to Shalev, which is assigned to the assignee of the present application and is incorporated herein by reference, describes apparatus for treating a condition of an ear of a subject, comprising a stimulator adapted to stimulate at least one site of the subject, such as the SPG, at a level sufficient to treat the ear condition.
PCT Publication WO 05/030025 to Shalev et al., which is assigned to the assignee of the present application and is incorporated herein by reference, describes apparatus for treating a subject, including an elongated generally rigid support element having a length of at least 1.8 cm, and having a distal end. The apparatus also includes one or more electrodes fixed to the support element in a vicinity of the distal end thereof, and configured to be positioned in a vicinity of a site of the subject, such as the SPG, when the support element is inserted into a body of the subject, such that a portion of the support element remains outside of the body. The apparatus further includes a control unit, coupled to the support element, and adapted to drive the electrodes to apply an electrical current to the site, and to configure the current to increase cerebral blood flow (CBF) of the subject, so as to treat a condition of the subject.
U.S. Pat. No. 6,526,318 to Ansarinia and related PCT Publication WO 01/97905 to Ansarinia, which are incorporated herein by reference, describe a method for the suppression or prevention of various medical conditions, including pain, movement disorders, autonomic disorders, and neuropsychiatric disorders. The method includes positioning an electrode on or proximate to at least one of the patient's SPG, sphenopalatine nerves, or vidian nerves, and activating the electrode to apply an electrical signal to such nerve. In a further embodiment for treating the same conditions, the electrode used is activated to dispense a medication solution or analgesic to such nerve.
U.S. Pat. No. 6,405,079 to Ansarinia, which is incorporated herein by reference, describes a method for the suppression or prevention of various medical conditions, including pain, movement disorders, autonomic disorders, and neuropsychiatric disorders. The method includes positioning an electrode adjacent to or around a sinus, the dura adjacent a sinus, or falx cerebri, and activating the electrode to apply an electrical signal to the site. In a further embodiment for treating the same conditions, the electrode dispenses a medication solution or analgesic to the site.
U.S. Pat. No. 6,788,975 to Whitehurst et al., which is incorporated herein by reference, describes an implantable stimulator with at least two electrodes that is small enough to have the electrodes located adjacent to a nerve structure at least partially responsible for epileptic seizures. The nerve structure may include a trigeminal ganglion or ganglia, a trigeminal nerve, or a branch of a trigeminal nerve, a greater occipital nerve, lesser occipital nerve, third occipital nerve, facial nerve, glossopharyngeal nerve, or a branch of any of these neural structures. Electrical stimulation of such targets may provide significant therapeutic benefit in the management of epilepsy.
U.S. Pat. No. 5,716,377 to Rise et al., which is incorporated herein by reference, describes techniques for stimulating the brain to treat movement disorders resulting in abnormal motor behavior by means of an implantable signal generator and electrode. A sensor is used to detect the symptoms resulting from the motion disorder. A microprocessor algorithm analyzes the output from the sensor in order to regulate the stimulation delivered to the brain.
U.S. Pat. No. 6,415,184 to Ishikawa et al., which is incorporated herein by reference, describes a ball semiconductor for stimulating a mass of nervous system brain tissue for therapeutic purposes. The ball is embedded in a mass of nervous system tissue of a brain. Electrical pulses generated and transmitted to the ball by a remote electrical pulse generator system are picked up by a receiving antenna of the ball, and are applied to an electrode pair of the ball to cause the mass of nervous system tissue of the brain located between output pads of the electrode to become stimulated, as therapy for a pathological condition, such as epilepsy.
U.S. Pat. No. 6,606,521 to Paspa et al., which is incorporated herein by reference, describes an implantable medical lead having markings, which aid in the accurate localization of lead electrodes at a specific point of the brain for neurostimulation. Also described is an implantable medical lead having a removable extension that provides a minimal length of excess lead protruding from the lead insertion site. The lead and method of implantation facilitate use of a neurostimulator device that is implanted directly in a patient's cranium.
U.S. Pat. No. 6,591,138 to Fischell et al., which is incorporated herein by reference, describes a system for treating neurological conditions by low-frequency time varying electrical stimulation. The system includes an electrical device for applying such low-frequency energy, in a range below approximately 10 Hz, to the patient's brain tissue. An implantable embodiment applies direct electrical stimulation to electrodes implanted in or on the patient's brain, while a non-invasive embodiment causes a magnetic field to induce electrical currents in the patient's brain.
U.S. Pat. No. 6,343,226 to Sunde et al., which is incorporated herein by reference, describes a quadripolar deep brain stimulation electrode for treating symptoms of central and peripheral nervous system disorders, such as Parkinson's disease, epilepsy, psychiatric illness, and intractable pain. It is important to determine the optimal placement of an implanted electrode. An electrode device is described that allows stimulation of a large volume of neural tissue in combination with simultaneous microelectrode recording. The device is described as allowing for a less traumatic localization of the optimal neural stimulation area by microelectrode recording in combination with the placement of the permanent deep brain stimulation electrode.
US Patent Application Publication 2005/0065427 to Magill et al., which is incorporated herein by reference, describes a method for locating the position of a selected neural center in the central nervous system, including stimulating neurons at a first central nervous system position, measuring the field potential evoked at a second central nervous system position, and comparing the evoked field potential against a known evoked field potential from said neural center.
US Patent Application Publication 2005/0113877 to Spinelli et al., which is incorporated herein by reference, describes implantable devices and methods for treating various disorders of the pelvic floor by means of electrical stimulation of the pudendal or other nerves. Neurophysiological monitoring is utilized to assess the evoked responses of the pudendal nerve, and thereby to provide a method for determining the optimal stimulation site.
U.S. Pat. No. 5,314,495 to Kovacs, which is incorporated herein by reference, describes a microelectrode interface for localizing the stimulation and recording of action potentials at a portion of a nervous system. A circuit is described for applying current only to one or more selected pairs of microelectrodes in an array of microelectrodes. Row and column select lines, switches and multiplexes are used for passing current only between pairs of microelectrodes at selected locations in the array for stimulating a portion of a nervous system only at selected locations.
U.S. Pat. No. 6,432,986 to Levin and PCT Publication WO 99/03473 to Levin, which are incorporated herein by reference, describe techniques for inhibiting a cerebral neurovascular disorder or a muscular headache. The techniques include intranasally administering a pharmaceutical composition comprising a long-acting local anesthetic.
U.S. Pat. No. 6,491,940 to Levin, US Patent Application 2003/0133877 to Levin, and PCT Publication WO 00/44432 to Levin, which are incorporated herein by reference, describe techniques for inhibiting a cerebral neurovascular disorder or a muscular headache. The techniques include intranasally administering a pharmaceutical composition comprising a long-acting local anesthetic. Apparatus for delivering or applying the composition is also described.
US Patent Application 2001/0004644 to Levin and PCT Publication WO 01/43733 to Levin, which are incorporated herein by reference, describe techniques for inhibiting cephalic inflammation, including meningeal inflammation and cerebral inflammation. The techniques include intranasally administering a long-acting local anesthetic. Apparatus for delivering or applying the composition is also described, including a dorsonasally implanted electronic neural stimulator, such as a transepithelial neural stimulation device.
The following patents and patent application publications, all of which are incorporated herein by reference, may be of interest: U.S. Pat. No. 5,756,071 to Mattern et al., U.S. Pat. No. 5,752,515 to Jolesz et al., PCT Publications WO 03/084591, WO 03/020350, WO 03/000310, WO 02/068031, and WO 02/068029 to Djupesland, US Patent Application Publication 2003/0079742 to Giroux, U.S. Pat. Nos. 5,725,471 and 6,086,525 to Davey et al., PCT Publication WO 02/32504 to Zanger et al., US Patent Application Publication 2003/0050527 to Fox et al., U.S. Pat. No. 6,432,986 to Levin, PCT Publication WO 99/03473 to Levin, U.S. Pat. No. 6,491,940 to Levin, US Patent Application 2003/0133877 to Levin, and PCT Publication WO 00/44432 to Levin, US Patent Application 2001/0004644 to Levin, PCT Publication WO 01/43733 to Levin, U.S. Pat. No. 4,867,164 to Zabara, U.S. Pat. Nos. 6,341,236 and 6,671,556 to Osorio et al., U.S. Pat. No. 6,671,555 to Gielen et al., U.S. Pat. No. 5,978,702 to Ward et al., U.S. Pat. No. 6,205,359 to Boveja, U.S. Pat. No. 6,470,212 to Weijand et al., U.S. Pat. No. 6,640,137 to MacDonald, U.S. Pat. No. 6,735,475 to Whitehurst et al., PCT Publication WO 01/97906 to Whitehurst, U.S. Pat. No. 6,922,590 to Whitehurst, PCT Publication WO 05/062829 to Whitehurst et al., and US Patent Application Publication 2005/0154419 to Whitehurst et al.
Hotta H et al., in an article entitled, “Effects of stimulating the nucleus basalis of Meynert on blood flow and delayed neuronal death following transient ischemia in rat cerebral cortes,” Jap J Phys 52:383-393 (2002), which is incorporated herein by reference, report that stimulation of the nucleus basalis of Meynert (NBM) in the rat was accompanied by vasodilatation and increase in cortical blood flow. They suggest that NBM-originating vasodilative activation can protect the ischemia-induced delayed death of cortical neurons by preventing a blood flow decrease in widespread cortices.
Reis D J et al., in an article entitled, “Electrical stimulation of cerebellar fastigial nucleus reduces ischemic infarction elicited by middle cerebral artery occlusion in rat,” J Cereb Blood Flow Metab 11(5):810-8 (1991), which is incorporated herein by reference, report that electrical stimulation of the cerebellar fastigial nucleus (FN) profoundly increases cerebral blood flow via a cholinergic mechanism. Utilizing the rat middle cerebral artery occlusion (MCAO) model, they demonstrated that one hour of electrical stimulation of the FN has the capacity to substantially reduce the infarct size at the rim of the cortex dorsal and ventral to the infarction, and medially within the thalamus and striatum corresponding to the penumbral zone. They conclude that excitation of an intrinsic system in brain represented in the rostral FN has the capacity to substantially reduce an ischemic infarction.
Matsui T et al., in an article entitled, “The effects of cervical spinal cord stimulation (cSCS) on experimental stroke,” Pacing Clin Electrophysiol 12(4 Pt 2):726-32 (1989), which is incorporated herein by reference, report that cSCS increases regional cerebral blood flow, and, in a cat middle cerebral artery occlusion model (MCAO), reduced the rate of death within 24 hours after MCAO.
Segher O et al., in an article entitled, “Spinal cord stimulation reducing infract volume in model of focal cerebral ischemia in rats,” J Neurosurg 99(1):131-137 (2003), which is incorporated herein by reference, demonstrate that spinal cord stimulation increases cerebral blood flow in rats and significantly reduces stroke volume, suggesting that spinal cord stimulation could be used for treatment and prevention of stroke.
The following references, which are incorporated herein by reference, may be useful:
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SUMMARY OF THE INVENTION
In some embodiments of the present invention, a neural stimulation system comprises an implantable neural stimulator, an oral element, and an external control unit. The neural stimulator comprises an elongated support element, one or more electrodes fixed to the support element in a vicinity of a distal end thereof, and a wireless coupling element physically attached to the support element, e.g., in a vicinity of a proximal end thereof. The stimulator is adapted to be passed through a greater palatine foramen of a palate of an oral cavity of a subject into a greater palatine canal, such that the electrodes are brought into a vicinity of a sphenopalatine ganglion (SPG). For some applications, the stimulator comprises a locking element, which is adapted to hold the stimulator in place after implantation.
In some embodiments of the present invention, the distal end of the support element comprises a surgical punch, which enables the stimulator to be passed through the palate in a minimally-invasive procedure, without requiring a prior surgical incision in the mucosa. The wireless coupling element is sufficiently small so as to be able to pass through the punch incision without requiring the incision to be surgically enlarged. The use of the punch to insert the stimulator, rather than a more complicated surgical procedure, generally allows the stimulator to be quickly implanted in the subject.
The oral element of the system is adapted to be placed in the oral cavity, e.g., in a vicinity of or in contact with the roof of the oral cavity or the alveolar process of the maxilla, in a vicinity of the implanted wireless coupling element of the stimulator. The oral element comprises a power source, such as a rechargeable or disposable battery, and at least one wireless coupling element. The wireless coupling element of the oral element is adapted to wirelessly transmit energy to the wireless coupling element of the stimulator, for powering the stimulator. For some applications, the wireless coupling element of the oral element is additionally configured to transmit and/or receive data to/from the wireless coupling element of the stimulator. For some applications, the oral element transmits/receives data to/from the external control unit. Alternatively, the stimulator transmits/receives data directly to/from the external control unit.
In some embodiments of the present invention, a neural stimulation system comprises an implantable neural stimulator and an external control unit. The neural stimulator comprises an elongated support element, one or more electrodes fixed to the support element in a vicinity of a distal end thereof, and an implantable antenna coupled to the support element in a vicinity of a proximal end thereof. The support element is adapted to be passed through a palate of an oral cavity of a subject into a greater palatine canal, such that the electrodes are brought into a vicinity of a SPG. For some applications, the implantable antenna comprises a submucosal antenna comprising a thin, flexible sheet comprising at least one coil. The submucosal antenna is adapted to be implanted in the roof of the oral cavity between the oral mucosa and the palate, e.g., the hard palate, and to conform to the shape of the palate. For other applications, the implantable antenna comprises a coil antenna, which is coiled around at least a portion of the support element. In these embodiments, the system typically lacks an oral element. Instead, the external control unit is adapted to transmit power directly (typically as radiofrequency (RF) energy) to the submucosal antenna of the stimulator, and to transmit and/or receive data directly to/from the submucosal antenna. Typically, the external control unit is adapted to be placed in a vicinity of a head of the subject, such as in a vicinity of an ear of the subject, e.g., coupled to the ear.
In some embodiments of the present invention, the one or more electrodes of the stimulator comprise an array of electrodes, at least a portion of which are adapted to be separately activatable. After the stimulator has been implanted, the stimulation system uses a calibration algorithm to activate, during a plurality of calibration periods, respective different sets of one or more of the electrodes, in order to determine which set's activation causes a level of stimulation of the SPG closest to a desired level. Use of such an algorithm generally obviates the need to adjust the location of the stimulator after it has been implanted. For some applications, the level of stimulation of the SPG is determined by receiving feedback directly from the SPG, or from other neural tissue in a vicinity of the SPG, i.e., by using at least a portion of the electrodes to directly measure a level of stimulation of the SPG or the other neural tissue at or in a vicinity of the site(s) of the stimulation by the electrodes. Alternatively, the level of stimulation of the SPG is determined by assessing an indirect physiological parameter of the subject related to the level of SPG stimulation, such as cerebral blood flow (CBF).
In some embodiments of the present invention, the elongated support element of the stimulator has a length of between about 1.8 and about 4 cm, such as between about 1.8 cm and about 3 cm, e.g., between about 2.6 and about 3 cm, such as about 2.8 cm, and/or has a curvature that follows that of the greater palatine canal.
For some applications, treatment with the systems described herein is applied as soon as possible after diagnosis of the condition, such as in an emergency room or wherever the subject happens to be. For other applications, the system is appropriate for longer-term treatment, such as for modulating the permeability of the BBB, modulating cerebral blood flow (CBF), rehabilitation after brain events, or prevention and/or treatment of epilepsy. For some applications, the stimulator is adapted to be implanted for at least one week, e.g., at least one month, while for other applications, the stimulator is adapted to be implanted for less than one week, e.g., less than one day.
In some embodiments of the present invention, an electrical stimulator drives current into at least one “modulation target site” (MTS), as defined hereinbelow. Typically, the stimulator drives the current in order to control and/or modify SPG-related behavior, e.g., in order to induce changes in cerebral blood flow and/or to modulate permeability of the blood-brain barrier (BBB). Concurrently with or after placement of the stimulator near or in contact with an MTS, at least one physiological indicator of cerebral blood flow (CBF) is observed or measured. Optimization of placement of the stimulator onto the appropriate neural structure is performed by activating the stimulator, and generally simultaneously monitoring CBF while manipulating the placement of the stimulator so as to increase or decrease CBF, as appropriate. Alternatively or additionally, a similar optimization process is performed, either during or after implantation of the stimulator, to determine parameters of the applied current that achieve a desired effect, as indicated by CBF.
In some embodiments of the present invention, an electrical stimulation system is provided for the treatment of an adverse brain condition, such as an adverse cerebrovascular condition, e.g., an ischemic event. The system is configured to apply excitatory electrical stimulation to at least one “modulation target site” (MTS), as defined hereinbelow, such as a sphenopalatine ganglion (SPG). The system configures the stimulation to dilate cerebral vessels, thereby increasing cerebral blood flow (CBF) to affected brain tissue and tissue in a vicinity thereof, and/or to induce the release of one or more neuroprotective substances, such as neuromodulators (e.g., nitric oxide (NO) and/or vasoactive intestinal polypeptide (VIP)). Such increased CBF and/or release of neuroprotective substances decreases damage caused by the brain condition. The stimulation system is generally useful for treating brain ischemia, such as caused by ischemic stroke or other brain conditions.
For some applications, the system is configured to perform acute treatment of an adverse cerebrovascular event, such as ischemic stroke, by applying the stimulation within three hours of the stroke, while a significant penumbra remains. Experiments conducted by the inventors have demonstrated the efficacy of such acute treatment in an animal model. For other applications, the system is configured to perform post-acute treatment of ischemic stroke, by applying the stimulation more than three hours after the stroke, when a significant penumbra generally no longer remains. Experiments conducted by the inventors have demonstrated the efficacy of such post-acute treatment in an animal model. For still other applications, the system is configured to apply stimulation on a chronic, long-term basis, for at least one week, such as at least two weeks, at least four weeks, at least three months, or at least six months. During this chronic treatment, stimulation is typically applied intermittently, such as during one session per day. Experiments conducted by the inventors have demonstrated the efficacy of such post-acute treatment in an animal model.
In some embodiments of the present invention, the system is configured to perform staged treatment of an adverse brain event, such as a cerebrovascular event, e.g., an ischemic stroke. The system is configured to adjust at least one parameter of the applied stimulation responsively to an amount of time that has elapsed since the occurrence of the brain condition. For some applications, during a first, acute stage, the system sets the parameters of stimulation at a first, high level, which is sufficient to cause a high level of cerebral vessel dilation and/or a release of neuroprotective substances, but insufficient to induce a significant increase in permeability of the blood-brain barrier (BBB). Such stimulation is primarily intended to arrest the spreading of the initial ischemic core, such as by restoring blood flow to the penumbra in order to prevent damage to cells therein, and/or by releasing neuroprotective substances, such as NO and/or VIP. Such stimulation may also save some cells within the ischemic core, such as neuronal cells. The first stage of stimulation is typically appropriate during the period beginning at the time of the event, and ending at about 4 to 8 hours after the time of the event, such as at about 6 hours after the event. Alternatively, the first stage of stimulation is appropriate until about 24 hours after the time of the event.
During a second, rehabilitative stage, the system reduces the strength of the stimulation, and typically applies the stimulation intermittently, such as during one session per day, having a duration of between about 2 and about 3 hours. (For some applications, the session has a shorter duration, e.g., between about 0.5 and about 2 hours, or a longer duration, e.g., between about 3 and about 16 hours.) This rehabilitative level of stimulation generally continues to induce the release of neuroprotective substances, and/or maintains a slightly elevated level of blood flow to the brain. This stage of stimulation is typically applied during the period beginning at the conclusion of the first stage, and lasting at least one week, such as at least two weeks, at least one month, at least three months, or at least six months.
In the present patent application, a “modulation target site” (MTS) consists of:
an SPG (also called a pterygopalatine ganglion); a nerve of the pterygoid canal (also called a vidian nerve), such as a greater superficial petrosal nerve (a preganglionic parasympathetic nerve) or a lesser deep petrosal nerve (a postganglionic sympathetic nerve); a greater palatine nerve; a lesser palatine nerve; a sphenopalatine nerve; a communicating branch between the maxillary nerve and the sphenopalatine ganglion; an otic ganglion; an afferent fiber going into the otic ganglion; an efferent fiber going out of the otic ganglion; or an infraorbital nerve.
In some embodiments of the present invention, an electrical stimulation system is configured to apply excitatory electrical stimulation to at least one MTS of a subject, and to configure the stimulation to increase CBF of the subject and/or induce the release of one or more neuroprotective substances, such as neuromodulators (e.g., nitric oxide (NO) and/or vasoactive intestinal polypeptide (VIP)), without significantly opening the BBB of the subject. For some applications, the system sets a strength of the stimulation to less than 90% of the minimum strength necessary to begin significantly opening the BBB (the “minimum BBB-opening strength”), such as less than about 80%, about 70%, or about 60% of the minimum BBB-opening strength. For some applications, the system sets the strength of stimulation to a level appropriate for long-term rehabilitation or prevention of a brain condition, such as between about 10% and about 40% of the minimum BBB-opening strength, e.g., between about 20% and about 30% of the minimum BBB-opening strength. For other applications, the system sets the strength of stimulation to a level appropriate for acute treatment of a brain event, such as at least about 20% of the minimum BBB-opening strength, e.g., at least about 50%, 60%, 70%, or 80% of the minimum BBB-opening strength.
In some embodiments of the present invention, a method for treating a brain tumor comprises: (a) during a first period of time, applying excitatory electrical stimulation to at least one MTS at a first, relatively low strength, in conjunction with administration of a chemotherapeutic drug at a first, relatively high dosage; and (b) during a second period of time after the first period, applying the stimulation at a second strength greater than the first strength, in conjunction with administration of the drug at a second dosage lower than the first dosage. Typically, stimulation at the first strength is sufficient to open the blood-tumor barrier (BTB) in the core and tissue near the core of the tumor, where the BTB has generally been damaged, but not in the periphery of the tumor, where the BBB/BTB generally remains substantially intact. Stimulation at the second strength is typically sufficient to open the BBB in the periphery of the tumor and throughout the brain.
In some embodiments of the present invention, the cerebrovascular condition is caused by a cerebrovascular incident, such as stroke, aneurysm, or an arteriovenous malformation, or by an anoxic/hypoxic/ischemic event, such as anoxic brain injury caused by near drowning, kidney failure, heart failure, chemical exposure, myocardial infarction, or electric shock. As used in the present application, including in the claims, the phrase an “adverse cerebrovascular event” includes, but is not limited to, a cerebrovascular incident, such as stroke, aneurysm, or an arteriovenous malformations, and an anoxic/hypoxic/ischemic event, such as anoxic brain injury caused by near drowning, kidney failure, heart failure, chemical exposure, myocardial infarction, or electric shock. As used in the present application, including in the claims, the phrases an “adverse cerebrovascular event” and an “adverse cerebrovascular condition” exclude from their scope Alzheimer's disease and Parkinson's disease. Nevertheless, in some embodiments of the present invention, at least some of the techniques described herein may be used for treating these two diseases.
In some embodiments of the present invention, chemical stimulation of at least one MTS is achieved by presenting chemicals, for example in a liquid or gaseous state, to an air passage of the subject, such as a nasal cavity or a throat, or in a vicinity thereof. The temporal profile and other quantitative characteristics of such chemical modulation are believed by the present inventors to have a mechanism of action that has a neuroanatomical basis overlapping with that of the electrical modulation of the MTS. For some applications, chemical-presentation techniques described herein are practiced in combination with techniques described in PCT Patent Application PCT/IL03/000338 (published as PCT Publication WO 03/090599), filed Apr. 25, 2003 and/or US Patent Application Publication 2005/0159790, both of which are assigned to the assignee of the present patent application and are incorporated herein by reference.
Chemicals that may increase or decrease cerebral blood flow and/or the permeability of the blood-brain barrier (e.g., via modulation of SPG-related fibers), include, but are not limited to, propionic acid, cyclohexanone, amyl acetate, acetic acid, citric acid, carbon dioxide, sodium chloride, ammonia, menthol, alcohol, nicotine, piperine, gingerol, zingerone, allyl isothiocyanate, cinnamaldehyde, cuminaldehyde, 2-propenyl/2-phenylethyl isothiocyanate, thymol, and eucalyptol. The chemicals reach the appropriate neural structures and induce vasodilatation, vasoconstriction and/or cerebrovascular permeability changes.
In some embodiments of the present invention, chemical stimulation is applied to at least one MTS, using (a) a nasal applicator configured to deliver the stimulating chemical to an upper region of the nasal cavity, or (b) a transpalatine applicator inserted via the greater palatine canal.
In some embodiments of the present invention, stimulation of the MTS is achieved by applying mechanical stimulation to the MTS, e.g., vibration.
In some embodiments of the present invention, stimulation of at least one MTS is achieved by applying a neuroexcitatory agent to the MTS. Suitable neuroexcitatory agents include, but are not limited to, acetylcholine and urocholine. For some applications, the MTS is stimulated by applying a neuroinhibitory agent, such as atropine, hexamethonium, or a local anesthetic (e.g., lidocaine).
It is to be appreciated that references herein to specific modulation target sites are to be understood as including other modulation target sites, as appropriate.
It is further to be appreciated that insertion and modulation sites, methods of insertion and/or implantation, and parameters of modulation are described herein by way of illustration and not limitation, and that the scope of the present invention includes other possibilities which would be obvious to someone of ordinary skill in the art who has read the present patent application.
It is yet further to be appreciated that while some embodiments of the invention are generally described herein with respect to electrical transmission of power and electrical modulation of tissue, other modes of energy transport may be used as well. Such energy includes, but is not limited to, direct or induced electromagnetic energy, radiofrequency (RF) transmission, mechanical vibration, ultrasonic transmission, optical power, and low power laser energy (via, for example, a fiber optic cable).
It is additionally to be appreciated that whereas some embodiments of the present invention are described with respect to application of electrical currents to tissue, this is to be understood in the context of the present patent application and in the claims as being substantially equivalent to applying an electrical field, e.g., by creating a voltage drop between two electrodes.
In embodiments of the present invention, treating an adverse brain event or condition typically includes identifying that a subject is suffering from, and/or has suffered from, the brain event or condition.
In some embodiments of the present invention, magnetic stimulation is applied to at least one MTS using a magnetic induction device that comprises a control unit, and at least one coil that is adapted to be placed in a vicinity of the MTS. For some applications, e.g., in which the MTS includes an SPG of the subject, the coil is adapted to be inserted into a nasal cavity of the subject. Alternatively, the coil is adapted to be placed in a vicinity of a temporomandibular joint, in a vicinity of the MTS. Further alternatively, the coil is adapted to be placed completely or partially around the head, and to focus the magnetic field on the MTS.
There is therefore provided, in accordance with an embodiment of the present invention, apparatus for application to a subject, including:
an elongated support element having a length of between 1.8 cm and 4 cm, and having proximal and distal ends;
one or more electrodes fixed to the support element in a vicinity of the distal end thereof, and adapted to apply an electrical current to a sphenopalatine ganglion (SPG) of the subject;
a receiver, fixed to the support element, and electrically coupled to the electrodes; and
a wireless transmitter, adapted to be placed in an oral cavity of the subject, and to be wirelessly coupled to the receiver.
For some applications, the wireless transmitter is adapted to be electromagnetically coupled to the receiver, or wirelessly coupled to the receiver via ultrasound. Alternatively, the receiver is adapted to be wireless coupled to the wireless transmitter by induction. For some applications, the electrodes are adapted to apply the current using only power received by the receiver from the wireless transmitter.
For some applications, the apparatus includes an oral appliance, adapted to be fixed to the transmitter, and shaped so as to define a surface that fits closely to a roof of the oral cavity. Alternatively, the apparatus includes an oral appliance, adapted to be fixed to the transmitter, and adapted to be coupled to a tooth of the subject, and/or adapted to be coupled to gingival covering an alveolar process of the subject.
For some applications, the apparatus includes an oral appliance, which includes: a capsule, which is configured to be placed and held between an alveolar process and an inner surface of a cheek of the subject; the transmitter; and an elongated coupling element, which couples the transmitter to the capsule. For some applications, the transmitter is adapted to be implanted in a tooth of the subject. For some applications, at least a portion of the receiver is adapted to be positioned between mucosa and a hard palate of the subject. Alternatively, at least a portion of the receiver is adapted to be positioned between mucosa and an alveolar process of a maxilla of the subject.
For some applications, the apparatus includes one or more electrode leads, which electrically couple the receiver to the electrodes, and which serve as the support element. For some applications, the distal end of the support element includes a surgical punch.
In an embodiment, the apparatus includes an external control unit, adapted to be placed outside of a head of the subject, which includes a control unit wireless coupling element, which is adapted to wirelessly transmit data from the control unit to the receiver.
For some applications, the electrodes include exactly one cathode and exactly one anode, and a closest distance between the cathode and the anode is greater than a closest distance between any portion of the cathode and any portion of the SPG when the electrodes are positioned in a vicinity of the SPG.
For some applications, the support element, electrodes, and receiver are adapted to be implanted in the subject for at least one week. Alternatively, the support element, electrodes, and receiver are adapted to be implanted in the subject for less than one day.
For some applications, the support element is sufficiently rigid to enable insertion of the support element into a body of the subject by pushing from a vicinity of the proximal end of the support element.
For some applications, the support element has a curvature that follows that of a greater palatine canal of the subject.
In an embodiment, the receiver is fixed to the support element in a vicinity of the proximal end of the support element. For some applications, the apparatus includes a circuit module, which is fixed to the proximal end of the support element, and which includes a printed circuit board and the receiver. For some applications, the circuit module includes one or more layers of coating applied thereto.
For some applications, the support element is folded in a vicinity of the proximal end of the support element, at an angle approximately equal to an angle between a greater palatine canal of the subject and a hard palate of the subject in a vicinity of a greater palatine foramen of a subject, and the circuit module is adapted to be placed submucosally against a lower surface of the hard palate.
Alternatively, the proximal end of the support element is fixed to the circuit module such that an angle between the support element and a surface of the circuit module is approximately equal to an angle between a greater palatine canal of the subject and a hard palate of the subject in a vicinity of a greater palatine foramen of a subject, and the circuit module is adapted to be placed submucosally against a lower surface of the hard palate. For some applications, the proximal end of the support element is fixed to the circuit module in a vicinity of a center of the surface of the circuit module, or in a vicinity of an edge of the surface of the circuit module.
For some applications, the proximal end of the support element is fixed to the circuit module in a vicinity of an edge of the circuit module, and the circuit module is adapted to be placed submucosally against an alveolar process of a maxilla of the subject.
In an embodiment, the apparatus includes: an external control unit, adapted to be placed outside of a head of the subject, the external control unit including a control unit wireless coupling element; a support element wireless coupling element, coupled to the support element; and circuitry, coupled to the support element, and adapted to drive the wireless coupling element to wirelessly transmit feedback information to the external control unit. For some applications, the support element wireless coupling element and the receiver include a common transducer element.
In an embodiment, the apparatus includes: an oral element, which includes the wireless transmitter; an external driver, which includes a power source and circuitry, and which is adapted to be placed outside a body of the subject; and one or more wires which electrically couple the external driver to the oral element. For some applications, the external driver is adapted to be physically coupled to the body of the subject. For some applications, the apparatus includes an external control unit, which is adapted to be placed outside the body of the subject, and which is coupled to the external driver.
In an embodiment, the apparatus includes an oral element, which includes the wireless transmitter and oral element circuitry coupled to the wireless transmitter; and a power source, adapted to provide power to the wireless transmitter and circuitry. For some applications, the oral element includes the power source. Alternatively, the power source is adapted to be placed outside a body of the subject, and to be coupled to the oral element. For some applications, the apparatus includes receiver circuitry, which is coupled to the support element and the receiver, and the oral element circuitry is adapted to drive the wireless transmitter to transmit energy that does not include a stimulation waveform for application by the electrodes, the receiver is adapted to receive the energy, and the receiver circuitry is adapted to generate the stimulation waveform using the energy, and to drive the electrodes to apply the stimulation waveform to the SPG.
For some applications, the apparatus includes receiver circuitry, which is coupled to the support element and the receiver, and the oral element circuitry is adapted to drive the wireless transmitter to transmit energy that includes a stimulation waveform for application by the electrodes, the receiver is adapted to receive the energy, and the receiver circuitry is adapted to drive the electrodes to apply the stimulation waveform to the SPG.
For some applications, the oral element is adapted to be fixed to a roof of the oral cavity. Alternatively, the oral element is adapted to temporarily placed against the roof of the oral cavity, without being fixed thereto.
For some applications, the apparatus includes an external control unit, adapted to be placed outside of a head of the subject, the external control unit including a control unit wireless coupling element, which is adapted to wirelessly transmit data from the control unit to the oral element, and the oral element is adapted to wirelessly transmit the received data to the receiver. For some applications, the oral element is adapted to wirelessly transmit feedback information to the external control unit.
In an embodiment, the support element has a length of between 1.8 and 3 cm, such as between 2.6 and 3 cm.
In an embodiment, at least a portion of the support element is adapted to be placed in a greater palatine canal of the subject. For some applications, the support element includes a lock, adapted to hold the support element in place after insertion thereof into the greater palatine canal. For some applications, the support element is adapted to be inserted into the greater palatine canal such that no portion of the support element protrudes into the oral cavity. For example, the receiver may be adapted to be contained entirely within the greater palatine canal when the support element is inserted into the greater palatine canal. For some applications, the receiver includes at least one coil that is coiled around at least a portion of the support element. For some applications, the at least one coil includes a plurality of coils which are oriented in a plurality of respective orientations.
For some applications, the apparatus includes circuitry adapted to measure, using at least one of the electrodes, a level of stimulation induced by the applied current, such as a level of stimulation of the SPG.
For some applications, the one or more electrodes include a plurality of electrodes, and the apparatus includes circuitry adapted to perform a calibration procedure by activating, during a plurality of calibration periods, respective different sets of one or more of the electrodes. For some applications, the circuitry is adapted to measure, during each of the calibration periods, using at least one of the electrodes, an indication of a level of stimulation induced by the activation of the respective set of electrodes, such as a level of stimulation of the SPG.
There is further provided, in accordance with an embodiment of the present invention, apparatus for application to a subject, including:
one or more electrodes adapted to apply an electrical current to tissue of the subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve;
a receiver, electrically coupled to the one or more electrodes; and
a wireless transmitter, adapted to be placed in an oral cavity of the subject, and to be wirelessly coupled to the receiver.
In an embodiment, the tissue includes the SPG, and the one or more electrodes are adapted to apply the current to the SPG.
For some applications, the wireless transmitter is adapted to be electromagnetically coupled to the receiver, or wirelessly coupled to the receiver via ultrasound. Alternatively, the receiver is adapted to be wirelessly coupled to the wireless transmitter by induction.
For some applications, the apparatus includes an oral appliance, adapted to be fixed to the transmitter, and shaped so as to define a surface that fits closely to a roof of the oral cavity.
There is also provided, in accordance with an embodiment of the present invention, apparatus for application to a subject, including:
an elongated support element adapted to be placed within a greater palatine canal of the subject, sized to extend from a palate of the subject to a sphenopalatine ganglion (SPG) of the subject, and having distal and proximal ends; and
one or more electrodes fixed to the support element in a vicinity of the distal end thereof; and
a control unit, coupled to the electrodes, and adapted to drive the electrodes to apply an electrical current to the SPG.
In an embodiment, the support element is adapted to have a length that is adjustable during an implantation procedure. For some applications, the support element includes at least two portions that are telescopically coupled to one another. For some applications, the apparatus includes a sleeve, which surrounds a portion of the support element. For some applications, a portion of the support element is shaped so as to define one or more accordion pleats. For some applications, the apparatus includes one or more electrode leads coupled to the electrodes, which leads serve as the support element and are accordion-pleated, a portion of which leads are helically wound so as to form a spring, or which leads are shaped so as to define at least one omega-shaped portion.
In an embodiment, the support element includes a support element electrical contact in a vicinity of the proximal end thereof, the control unit includes a control unit electrical contact, and the control unit is adapted to be placed in an oral cavity of the subject such that the control unit electrical contact is brought into physical contact with the support element electrical contact, thereby coupling the control unit to the electrodes. For some applications, the control unit is adapted to temporarily placed against a roof of the oral cavity, without being fixed thereto. For some applications, the control unit is adapted to be fixed to a roof of the oral cavity. For some applications, the support element electrical contact is adapted to be in sealed contact with mucosa of the subject. Alternatively or additionally, the support element electrical contact includes a matrix, which is adapted to promote mucosal tissue growth therein.
In an embodiment, the apparatus includes a receiver, which is fixed to the support element; and a wireless transmitter, which is coupled to the control unit, and which is adapted to be wirelessly coupled to the receiver, thereby coupling the control unit to the electrodes. For some applications, the wireless transmitter is adapted to be placed in an oral cavity of the subject. Alternatively, the wireless transmitter is adapted to be placed outside of a head of the subject. For some applications, the apparatus includes an autonomically-powered power supply physically coupled to the support element, which is adapted to provide power for the electrodes, and the control unit is adapted to wirelessly transmit data to the receiver.
There is additionally provided, in accordance with an embodiment of the present invention, apparatus including an implantable neural stimulator, which includes:
one or more electrodes adapted to be placed in a vicinity of a greater palatine foramen of a subject; and
a control unit, coupled to the electrodes, and adapted to drive the electrodes to apply an electrical current to a greater palatine nerve of the subject.
For some applications, the electrodes are adapted to be placed within 5 mm of the greater palatine foramen. For some applications, the electrodes are adapted to be contained entirely within a greater palatine canal of the subject. For some applications, at least a portion of the electrodes is adapted to be located between mucosa and a palate of the subject.
There is yet additionally provided, in accordance with an embodiment of the present invention, apparatus including an implantable neural stimulator, which includes:
one or more electrodes adapted to apply an electrical current to tissue of a subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve;
an implantable submucosal antenna, which includes at least one coil, and is adapted to be implanted between oral mucosa and a palate of the subject; and
one or more electrode leads, which electrically couple the submucosal antenna to the electrodes.
In an embodiment, the tissue includes the SPG, and the one or more electrodes are adapted to apply the current to the SPG.
In an embodiment, the submucosal antenna includes a flexible sheet, which includes the at least one coil.
For some applications, the apparatus includes an external driver, which includes a power source and circuitry, which is adapted to be placed outside a body of the subject, and which is adapted to be wirelessly coupled to the submucosal antenna; and an external control unit, which is adapted to be placed outside the body of the subject, and which is coupled to the external driver.
In an embodiment, the stimulator includes an elongated support element having proximal and distal ends, which is adapted to be inserted into a greater palatine canal of the subject, and the one or more electrodes are coupled to the support element in a vicinity of the distal end, and the submucosal antenna is coupled to the support element in a vicinity of the proximal end. For some applications, the support element has a length of between 2.6 cm and 3 cm. For some applications, the support element is adapted to have a length that is adjustable during an implantation procedure.
In an embodiment, the apparatus includes a control unit, adapted to be wirelessly coupled to the submucosal antenna. For some applications, the control unit is adapted to transmit power and data to the submucosal antenna, and the stimulator is adapted to use the power to generate a stimulation waveform at least in part responsively to the received data, and to drive the one or more electrodes to apply the stimulation waveform. For some applications, the control unit is adapted to be placed externally to a body of the subject, such as in a vicinity of a head of the subject, e.g., in a vicinity of an ear of the subject.
There is still additionally provided, in accordance with an embodiment of the present invention, apparatus including an implantable neural stimulator, which includes:
a plurality of electrodes adapted to apply an electrical current to a site of a subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve; and
a control unit, coupled to the electrodes, and adapted to perform a calibration procedure by activating, during a plurality of calibration periods, respective different sets of one or more of the electrodes.
For some applications, the control unit is adapted to be placed externally to a body of the subject, and to be wirelessly coupled to the electrodes.
In an embodiment, the control unit is adapted to receive, during each of the calibration periods, an indication of a level of stimulation induced by the activation of the respective set of electrodes, such as a level of stimulation of the site. For some applications, the control unit is adapted to select the set of electrodes the activation of which induced the level of stimulation nearest a desired level of stimulation.
For some applications, the control unit is adapted to receive the indication of the level of stimulation, e.g., of the site, by using at least a portion of the electrodes to measure the level of stimulation. For some applications, the control unit is adapted to measure, using the at least a portion of the electrodes, an electric field of nervous tissue, e.g., of the site, induced by the activation of the respective set of electrodes. For some applications, the at least a portion of the electrodes includes one or more of the electrodes of the respective set of electrodes. For some applications, the at least a portion of the electrodes includes one or more of the electrodes positioned in a vicinity of the electrodes of the respective set of electrodes.
For some applications, the indication includes an indirect physiological parameter of the subject related to the level of the stimulation, and the control unit is adapted to receive the indirect physiological parameter during each of the calibration periods. For some applications, the indirect physiological parameter includes an indication of cerebral blood flow (CBF) of the subject, and the control unit is adapted to receive the indication of CBF. For some applications, the indirect physiological parameter includes an indication of blood-brain barrier (BBB) permeability of the subject, and the control unit is adapted to receive the indication of BBB permeability. For some applications, the apparatus includes a device adapted to measure the indirect physiological parameter, and the control unit is adapted to receive the indirect physiological parameter measured by the device.
In an embodiment, the site includes the SPG, and the electrodes are adapted to apply the current to the SPG. For some applications, the stimulator includes an elongated support element having a distal end, and adapted to be inserted into a greater palatine canal of the subject via a palate of the subject, and the electrodes are coupled to the support element in a vicinity of the distal end.
There is still further provided, in accordance with an embodiment of the present invention, apparatus including an implantable neural stimulator, which includes:
a set of one or more electrodes adapted to be placed in a vicinity of a site of a subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve; and
a control unit, coupled to the set of electrodes, and adapted to:
drive at least one of the electrodes to apply an electrical current to the site, and
using at least one of the electrodes, measure a level of stimulation induced by the applied current.
In an embodiment, the level of stimulation includes a level of stimulation of the site induced by the applied current, and the control unit is adapted to measure the level of stimulation of the site, using the at least one of the electrodes.
In an embodiment, the site includes the SPG, and the electrodes are adapted to be placed in the vicinity of the SPG.
For some applications, the control unit is adapted to measure the level of stimulation using at least one of the at least one of the electrodes that applies the current to the site. For some applications, the control unit is adapted to measure the level of stimulation using at least one of the electrodes positioned in a vicinity of the at least one of the electrodes that applies the current to the site. For some applications, the control unit is adapted to measure, using the at least one of the electrodes, an electric field of nervous tissue, e.g., of the site, induced by the applied current.
There is also provided, in accordance with an embodiment of the present invention, apparatus including an implantable neural stimulator, which includes:
an elongated support element having a length of between 2.6 cm and 3 cm, having a distal end, and including, at the distal end, a surgical punch adapted to facilitate insertion of the support element through mucosa of the subject into a greater palatine canal of a subject, via a greater palatine foramen of the subject; and
one or more electrodes fixed to the support element in a vicinity of the distal end thereof, and adapted to apply an electrical current to a sphenopalatine ganglion (SPG) of the subject.
For some applications, the support element includes a lock, adapted to hold the support element in place after insertion thereof into the greater palatine canal.
There is further provided, in accordance with an embodiment of the present invention, apparatus including an implantable neural stimulator, which includes:
an elongated support element having a length of between 2.6 cm and 3 cm, having a distal end, and adapted to be placed in a greater palatine canal of a subject;
one or more electrodes fixed to the support element in a vicinity of the distal end thereof, and adapted to apply an electrical current to a sphenopalatine ganglion (SPG) of the subject; and
a needle shaped so as to define a sharp distal end and a bore, which bore is adapted to hold the support element and the electrodes during insertion of the support element and the electrodes into the greater palatine canal, and to be withdrawn from the greater palatine canal thereafter, leaving the support element and electrodes in the greater palatine canal.
For some applications, the support element includes a lock, adapted to hold the support element in place after insertion thereof into the greater palatine canal.
There is still further provided, in accordance with an embodiment of the present invention, apparatus including an implantable neural stimulator, which includes:
one or more electrodes adapted to apply an electrical current to tissue of a subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve;
a receiver, electrically coupled to the one or more electrodes;
an oral appliance, which includes:
a capsule, which is configured to be placed and held between an alveolar process and an inner surface of a cheek of the subject;
a wireless transmitter, adapted to be wirelessly coupled to the receiver; and
an elongated coupling element, which couples the transmitter to the capsule; and
a power source, electrically coupled to the wireless transmitter.
In an embodiment, the capsule includes the power source. Alternatively, the apparatus includes a cable, and the power source is adapted to be placed outside of a body of the subject, and is physically and electrically coupled to the capsule via the cable.
For some applications, the capsule is generally cylindrical. For some applications, the capsule includes a soft coating.
In an embodiment, the coupling element is configured such that the transmitter is positioned on a lingual side of teeth of the subject when the capsule is held between the alveolar process and the inner surface of the cheek. For some applications, the coupling element is configured to pass over an occlusal surface of one or more teeth of the subject. Alternatively, the coupling element is configured to pass around a distal surface of a most distal molar of the subject.
There is additionally provided, in accordance with an embodiment of the present invention, a method including:
inserting an elongated support element into a body of a subject, the element having a length of between about 1.8 cm and about 4 cm, and having proximal and distal ends;
wirelessly transmitting energy from within an oral cavity of the subject;
receiving the energy at the support element; and
using the received energy, applying, from a vicinity of the distal end of the support element, an electrical current to a sphenopalatine ganglion (SPG) of the subject.
In an embodiment, inserting the support element includes:
preparing a submucosal surface on a hard palate of the subject;
inserting the support element into a greater palatine canal of the subject; and
placing a circuit module, which is fixed to the proximal end of the support element, against the prepared submucosal surface, and
receiving the energy at the support element includes receiving the energy at the circuit module.
In an embodiment, inserting the support element includes:
preparing a submucosal surface on an alveolar process of a maxilla of the subject;
inserting the support element into a greater palatine canal of the subject; and
placing a circuit module, which is fixed to the proximal end of the support element, against the prepared submucosal surface, and
receiving the energy at the support element includes receiving the energy at the circuit module.
There is yet additionally provided, in accordance with an embodiment of the present invention, a method including:
wirelessly transmitting energy from within an oral cavity of a subject;
receiving the energy; and
using the received energy, applying an electrical current to tissue of the subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve.
There is also provided, in accordance with an embodiment of the present invention, a method including:
inserting an elongated support element into a greater palatine canal of the subject, such that the support element extends from a palate of the subject to a sphenopalatine ganglion (SPG) of the subject, the support element having a distal end; and
applying, from a vicinity of the distal end, an electrical current to the SPG.
There is further provided, in accordance with an embodiment of the present invention, a method including applying an electrical current to a greater palatine nerve of a subject from a site in a vicinity of a greater palatine foramen of a subject.
There is still further provided, in accordance with an embodiment of the present invention, a method including:
implanting, between oral mucosa and a palate of the subject, a submucosal antenna that includes at least one coil;
wirelessly transmitting energy to the submucosal antenna;
receiving the energy at the submucosal antenna; and
using the energy, applying an electrical current to tissue of a subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve.
There is additionally provided, in accordance with an embodiment of the present invention, a method method including performing a calibration procedure by applying an electrical current to an anatomical site of a subject, during a plurality of calibration periods, from respective different sets of one or more stimulation sites in a vicinity of the anatomical site, the anatomical site selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve.
There is yet additionally provided, in accordance with an embodiment of the present invention, a method including:
placing a set of one or more electrodes in a vicinity of a site of a subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve;
driving at least one of the electrodes to apply an electrical current to the site; and
using at least one of the electrodes, measuring a level of stimulation induced by the applied current.
There is also provided, in accordance with an embodiment of the present invention, a method including:
inserting, into a greater palatine canal of a subject, via a greater palatine foramen of the subject, an elongated support element having a length of between 2.6 cm and 3 cm and having a distal end, by using the distal end of the support element to punch an incision in mucosa of the subject; and
applying, from a vicinity of the distal end of the support element, an electrical current to a sphenopalatine ganglion (SPG) of the subject.
There is further provided, in accordance with an embodiment of the present invention, a method including:
placing an elongated support element, having a length of between 2.6 cm and 3 cm and having a distal end, into a bore of a needle shaped so as to define a sharp distal end;
inserting, into a greater palatine canal of a subject, the needle holding the support element;
withdrawing the needle from the greater palatine canal thereafter, leaving the support element in the greater palatine canal; and
applying, from a vicinity of the distal end of the support element, an electrical current to a sphenopalatine ganglion (SPG) of the subject.
There is still further provided, in accordance with an embodiment of the present invention, a method including:
placing a capsule between an alveolar process and an inner surface of a cheek of a subject;
placing, in an oral cavity of the subject, a wireless transmitter coupled to the capsule by an elongated coupling element;
wirelessly transmitting energy from the wireless transmitter; and
receiving the energy, and, using the received energy, applying an electrical current to tissue of the subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve.
There is additionally provided, in accordance with an embodiment of the present invention, apparatus including:
an instrument, adapted to detect an indication of cerebral blood flow (CBF) of a subject, and to generate a signal responsive thereto;
one or more electrodes, adapted to be placed in a vicinity of a site of the subject selected from a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve; and
a control unit, adapted to:
receive the signal,
drive the one or more electrodes to apply a current to the site capable of inducing a change in the CBF, and
configure a parameter of the current responsively to the signal.
For some applications, the instrument includes a laser Doppler perfusion device, a transcranial Doppler ultrasonography device, a thermometer, or a near infrared spectroscopy (NIRS) device. Alternatively, the instrument includes an image sensor, adapted to image an eye of the subject, and the indication of CBF includes an indication of vasodilation of blood vessels of the eye. For some applications, the indication of vasodilation of the blood vessels of the eye includes a ratio of red to white in a sclera of the eye, and the instrument is adapted to determine the ratio.
There is yet additionally provided, in accordance with an embodiment of the present invention, a method including:
placing one or more electrodes in a vicinity of a site of a subject selected from a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve;
applying a current to the site capable of inducing a change in cerebral blood flow (CBF) of the subject;
detecting an indication of the CBF; and
responsively to the indication, adjusting at least one of: a placement of the electrodes, and a parameter of the applied current.
There is further provided, in accordance with an embodiment of the present invention, apparatus for treatment, including:
one or more electrodes, configured to be applied to a site of a subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve; and
adverse cerebrovascular condition treatment functionality, which includes a control unit configured to:
drive the one or more electrodes to apply electrical stimulation to the site during a plurality of stimulation periods which includes at least first and last stimulation periods,
set an inter-period interval between initiation of the first stimulation period and initiation of the last stimulation period to be at least 24 hours, and
configure the stimulation during the first and last stimulation periods to induce at least one neuroprotective occurrence selected from the group consisting of: an increase in cerebral blood flow (CBF) of the subject, and a release of one or more neuroprotective substances.
For some applications, the control unit is configured to set the inter-period interval to be no more than a maximum value. For some applications, the control unit is configured to set the inter-period interval to be no more than nine months.
In an embodiment, the control unit is configured to store a maximum total time of stimulation per each time period having a given duration, and to drive the one or more electrodes to apply the stimulation no more than the maximum total time per each time period having the given duration.
In an embodiment, the plurality of stimulation periods includes at least one second stimulation period between the first and last stimulation periods, and the control unit is configured to drive the one or more electrodes to apply the stimulation during the first, second, and last stimulation periods, and to configure the stimulation during the first, second, and last stimulation periods to induce the at least one neuroprotective occurrence.
In an embodiment, the initiation of the last stimulation period occurs simultaneously with a conclusion of the first stimulation period, and the control unit is configured to drive the one or more electrodes to apply the stimulation continuously from the initiation of the first stimulation period to a conclusion of the last stimulation period. Alternatively, the initiation of the last stimulation period occurs after a conclusion of the first stimulation period, and the control unit is configured to withhold driving the one or more electrodes to apply the stimulation during at least one non-stimulation period between the conclusion of the first stimulation period and the initiation of the last stimulation period.
For some applications, the control unit is configured to drive the one or more electrodes to apply the stimulation for between one and six hours during each of the first and last stimulation periods.
For some applications, the control unit is configured to set a strength of the stimulation during at least one of the plurality of stimulation periods to be insufficient to induce a significant increase in permeability of a blood-brain barrier (BBB) of the subject. For example, the control unit may be configured to set the strength of the stimulation during the at least one of the plurality of stimulation periods to be less than 40% of a strength that is sufficient to induce the significant increase in permeability of the BBB.
In an embodiment, the apparatus includes a user interface, which is configured to receive as input a treatment duration value, and the control unit is configured to set the inter-period interval to be equal to the inputted treatment duration value. For some applications, the control unit is configured to store a predetermined maximum treatment duration value, and to compare the inputted treatment duration value with the maximum treatment duration value.
For some applications, the control unit is configured to set the inter-period interval to be at least 48 hours. For some applications, the control unit is configured to drive the one or more electrodes to apply the stimulation non-continuously during two or more of the plurality of the stimulation periods during each 24-hour period between the initiation of the first stimulation period and the initiation of the last stimulation period.
In an embodiment, the control unit is configured to set the inter-period interval to be at least one week. For some applications, the plurality of stimulation periods includes a plurality of daily stimulation periods, and the control unit is configured to drive the one or more electrodes to apply the stimulation during at least one of the daily stimulation periods on every day between the initiation of the first stimulation period and the initiation of the last stimulation period, and to configure the stimulation during the plurality of daily stimulation periods to induce the at least one neuroprotective occurrence.
For some applications, the control unit is configured to drive the one or more electrodes to apply the stimulation for at least 30 minutes every day, such as at least 60 minutes every day, between the initiation of the first stimulation period and the initiation of the last stimulation period.
For some applications, the control unit is configured to set the inter-period interval to be at least two weeks, such as at least four weeks.
For some applications, the control unit is configured to set a strength of the stimulation during at least one of the plurality of stimulation periods to be less than 40% of a strength that induces a maximum increase in CBF in the subject that is achievable by applying the stimulation. Alternatively or additionally, for some applications, the control unit is configured to set a strength of the stimulation during at least one of the plurality of stimulation periods to a level that induces less than 40% of a maximum increase in CBF in the subject that is achievable by applying the stimulation.
For some applications, the control unit is configured to drive the one or more electrodes to apply the stimulation for less than six hours during each of the first and last stimulation periods.
In an embodiment, the site includes the SPG, and the one or more electrodes are configured to be applied to the SPG. For some applications, the apparatus includes an elongated support element configured to be placed within a greater palatine canal of the subject, sized to extend from a palate of the subject to the SPG, and having a distal end, and the electrodes are fixed to the support element in a vicinity of the distal end thereof.
In an embodiment, the control unit is configured to drive the one or more electrodes to apply the stimulation during the first period at a first stimulation strength and during the last period at a second stimulation strength, and to set the second stimulation strength to be different from the first stimulation strength, such as less than or greater than the first stimulation strength.
For some applications, the adverse cerebrovascular condition treatment functionality includes stroke treatment functionality, such as ischemic stroke treatment functionality.
There is further provided, in accordance with an embodiment of the present invention, a method for treatment, including:
identifying that a subject suffers from an adverse cerebrovascular condition;
responsively to the identifying, applying electrical stimulation to a site of the subject during a plurality of stimulation periods which includes at least first and last stimulation periods, the site selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve;
setting an inter-period interval between initiation of the first stimulation period and initiation of the last stimulation period to be at least 24 hours; and
configuring the stimulation during the first and last stimulation periods to induce at least one neuroprotective occurrence selected from the group consisting of: an increase in cerebral blood flow (CBF) of the subject, and a release of one or more neuroprotective substances.
In an embodiment, the adverse cerebrovascular condition includes an ischemic stroke, and identifying that the subject suffers from the condition includes identifying that the subject has experienced the ischemic stroke. Alternatively, for some applications, the condition includes an aneurysm or an arteriovenous malformation, or an anoxic brain injury caused, for example, by near drowning, kidney failure, heart failure, chemical exposure, myocardial infarction, or electric shock.
For some applications, applying the stimulation during the first and last stimulation periods includes applying the stimulation for less than six hours during each of the first and last stimulation periods.
In an embodiment, applying the stimulation includes placing an electrical stimulator in a vicinity of the site, and activating the stimulator to apply the stimulation.
In an embodiment, the condition includes an adverse cerebrovascular event, identifying that the subject suffers from the condition includes identifying that the subject has experienced the event, and applying the stimulation includes applying the stimulation beginning at least three hours after the event, such as at least six hours after the event, at least nine hours after the event, at least 12 hours after the event, or at least 24 hours after the event.
There is still further provided, in accordance with an embodiment of the present invention, apparatus for treating a subject, including:
one or more electrodes, configured to be applied to a site of the subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve; and
a control unit, configured to:
drive the one or more electrodes to apply electrical stimulation to the site, and
configure the stimulation to excite nervous tissue of the site at a strength sufficient to induce at least one neuroprotective occurrence selected from the group consisting of: an increase in cerebral blood flow (CBF) of the subject, and a release of one or more neuroprotective substances, and insufficient to induce a significant increase in permeability of a blood-brain barrier (BBB) of the subject.
In an embodiment, the control unit is configured to set the strength to less than 90% of a strength sufficient to induce the significant increase in the permeability of the BBB. Alternatively or additionally, the control unit is configured to set the strength to less than 40% of a strength sufficient to induce the significant increase in the permeability of the BBB.
For some applications, the control unit is configured to set the strength to more than 50% of a strength sufficient to induce the significant increase in the permeability of the BBB.
In an embodiment, the site includes the SPG, and the electrodes are configured to be applied to the SPG. For some applications, the apparatus includes an elongated support element configured to be placed within a greater palatine canal of the subject, sized to extend from a palate of the subject to the SPG, and having a distal end, and the electrodes are fixed to the support element in a vicinity of the distal end thereof.
There is additionally provided, in accordance with an embodiment of the present invention, apparatus for treating a subject, including:
one or more electrodes, configured to be applied to a site of the subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve; and
a control unit, configured to:
drive the one or more electrodes to apply electrical stimulation to the site during at least a first period of time and a second period of time after the first period, each of the first and second periods of time having a duration of at least one minute, and
configure the stimulation to excite nervous tissue of the site during the first period at a first stimulation strength and during the second period at a second stimulation strength less than the first stimulation strength, wherein the first and second stimulation strengths are sufficient to induce an increase in cerebral blood flow (CBF) of the subject.
In an embodiment, each of the first and second periods has a duration of at least one hour, and the control unit is configured to drive the one or more electrodes to apply the stimulation during the first and second periods each having the duration of at least one hour.
In an embodiment, the control unit is configured to set the first and second stimulation strengths to be insufficient to induce a significant increase in permeability of a blood-brain barrier (BBB) of the subject.
For some applications, the control unit is configured to receive an input of a point in time, and to determine the first and second time periods with respect to the point in time.
In an embodiment, the control unit is configured to apply the stimulation during a third period of time after the second period, and configure the stimulation to excite the nervous tissue during the third period at a third stimulation strength that is less than the second stimulation strength.
In an embodiment, the site includes the SPG, and the electrodes are configured to be applied to the SPG. For some applications, the apparatus includes an elongated support element configured to be placed within a greater palatine canal of the subject, sized to extend from a palate of the subject to the SPG, and having a distal end, and the electrodes are fixed to the support element in a vicinity of the distal end thereof.
There is still additionally provided, in accordance with an embodiment of the present invention, a method for treating a subject, including:
applying electrical stimulation to a site of the subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve; and
configuring the stimulation to excite nervous tissue of the site at a strength sufficient to induce at least one neuroprotective occurrence selected from the group consisting of: an increase in cerebral blood flow (CBF) of the subject, and a release of one or more neuroprotective substances, and insufficient to induce a significant increase in permeability of a blood-brain barrier (BBB) of the subject.
There is yet additionally provided, in accordance with an embodiment of the present invention, a method for treating a subject, including:
applying electrical stimulation to a site of the subject during at least a first period of time and a second period of time after the first period, each of the first and second periods of time having a duration of at least one minute, the site selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve; and
configuring the stimulation to excite nervous tissue of the site during the first period at a first stimulation strength and during the second period at a second stimulation strength less than the first stimulation strength, wherein the first and second stimulation strengths are sufficient to induce an increase in cerebral blood flow (CBF) of the subject.
There is also provided, in accordance with an embodiment of the present invention, a method for treatment, including:
identifying that a subject has suffered from an adverse cerebrovascular event;
responsively to the identifying, applying, beginning at least three hours after the event, electrical stimulation to a site of the subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve; and
configuring the stimulation to excite nervous tissue of the site at a strength sufficient to induce at least one neuroprotective occurrence selected from the group consisting of: an increase in cerebral blood flow (CBF) of the subject, and a release of one or more neuroprotective substances.
For some applications, applying the stimulation includes applying the stimulation beginning at least six hours after the event, such as least nine hours after the event, at least 12 hours after the event, or at least 24 hours after the event.
For some applications, configuring the stimulation includes setting the strength to be insufficient to induce a substantial increase in permeability of a blood-brain barrier (BBB) of the subject.
In an embodiment, the event includes a stroke, e.g., an ischemic stroke, and applying the stimulation includes applying the stimulation beginning at least three hours after the stroke. Alternatively, for some applications, the event includes an aneurysm or an arteriovenous malformation, or an anoxic brain injury caused, for example, by near drowning, kidney failure, heart failure, chemical exposure, myocardial infarction, or electric shock.
For some applications, applying the stimulation includes applying the stimulation intermittently.
In an embodiment, applying the stimulation includes applying the stimulation during a plurality of stimulation periods which includes at least first and last stimulation periods, wherein initiation of the first period is at least three hours after the event; and setting an inter-period interval between the initiation of the first stimulation period and initiation of the last stimulation period to be at least 24 hours, and configuring the stimulation includes configuring the stimulation during the first and last stimulation periods to induce the at least one neuroprotective occurrence.
In an embodiment, the site includes the SPG, and applying the stimulation includes applying the stimulation to the SPG. For some applications, applying the stimulation includes placing an elongated support element within a greater palatine canal of the subject, sized to extend from a palate of the subject to the SPG, and having a distal end; and applying the stimulation from a vicinity of the distal end of the support element.
There is further provided, in accordance with an embodiment of the present invention, a method for treating a subject, including:
applying, for at least 15 minutes per day during a period of at least one week, an electrical current to a site of the subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve; and
configuring the current to excite nervous tissue of the site at a strength sufficient to induce at least one of: an increase in cerebral blood flow (CBF) of the subject, and a release of one or more neuroprotective substances.
For some applications, configuring the current includes setting the strength to be less than 40% of a strength that induces a maximum increase in CBF in the subject that is achievable by applying the current. Alternatively or additionally, configuring the current includes setting the strength to a level that induces less than 40% of a maximum increase in CBF in the subject that is achievable by applying the current.
For some applications, applying the current includes applying the current for less than 6 hours per day.
For some applications, applying the current includes implanting an electrical stimulator in a vicinity of the site, and activating the stimulator to apply the current.
In an embodiment, configuring the current includes setting the strength to be insufficient to induce a significant increase in permeability of a blood-brain barrier (BBB) of the subject. For some applications, setting the strength includes setting the strength to be less than 40% of a strength that is sufficient to induce the significant increase in permeability of the BBB.
In an embodiment, the site includes the SPG, and applying the current includes applying the current to the SPG. For some applications, applying the current includes: placing an elongated support element within a greater palatine canal of the subject, sized to extend from a palate of the subject to the SPG, and having a distal end; and applying the current from a vicinity of the distal end of the support element.
For some applications, applying the current includes applying the current for at least 30 minutes per day during the period of at least one week, such as for at least 60 minutes per day during the period of at least one week.
There is additionally provided, in accordance with an embodiment of the present invention, a method for treating a brain tumor of a subject, including:
administering a chemotherapeutic drug to the subject;
during a first period of time during which the drug is at a first level in a systemic circulation of the subject, applying electrical stimulation to a site of the subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve, and configuring the stimulation to excite nervous tissue of the site at a first strength sufficient to induce an increase in permeability of a blood-tumor barrier (BTB) of the subject; and
during a second period of time during which the drug is at a second level in the systemic circulation, the second level lower than the first level, applying the stimulation to the site, and configuring the stimulation to excite the nervous tissue at a second strength that is greater than the first strength.
In an embodiment, configuring the stimulation during the first period includes setting the first strength to be insufficient to induce a significant increase in permeability of a blood-brain barrier (BBB) of the subject. Alternatively or additionally, configuring the stimulation during the second period includes setting the second strength to be sufficient to induce a significant increase in permeability of a BBB of the subject. Further alternatively or additionally, configuring the stimulation during the first and second periods includes setting the first strength to be insufficient to induce a significant increase in permeability of a BBB of the subject, and the second strength to be sufficient to induce the significant increase in the permeability of the BBB.
In an embodiment, the site includes the SPG, and applying the stimulation includes applying the stimulation to the SPG. For some applications, applying the stimulation during the first and second periods includes: placing an elongated support element within a greater palatine canal of the subject, sized to extend from a palate of the subject to the SPG, and having a distal end; and applying the stimulation from a vicinity of the distal end of the support element.
There is yet additionally provided, in accordance with an embodiment of the present invention, a method for treating a brain tumor of a subject, including:
administering a chemotherapeutic drug to the subject;
applying electrical stimulation to a site of the subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve; and
configuring the stimulation to excite nervous tissue of the site at a strength sufficient to induce an increase in permeability of a blood-tumor barrier (BTB) of the subject, but insufficient to induce a substantial increase in permeability of a blood-brain barrier (BBB) of the subject.
In an embodiment, the site includes the SPG, and applying the stimulation includes applying the stimulation to the SPG. For some applications, applying the stimulation includes: placing an elongated support element within a greater palatine canal of the subject, sized to extend from a palate of the subject to the SPG, and having a distal end; and applying the stimulation from a vicinity of the distal end of the support element.
There is also provided, in accordance with an embodiment of the present invention, apparatus for treating a condition of a subject, including:
a coil, adapted to be positioned in a vicinity of a site selected from the list consisting of: a sphenopalatine ganglion (SPG) of the subject, a greater palatine nerve of the subject, a lesser palatine nerve of the subject, a sphenopalatine nerve of the subject, a communicating branch between a maxillary nerve and an SPG of the subject, an otic ganglion of the subject, an afferent fiber going into the otic ganglion of the subject, an efferent fiber going out of the otic ganglion of the subject, an infraorbital nerve of the subject, a vidian nerve of the subject, a greater superficial petrosal nerve of the subject, and a lesser deep petrosal nerve of the subject; and
a control unit, adapted to drive the coil to generate a magnetic field in the vicinity of the site capable of inducing an increase in cerebral blood flow (CBF) of the subject.
In an embodiment, the site includes the SPG of the subject, and the coil is adapted to be positioned in the vicinity of the SPG.
For some applications, the control unit is adapted to generate the magnetic field with a strength sufficient to stimulate the site, and insufficient to substantially stimulate brain tissue of the subject.
For some applications, the apparatus includes a cooling element, adapted to prevent excessive heating of the coil.
For some applications, the coil includes between about 4 and about 30 loops of wire.
In an embodiment, the coil is adapted to be inserted into a nasal cavity of the subject.
For some applications, the coil is substantially figure-eight-shaped. Alternatively, the coil is substantially 4-leaf-shaped. Further alternatively, the coil is substantially circular.
For some applications, the coil has a diameter of between about 3 mm and about 12 mm.
In an embodiment, the coil is adapted to be placed in a vicinity of a temporomandibular joint of the subject. For some applications, the coil has a diameter of between about 3 cm and about 12 cm.
In an embodiment, the coil is adapted to be placed around at least a portion of a head of the subject. For some applications, the coil has a diameter of between about 3 cm and about 12 cm.
There is additionally provided, in accordance with an embodiment of the present invention, apparatus for treating a condition of a subject, including:
a coil, adapted to be positioned in a vicinity of a site selected from the list consisting of: a sphenopalatine ganglion (SPG) of the subject, a greater palatine nerve of the subject, a lesser palatine nerve of the subject, a sphenopalatine nerve of the subject, a communicating branch between a maxillary nerve and an SPG of the subject, an otic ganglion of the subject, an afferent fiber going into the otic ganglion of the subject, an efferent fiber going out of the otic ganglion of the subject, an infraorbital nerve of the subject, a vidian nerve of the subject, a greater superficial petrosal nerve of the subject, and a lesser deep petrosal nerve of the subject; and
a control unit, adapted to drive the coil to generate a magnetic field in the vicinity of the site capable of inducing an increase in permeability of a blood-brain barrier (BBB) of the subject.
In an embodiment, the site includes the SPG of the subject, and the coil is adapted to be positioned in the vicinity of the SPG.
For some applications, the control unit is adapted to generate the magnetic field with a strength sufficient to stimulate the site, and insufficient to substantially stimulate brain tissue of the subject.
For some applications, the apparatus includes a cooling element, adapted to prevent excessive heating of the coil.
For some applications, the coil includes between about 4 and about 30 loops of wire.
In an embodiment, the coil is adapted to be inserted into a nasal cavity of the subject.
For some applications, the coil is substantially figure-eight-shaped. Alternatively, the coil is substantially 4-leaf-shaped. Further alternatively, the coil is substantially circular. For some applications, the coil has a diameter of between about 3 mm and about 12 mm.
In an embodiment, the coil is adapted to be placed in a vicinity of a temporomandibular joint of the subject. For some applications, the coil has a diameter of between about 30 mm and about 120 mm.
In an embodiment, the coil is adapted to be placed around at least a portion of a head of the subject. For some applications, the coil has a diameter of between about 10 cm and about 25 cm.
There is also provided, in accordance with an embodiment of the present invention, apparatus for facilitating a diagnosis of a condition of a subject, including:
a coil, adapted to be positioned in a vicinity of a site selected from the list consisting of: a sphenopalatine ganglion (SPG) of the subject, a greater palatine nerve of the subject, a lesser palatine nerve of the subject, a sphenopalatine nerve of the subject, a communicating branch between a maxillary nerve and an SPG of the subject, an otic ganglion of the subject, an afferent fiber going into the otic ganglion of the subject, an efferent fiber going out of the otic ganglion of the subject, an infraorbital nerve of the subject, a vidian nerve of the subject, a greater superficial petrosal nerve of the subject, and a lesser deep petrosal nerve of the subject; and
a control unit, adapted to drive the coil to generate a magnetic field in the vicinity of the site capable of inducing an increase in permeability of a blood-brain barrier (BBB) of the subject sufficient to increase passage of a diagnostic agent across the BBB into a central nervous system (CNS) of the subject.
In an embodiment, the site includes the SPG of the subject, and the coil is adapted to be positioned in the vicinity of the SPG.
For some applications, the control unit is adapted to generate the magnetic field with a strength sufficient to stimulate the site, and insufficient to substantially stimulate brain tissue of the subject.
For some applications, the apparatus includes a cooling element, adapted to prevent excessive heating of the coil.
For some applications, the coil includes between about 4 and about 30 loops of wire.
In an embodiment, the coil is adapted to be inserted into a nasal cavity of the subject. For some applications, the coil is substantially figure-eight-shaped. Alternatively, the coil is substantially 4-leaf-shaped. Further alternatively, the coil is substantially circular. For some applications, the coil has a diameter of between about 3 mm and about 12 mm.
In an embodiment, the coil is adapted to be placed in a vicinity of a temporomandibular joint of the subject. For some applications, the coil has a diameter of between about 3 cm and about 12 cm.
In an embodiment, the coil is adapted to be placed around at least a portion of a head of the subject. For some applications, the coil has a diameter of between about 3 cm and about 12 cm.
There is further provided, in accordance with an embodiment of the present invention, apparatus for facilitating delivery of a drug to a subject, including:
a coil, adapted to be positioned in a vicinity of a site selected from the list consisting of: a sphenopalatine ganglion (SPG) of the subject, a greater palatine nerve of the subject, a lesser palatine nerve of the subject, a sphenopalatine nerve of the subject, a communicating branch between a maxillary nerve and an SPG of the subject, an otic ganglion of the subject, an afferent fiber going into the otic ganglion of the subject, an efferent fiber going out of the otic ganglion of the subject, an infraorbital nerve of the subject, a vidian nerve of the subject, a greater superficial petrosal nerve of the subject, and a lesser deep petrosal nerve of the subject; and
a control unit, adapted to drive the coil to generate a magnetic field in the vicinity of the site capable of inducing an increase in permeability of a blood-brain barrier (BBB) of the subject sufficient to increase passage of the drug across the BBB into a central nervous system (CNS) of the subject.
In an embodiment, the site includes the SPG of the subject, and the coil is adapted to be positioned in the vicinity of the SPG.
For some applications, the control unit is adapted to generate the magnetic field with a strength sufficient to stimulate the site, and insufficient to substantially stimulate brain tissue of the subject.
For some applications, the apparatus includes a cooling element, adapted to prevent excessive heating of the coil.
For some applications, the coil includes between about 4 and about 30 loops of wire.
In an embodiment, the coil is adapted to be inserted into a nasal cavity of the subject. For some applications, the coil is substantially figure-eight-shaped. Alternatively, the coil is substantially 4-leaf-shaped. Further alternatively, the coil is substantially circular. For some applications, the coil has a diameter of between about 3 mm and about 12 mm.
In an embodiment, the coil is adapted to be placed in a vicinity of a temporomandibular joint of the subject. For some applications, the coil has a diameter of between about 3 cm and about 12 cm.
In an embodiment, the coil is adapted to be placed around at least a portion of a head of the subject. For some applications, the coil has a diameter of between about 3 cm and about 12 cm.
There is still further provided, in accordance with an embodiment of the present invention, apparatus for facilitating a diagnosis of a condition of a subject, including:
a coil, adapted to be positioned in a vicinity of a site selected from the list consisting of: a sphenopalatine ganglion (SPG) of the subject, a greater palatine nerve of the subject, a lesser palatine nerve of the subject, a sphenopalatine nerve of the subject, a communicating branch between a maxillary nerve and an SPG of the subject, an otic ganglion of the subject, an afferent fiber going into the otic ganglion of the subject, an efferent fiber going out of the otic ganglion of the subject, an infraorbital nerve of the subject, a vidian nerve of the subject, a greater superficial petrosal nerve of the subject, and a lesser deep petrosal nerve of the subject; and
a control unit, adapted to drive the coil to generate a magnetic field in the vicinity of the site capable of inducing an increase in permeability of a blood-brain barrier (BBB) of the subject sufficient to increase passage of a constituent of a central nervous system (CNS) of the subject across the BBB into a systemic blood circulation of the subject.
In an embodiment, the site includes the SPG of the subject, and the coil is adapted to be positioned in the vicinity of the SPG.
For some applications, the control unit is adapted to generate the magnetic field with a strength sufficient to stimulate the site, and insufficient to substantially stimulate brain tissue of the subject.
For some applications, the apparatus includes a cooling element, adapted to prevent excessive heating of the coil.
For some applications, the coil includes between about 4 and about 30 loops of wire.
In an embodiment, the coil is adapted to be inserted into a nasal cavity of the subject. For some applications, the coil is substantially figure-eight-shaped. Alternatively, the coil is substantially 4-leaf-shaped. Alternatively, the coil is substantially circular. For some applications, the coil has a diameter of between about 3 mm and about 12 mm.
In an embodiment, the coil is adapted to be placed in a vicinity of a temporomandibular joint of the subject. For some applications, the coil has a diameter of between about 3 cm and about 12 cm.
In an embodiment, the coil is adapted to be placed around at least a portion of a head of the subject. For some applications, the coil has a diameter of between about 3 cm and about 12 cm.
There is also provided, in accordance with an embodiment of the present invention, a method for treating a condition of a subject, including:
selecting a site from the list consisting of: a sphenopalatine ganglion (SPG) of the subject, a greater palatine nerve of the subject, a lesser palatine nerve of the subject, a sphenopalatine nerve of the subject, a communicating branch between a maxillary nerve and an SPG of the subject, an otic ganglion of the subject, an afferent fiber going into the otic ganglion of the subject, an efferent fiber going out of the otic ganglion of the subject, an infraorbital nerve of the subject, a vidian nerve of the subject, a greater superficial petrosal nerve of the subject, and a lesser deep petrosal nerve of the subject; and
generating a magnetic field in the vicinity of the site capable of inducing an increase in cerebral flood flow of the subject, so as to treat the condition.
There is further provided, in accordance with an embodiment of the present invention, a method for treating a condition of a subject, including:
selecting a site from the list consisting of: a sphenopalatine ganglion (SPG) of the subject, a greater palatine nerve of the subject, a lesser palatine nerve of the subject, a sphenopalatine nerve of the subject, a communicating branch between a maxillary nerve and an SPG of the subject, an otic ganglion of the subject, an afferent fiber going into the otic ganglion of the subject, an efferent fiber going out of the otic ganglion of the subject, an infraorbital nerve of the subject, a vidian nerve of the subject, a greater superficial petrosal nerve of the subject, and a lesser deep petrosal nerve of the subject; and
generating a magnetic field in the vicinity of the site capable of inducing an increase in permeability of a blood-brain barrier (BBB) of the subject, so as to treat the condition.
There is also provided, in accordance with an embodiment of the present invention, a method for facilitating a diagnosis of a condition of a subject, including:
selecting a site from the list consisting of: a sphenopalatine ganglion (SPG) of the subject, a greater palatine nerve of the subject, a lesser palatine nerve of the subject, a sphenopalatine nerve of the subject, a communicating branch between a maxillary nerve and an SPG of the subject, an otic ganglion of the subject, an afferent fiber going into the otic ganglion of the subject, an efferent fiber going out of the otic ganglion of the subject, an infraorbital nerve of the subject, a vidian nerve of the subject, a greater superficial petrosal nerve of the subject, and a lesser deep petrosal nerve of the subject; and
generating a magnetic field in the vicinity of the site capable of inducing an increase in permeability of a blood-brain barrier (BBB) of the subject sufficient to increase passage of a diagnostic agent across the BBB into a central nervous system (CNS) of the subject.
There is further provided, in accordance with an embodiment of the present invention, a method for facilitating delivery of a drug to a subject, including:
selecting a site from the list consisting of: a sphenopalatine ganglion (SPG) of the subject, a greater palatine nerve of the subject, a lesser palatine nerve of the subject, a sphenopalatine nerve of the subject, a communicating branch between a maxillary nerve and an SPG of the subject, an otic ganglion of the subject, an afferent fiber going into the otic ganglion of the subject, an efferent fiber going out of the otic ganglion of the subject, an infraorbital nerve of the subject, a vidian nerve of the subject, a greater superficial petrosal nerve of the subject, and a lesser deep petrosal nerve of the subject; and
generating a magnetic field in the vicinity of the site capable of inducing an increase in permeability of a blood-brain barrier (BBB) of the subject sufficient to increase passage of the drug across the BBB into a central nervous system (CNS) of the subject.
In an embodiment, the method includes administering the drug to a body of the subject, in conjunction with generating the magnetic field.
There is still further provided, in accordance with an embodiment of the present invention, a method for facilitating a diagnosis of a condition of a subject, including:
selecting a site from the list consisting of: a sphenopalatine ganglion (SPG) of the subject, a greater palatine nerve of the subject, a lesser palatine nerve of the subject, a sphenopalatine nerve of the subject, a communicating branch between a maxillary nerve and an SPG of the subject, an otic ganglion of the subject, an afferent fiber going into the otic ganglion of the subject, an efferent fiber going out of the otic ganglion of the subject, an infraorbital nerve of the subject, a vidian nerve of the subject, a greater superficial petrosal nerve of the subject, and a lesser deep petrosal nerve of the subject; and
generating a magnetic field in the vicinity of the site capable of inducing an increase in permeability of a blood-brain barrier (BBB) of the subject sufficient to increase passage of a constituent of a central nervous system (CNS) of the subject across the BBB into a systemic blood circulation of the subject.
For some applications, the method includes measuring a concentration of the constituent in the systemic blood circulation.
There is also provided, in accordance with an embodiment of the present invention, a method for modifying a property of a brain of a subject, including generating a magnetic field in the vicinity of a branch of a cranial nerve V of the subject configured to affect physiological activity of a sphenopalatine ganglion (SPG) of the subject at a level sufficient to induce an increase in permeability of a blood-brain barrier (BBB) of the subject.
There is further provided, in accordance with an embodiment of the present invention, a method for modifying a property of a brain of a subject, including generating a magnetic field in the vicinity of a branch of a cranial nerve V of the subject configured to affect physiological activity of a sphenopalatine ganglion (SPG) of the subject at a level sufficient to induce an increase in cerebral blood flow (CBF) of the subject.
The present invention will be more fully understood from the following detailed description of the embodiments thereof, taken together with the drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a neural stimulation system, in accordance with an embodiment of the present invention;
FIG. 2 is a schematic cross-sectional illustration of a spring-loaded locking element engaging the greater palatine canal, in accordance with an embodiment of the present invention;
FIGS. 3A and 3B are schematic illustrations of a laterally displaced configuration of a stimulator of the system of FIG. 1 , in accordance with an embodiment of the present invention;
FIGS. 4A and 4B are schematic illustrations of out-of-plane configurations of the stimulator of the system of FIG. 1 , in accordance with respective embodiments of the present invention;
FIGS. 5A-D are schematic illustrations of a longitudinally-oriented configuration of the stimulator of the system of FIG. 1 , in accordance with an embodiment of the present invention;
FIGS. 6A-D are schematic illustrations of variable-length support elements of the system of FIG. 1 , in accordance with respective embodiments of the present invention;
FIGS. 7A-B are schematic illustrations of an oral element of the system of FIG. 1 , in accordance with respective embodiments of the present invention;
FIG. 8 is a schematic illustration of an oral element of the system of FIG. 1 coupled to an oral appliance, in accordance with an embodiment of the present invention;
FIG. 9 is a schematic illustration of a contact-based energy transmission configuration of the system of FIG. 1 , in accordance with an embodiment of the present invention;
FIG. 10 is a schematic illustration of a configuration of a contact of the configuration of FIG. 9 , in accordance with an embodiment of the present invention;
FIG. 11A-B are schematic illustrations of energy and data transmission paths between components of the system of FIG. 1 , in accordance with respective embodiments of the present invention;
FIG. 12 is a schematic illustration of another neural stimulation system, in accordance with an embodiment of the present invention;
FIG. 13 is a schematic illustration of an implantable submucosal antenna of the system of FIG. 12 , in accordance with an embodiment of the present invention;
FIGS. 14A-B are schematic illustrations of energy and data transmission paths between components of the system of FIG. 12 , in accordance with respective embodiments of the present invention;
FIG. 15 is a schematic illustration of a configuration of the stimulator of the stimulation system of FIGS. 12-14 , in accordance with an embodiment of the present invention;
FIG. 16 is a schematic illustration of an electrode configuration, in accordance with an embodiment of the present invention;
FIGS. 17A-C are schematic illustrations of an array of electrodes, in accordance with an embodiment of the present invention;
FIG. 18 is a schematic pictorial view of a stimulation system for stimulation of a modulation target site, in accordance with an embodiment of the present invention;
FIG. 19 is a schematic illustration of a vasodilation measurement instrument, in accordance with an embodiment of the present invention;
FIG. 20 is a schematic illustration of a laser Doppler imaging (LDI) device, in accordance with an embodiment of the present invention;
FIG. 21 is a schematic illustration of a thermometer, in accordance with an embodiment of the present invention;
FIG. 22 is a schematic illustration of a transcranial Doppler ultrasonography device, in accordance with an embodiment of the present invention;
FIGS. 23A and 23B are schematic illustrations of nasal magnetic induction devices, in accordance with an embodiment of the present invention;
FIGS. 24A and 24B are schematic illustrations of an external magnetic induction device, in accordance with an embodiment of the present invention;
FIG. 25 is a schematic pictorial view of an electrical stimulation system comprising an implantable stimulator for stimulation of an MTS, in accordance with an embodiment of the present invention;
FIG. 26 is a schematic pictorial view of another stimulator for stimulation of an MTS, in accordance with an embodiment of the present invention;
FIG. 27 is a graph illustrating electrical stimulation protocols, in accordance with an embodiment of the present invention;
FIG. 28 is a graph showing a rehabilitation protocol for treating stroke, in accordance with an embodiment of the present invention;
FIG. 29 is a graph showing changes in cerebral blood flow (CBF) vs. baseline using three different SPG stimulation protocols, measured in accordance with an embodiment of the present invention;
FIG. 30 is a graph showing the effect of SPG stimulation beginning three hours after permanent middle cerebral artery occlusion (pCMAO) in rats, measured in accordance with an embodiment of the present invention;
FIGS. 31 and 32 are graphs showing results of an in vivo experiment assessing the effect of SPG stimulation performed three hours following stroke, measured in accordance with an embodiment of the present invention;
FIGS. 33A-C are graphs showing the results of in vivo experiments assessing the effect of SPG stimulation performed three hours following stroke, measured in accordance with respective embodiments of the present invention;
FIG. 34 is a graph showing results of an in vivo experiment assessing the effect of rehabilitative SPG stimulation, measured in accordance with an embodiment of the present invention;
FIGS. 35A-C are graphs showing results of an in vivo experiment assessing the effect of rehabilitative SPG stimulation, measured in accordance with an embodiment of the present invention;
FIGS. 36A-H are graphs showing results of an in vivo experiment assessing the effect of long-term rehabilitative SPG stimulation, measured in accordance with an embodiment of the present invention; and
FIG. 37 is a graph showing a protocol for treating a brain tumor, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic illustration of a neural stimulation system 20 , in accordance with an embodiment of the present invention. System 20 typically comprises an implantable neural stimulator 30 , an oral element 32 , and an external control unit 34 . Stimulator 30 comprises an elongated support element 36 , one or more electrodes 38 fixed to the support element in a vicinity of a distal end thereof, and circuitry 40 coupled to the support element in a vicinity of a proximal end thereof. Circuitry 40 typically comprises a wireless coupling element (which typically comprises a coil), and additional elements, such as one or more rectifiers, capacitors, amplifiers, or filters. One or more leads (not shown in FIG. 1 ), which pass along, through, or around support element 36 , couple electrodes 38 to circuitry 40 . Alternatively, the leads function as the support element, i.e., the support element does not comprise any structural elements in addition to the leads. Further alternatively, the leads provide a substantial portion of the structural support of the support element, and the balance of the structural support is provided by other elements. For example, support element 36 may comprise the leads and a flexible sleeve surrounding the leads; the leads supply most of the structural support of the support element, while the sleeve allows smooth passage of the leads through the greater palatine canal. Circuitry 40 is shown schematically in FIG. 1 ; several more detailed configurations of the circuitry are described hereinbelow with reference to FIGS. 3A-B , 4 A-B, and 5 A-D.
Stimulator 30 is adapted to be passed through a greater palatine foramen 42 of a hard palate 50 of an oral cavity 52 of a subject into a greater palatine canal 54 , such that electrodes 38 are brought into a vicinity of a sphenopalatine ganglion (SPG) 56 . For some applications, the entire stimulator is contained within greater palatine canal 54 , while for other applications, at least a portion of the circuitry and/or the support element are positioned submucosally in the oral cavity. For clarity of illustration, the greater and lesser palatine nerves, and the greater and less palatine arteries are not shown in the figures. During an implantation procedure, stimulator 30 is typically passed through greater palatine foramen 42 posterior to the greater palatine nerve and artery, which are manipulated into an anterior position within the canal.
For some applications, electrodes 38 apply a monophasic waveform to SPG 56 , while for other applications, electrodes 38 apply a biphasic waveform. Alternatively or additionally, waveforms and/or stimulation techniques may be used that are described in one or more of the patent applications incorporated by reference hereinbelow, or waveforms and/or stimulation techniques may be used that are known in the art of neural stimulation.
For some applications, the distal end of support element 36 comprises a surgical punch 60 , which is adapted to be passed through mucosa 58 and greater palatine foramen 42 without requiring a prior surgical incision in the mucosa, i.e., without requiring the use of a surgical knife or other tool. Circuitry 40 is sufficiently small so as to be able to pass through the punch incision without requiring the incision to be surgically enlarged.
For some applications, stimulator 30 comprises a locking element, such as in a vicinity of the proximal end thereof, which is adapted to hold the stimulator in place after insertion. For some applications, the locking element comprises a screw, which is adapted to couple the stimulator to the palate or the alveolar process of the maxilla. Alternatively or additionally, the locking element comprises a bonding agent, which is adapted to bond the stimulator to the palate, the alveolar process of the maxilla, or an internal surface of greater palatine canal 54 .
Reference is made to FIG. 2 , which is a schematic cross-sectional illustration of a spring-loaded locking element 62 engaging greater palatine canal 54 , in accordance with an embodiment of the present invention. Locking element 62 applies lateral pressure on the interior surface of a portion of greater palatine canal 54 in a vicinity of foramen 42 , thereby locking elongated support element 36 in place in the canal. Locking element 62 is configured so as to not interfere with a descending palatine artery 64 or a greater palatine nerve 66 , both of which pass through greater palatine canal 54 .
For some applications, support element 36 has a length of between about 1.8 and about 3 cm, such as between about 2.6 cm and about 3 cm, e.g., between about 2.6 and about 3 cm, such as about 2.8 cm, and has a curvature that follows that of the greater palatine canal. For some applications, support element 36 has a diameter at its widest portion of between about 1 and about 4 mm. For some applications, support element 36 comprises a tube. For some applications, support element 36 is semi-rigid (i.e., it generally keeps its original shape during a placement procedure). For example, support element 36 may be sufficiently rigid to enable insertion of the support element into a body of the subject by pushing from a vicinity of a proximal end of the support element. For some applications, support element 36 and electrodes 38 together are similar to conventional concentric needle electrodes, such as Medtronic, Inc. needle electrode model DCN50, or Oxford Instruments Plc. needle electrode models X53153, X53155, X53156, X53158, or X53159.
Each of electrodes 38 typically comprises a suitable conductive material, for example, a physiologically-acceptable material such as silver, iridium, platinum, a platinum iridium alloy, titanium, nitinol, or a nickel-chrome alloy. For some applications, each of the electrodes has a surface area of between about 1 and about 8 mm 2 , such as about 2.653 or about 6.123 mm 2 . For some applications, electrodes 38 are recessed within support element 36 , while for other applications the electrodes are flush with the surface of the support element, or protrude therefrom. Electrodes 38 are insulated from one another with a physiologically-acceptable material such as polyethylene, polyurethane, or a co-polymer of either of these. For some applications, the electrodes are spiral in shape, for better contact, and may have a hook shaped distal end for hooking into or near the SPG. Alternatively or additionally, the electrodes may comprise simple wire electrodes, spring-loaded “crocodile” electrodes, or adhesive probes, as appropriate. For some applications, the electrodes are coated with a biocompatible material configured to enhance the surface area of the electrodes, thereby increasing the capacitance and reducing the resistance of the electrodes. For example, the material may comprise a platinum/iridium alloy, and/or may be applied with a sputtering process, such as commercially available from Johnson Matthey Plc, Advanced Metals Technology division (London, UK).
Optionally, support element 36 comprises one or more marks (not shown) that indicate the depth of insertion of stimulator 30 into greater palatine canal 54 . Alternatively or additionally, for some applications support element 36 comprises a stopper (not shown) in a vicinity of the marks, that mechanically prevents insertion of the support element into the canal beyond a certain depth.
Reference is made to FIGS. 3A-B , 4 A-B, and 5 A-D, which are schematic illustrations of several configurations of stimulator 30 , in accordance with respective embodiments of the present invention. In these embodiments, stimulator 30 comprises a circuit module 41 , which comprises circuitry 40 coupled to a printed circuit board. Circuit module 41 has a generally flat shape, typically with a thickness of less than about 2 mm, such as less than about 1.2 mm, e.g., about 1.05 mm. For some applications, one or more layers of coating are applied to circuit module 41 , such as in order to provide a conforming, thin, smooth, watertight, biocompatible, and/or mechanically-protective surface. For example, a first, innermost coating may comprise an inert biocompatible polymer, such as Parylene C, having a thickness of between about 10 and about 15 microns. A second watertight mineral-based sealant, such as Al 2 O 3 , SiO 2 , or Si 2 N 3 , may be applied over the innermost coating by sputtering. The thickness of the watertight sealant is typically between about 1 and about 2 microns. A third, outermost coating of an inert biocompatible polymer, such as Parylene C, having a thickness of between about 10 and about 15 microns, may be applied over the watertight sealant.
FIGS. 3A and 3B are schematic illustrations of a laterally displaced configuration of stimulator 30 , in accordance with an embodiment of the present invention. FIG. 3A shows stimulator 30 in an unfolded position. Circuit module 41 has a generally flat shape, and may be generally elliptical, as shown in FIG. 3A , or may have another shape, such as rectangular. Prior to insertion in greater palatine canal 54 , support element 36 is folded at a fold 44 at an angle α approximately equal to the angle between greater palatine canal 54 and hard palate 50 in a vicinity of foramen 42 . During an implantation procedure, (a) a submucosal surface on the hard palate is prepared, such as by raising a mucosal flap, by creating a mucosal opening using a retractor, and/or by preparing a submucosal pocket using a tool which has generally the same shape and dimensions as circuit module 41 , (b) support element 36 is inserted into greater palatine canal 54 , (c) circuit module 41 is placed against the exposed lower surface of hard palate 50 , and (d) mucosa 58 is closed over circuit module 41 and the portion of support element that protrudes from greater palatine canal 54 . For implantation procedures during which a mucosal flap is raised, an approximately 3 cm incision is typically required to raise the mucosal flap. For some applications, the circuit module is coupled to the hard palate, such as by using at least one nail or screw (coupling not shown). Typically, the distal portion of support element 36 beyond fold 44 has a length L 1 of between about 26 and about 30 mm, e.g., about 28 mm, and the entire stimulator 30 in an unfolded position, including circuit module 41 , has a length L 2 of between about 40 and about 44 mm, e.g., about 42 mm.
FIGS. 4A and 4B are schematic illustrations of out-of-plane configurations of stimulator 30 , in accordance with respective embodiments of the present invention. In these configurations, a proximal end 46 of support element 36 is coupled directly to circuit module 41 , such that an angle β between support element 36 and the surface of circuit module 41 is approximately equal to the angle between greater palatine canal 54 and hard palate 50 in a vicinity of foramen 42 . As in the configuration shown in FIGS. 3A and 3B , circuit module 41 has a generally flat shape, and may be generally elliptical, or may have another shape, such as rectangular. In the configuration shown in FIG. 4A , proximal end 46 of support element 36 is coupled to circuit module 41 in a vicinity of a center of the surface of the circuit module. For some applications, the circuit module is coupled to the support element such that the longer axis or side of the circuit module is oriented in an anterior-posterior direction. Alternatively, the longer axis or side of the circuit module is oriented in a left-right direction, or in another direction. Typically, support element 36 has a length of between about 26 and about 30 mm, e.g., about 28 mm.
In the configuration shown in FIG. 4B , proximal end 46 is coupled to circuit module in a vicinity of an edge of the surface of the circuit module. The support element may be coupled to any point on the edge, e.g., in a vicinity of an end of a major axis or a minor axis of the circuit module. For some applications, proximal end 46 of support element 36 is coupled to circuit module 41 at a location between the center of the circuit module and the edge of the circuit module. For some applications, the circuit module is coupled to the support element such that the circuit module extends in an anterior direction, in a posterior direction, towards the center of the mouth, or towards the maxillary bone. For example, when the circuit module extends in a posterior direction or towards the center of the mouth, the circuit module is less likely to interfere with branches of the greater palatine nerve or greater palatine artery that extend in an anterior direction from greater palatine foramen 42 . For some applications, circuit module 41 is generally kidney-shaped.
During an implantation procedure, (a) a submucosal surface on the hard palate is prepared, such as by raising a mucosal flap, by creating a mucosal opening using a retractor, and/or by preparing a submucosal pocket using a tool which has generally the same shape and dimensions as circuit module 41 , (b) support element 36 is inserted into greater palatine canal 54 , (c) circuit module 41 is placed against the exposed lower surface of hard palate 50 , and (d) mucosa 58 is closed over circuit module 41 . For implantation procedures during which a mucosal flap is raised, an approximately 7 mm incision is typically required to raise the mucosal flap. For some applications, the circuit module is coupled to the hard palate, such as by using at least one nail or screw (coupling not shown).
FIGS. 5A-D are schematic illustrations of a longitudinally-oriented configuration of stimulator 30 , in accordance with an embodiment of the present invention. In this configuration, a proximal end 46 of support element 36 is coupled to circuit module 41 . Circuit module 41 has a generally flat shape, and may be generally elliptical, as shown in FIG. 5A , or may have another shape, such as rectangular. As shown in FIGS. 5B-D , a proximal portion 48 of support element 36 which protrudes from greater palatine canal 54 is sufficiently flexible to follow the contour of the palate and alveolar process.
During an implantation procedure, (a) a submucosal surface on the hard palate is prepared, such as by raising a mucosal flap, by creating a mucosal opening using a retractor, and/or by preparing a submucosal pocket using a tool which has generally the same shape and dimensions as circuit module 41 , (b) support element 36 is inserted into greater palatine canal 54 , (c) circuit module 41 is placed against an alveolar process 68 of the maxilla, and (d) mucosa 58 is closed over circuit module 41 . For implantation procedures during which a mucosal flap is raised, an approximately 5 mm incision is typically required to raise the mucosal flap. For some applications, the circuit module is coupled to the alveolar process, such as by using at least one nail or screw (coupling not shown).
Reference is made to FIGS. 6A-D , which are schematic illustrations of variable-length support elements 36 , in accordance with respective embodiments of the present invention. In these embodiments, the length of support element 36 is adjustable during the implantation procedure, in order to accommodate differing lengths of greater palatine canal 54 . It is noted that the variation in the length of the greater palatine canal in adults is generally less than +/−2 mm, so the length of support elements 36 in these embodiment need only vary by a relatively small percentage.
In the configuration shown in FIG. 6A , support element 36 is configured to allow telescopic coupling of a portion 80 of the support element. Electrode leads 84 pass through support element 36 , including portion 80 . The leads have sufficient slack so as to not interfere with the expansion and contraction of telescopic portion 80 .
In the configuration shown in FIG. 6B , a portion of support element 36 is shaped so as to define one or more accordion pleats 82 . Accordion pleats 82 are typically biased such that they are generally extended when in a relaxed position. Electrode leads 84 pass through support element 36 , including the accordion portion. The leads have sufficient slack so as to not interfere with the expansion and contraction of accordion pleats 82 . For some applications, support element 36 comprises a sleeve 88 , which surrounds accordion pleats 82 . The sleeve typically has a length no greater than the length of support element 36 when the support element is in its most contracted position, i.e., the sleeve surrounds only a portion of the non-accordion-pleated portion of the electrode leads. Such a length allows the total length of the support element to vary without being constrained by the length of the sleeve. Sleeve 88 typically comprises a flexible, biocompatible material, such as silicone. Sleeve 88 typically has a length less than 28 mm, e.g., less than 26 mm. Alternatively, for some applications, electrode leads 84 are accordion-pleated, in which case the electrode leads serve as support element 36 .
In the configuration shown in FIG. 6C , electrode leads 84 are helically wound, so as to form a spring 86 . The spring is typically biased so as to have an expanded resting position. For some applications, support element 36 comprises sleeve 88 , which surrounds spring 86 . The sleeve typically has a length no greater than the length of support element 36 when the support element is in its most contracted position, i.e., the sleeve surrounds only a portion of the non-helically-wound portion of the electrode leads. Such a length allows the total length of the support element to vary without being constrained by the length of the sleeve.
In the configuration in FIG. 6D , electrode leads 84 are shaped to as to define at least one omega-shaped portion 90 . Portion 90 is typically biased so as to have extended resting positions. For some applications, support element 36 comprises sleeve 88 , as described above with reference to FIGS. 6B and 6C .
Reference is made to FIGS. 7A-B , which are schematic illustration of oral element 32 , in accordance with respective embodiments of the present invention. Oral element 32 is adapted to be placed in oral cavity 52 in a vicinity of implanted circuitry 40 of stimulator 30 , e.g., in a vicinity of or in contact with the roof of the oral cavity. Oral element 32 typically comprises a power source 72 , such as a rechargeable or disposable battery, circuitry 73 , and at least one wireless coupling element 74 . Depending on the specific application, wireless coupling element 74 transmits energy and/or data to circuitry 40 , as described hereinbelow. For some applications, wireless coupling element 74 comprises a relatively large coil or a plurality of smaller coils, which may increase the likelihood that at least some portion of the generated magnetic field achieves good wireless coupling with implanted circuitry 40 of stimulator 30 , even if oral element 32 is not precisely positioned or aligned with respect to stimulator 30 , or if oral element 32 moves slightly after it has been placed against the roof of the oral cavity. For some applications in which wireless coupling element 74 comprises a plurality of coils, the coils are oriented with respect to one another such that the respective axes of the coils are not parallel with one another. For example, the coils may be oriented such that two or three of the axes are approximately orthogonal with one another.
In the embodiment shown in FIG. 7A , oral element 32 is adapted to be temporarily placed in oral cavity 52 , without mechanically coupling the oral element to a surface of the oral cavity. For some applications, oral element 32 is coupled to an oral appliance, as described hereinbelow with reference to FIG. 8 . In the embodiment shown in FIG. 7B , oral element 32 is adapted to be fixed to the roof of oral cavity 52 , such as by using one or more screws 70 , nails, or other surgical fastening devices.
FIG. 8 is a schematic illustration of oral element 32 coupled to an oral appliance 92 , in accordance with an embodiment of the present invention. Oral appliance 92 , which is typically shaped generally similarly to an orthodontic retainer, is configured to hold the oral element in a vicinity of or in contact with the roof of the oral cavity in a vicinity of implanted circuitry 40 of stimulator 30 . The use of oral appliance 92 , rather than mechanical coupling of oral element 32 to the roof of the oral cavity, generally reduces the likelihood of contamination. For some applications, oral appliance 92 is generally soft or semi-flexible, while for other applications, the oral appliance is generally rigid.
For some applications, oral element 32 does not comprise power source 72 . Instead, power is provided by a power source located outside of the oral cavity. For example, the oral appliance may be coupled by a cable to an external driver comprising a power source. For some applications, the driver is coupled to a headset or necklace worn by the subject. The driver or a separate external control unit, instead of oral element 32 , comprises all or a portion of circuitry 73 . For some applications, the driver is coupled to external control unit 34 , while for other applications, the driver comprises external control unit 34 . Alternatively, oral element 32 is wirelessly coupled to external control unit 34 , which may or may not be coupled to the external driver.
Reference is again made to FIGS. 5B-D . In the embodiment of the present invention shown in FIG. 5B , oral element 32 is configured to be coupled to a molar 98 or other tooth of the subject. For example, the oral element may comprise a clip or adhesive. Typically, the oral element is configured to be removably coupled to the tooth. For example, the oral element may be coupled to the tooth only during applications of stimulation by stimulator 30 , and removed between applications of stimulation.
In the embodiment shown in FIG. 5C , oral element 32 is configured to be coupled to gingiva 99 covering alveolar process 68 , and, optionally, to one or more teeth. For some applications, the oral element 32 is coupled to gingiva 99 using a clamp 101 . Alternatively or additionally, the oral element is adapted to be held in place by the subject biting down on the element.
In the embodiment shown in FIG. 5D , oral element 32 comprises a capsule 200 , which, for some applications, comprises power source 72 and circuitry 73 . Oral element 32 further comprises an elongated connecting element 202 , which couples capsule 200 to wireless coupling element 74 . Capsule 200 is configured to be placed and held between alveolar process 68 and the inner surface of a cheek 204 . For some applications, capsule 200 is generally cylindrical, similar in shape and size to a conventional dental cotton roll. Optionally, the capsule comprises a soft coating. Oral element 32 is configured such that wireless coupling element 74 is positioned on the lingual side of the teeth. For some applications, connecting element 202 passes over the occlusal surface of one or more teeth, as shown in FIG. 5D , while for other applications, connecting element 202 passes around the distal surface of the most distal molar (configuration not shown). Alternatively, connecting element 202 serves as wireless coupling element 74 .
For some applications, capsule 200 does not comprise power source 72 . Instead, power is provided by a power source located outside of the oral cavity. For example, the capsule may be coupled by a cable to an external driver comprising a power source. For some applications, the driver is coupled to a headset or necklace worn by the subject. The driver or a separate external control unit, instead of capsule 200 , comprises all or a portion of circuitry 73 . For some applications, the driver is coupled to external control unit 34 , while for other applications, the driver comprises external control unit 34 .
In an embodiment of the present invention, system 20 comprises a nasal element instead of or in addition to oral element 32 (configuration not shown). The nasal element is adapted to be inserted into a nostril of the subject, e.g., into the nasal vestibule. The nasal element comprises at least one wireless coupling element 74 that is wirelessly coupled to a transmit/receiver of stimulator 30 , for transmitting/receiving power and/or data to/from the stimulator. In this embodiment, circuitry 40 of stimulator 30 is not necessarily positioned at the proximal end of the stimulator.
For some applications, circuitry 40 of stimulator 30 comprises a wireless coupling element. Wireless coupling element 74 of oral element 32 is adapted to wirelessly transmit energy and/or data to the wireless coupling element of circuitry 40 , and/or to wirelessly receive data form the wireless coupling element of circuitry 40 . For these applications, each of the wireless coupling elements typically comprises at least one coil. For some applications, the wireless coupling elements are wirelessly coupled to one another using induction, such as when the wireless coupling elements are positioned in close proximity to one another. Alternatively, the wireless coupling elements are wirelessly coupled to one another using RF energy, such as when the wireless coupling elements are positioned at a greater distance from each other. Further alternatively, the wireless coupling elements are wirelessly coupled to one another using another form of energy, such as ultrasound energy, in which case the wireless coupling elements comprises ultrasound transducers, e.g., piezoelectric transducers. “Transducer element,” as used in the present application including the claims, means an element adapted to wirelessly transmit and/or receive energy and/or data, including a coil, a piezoelectric transducer, and other wireless transducers known in the art.
In an embodiment of the present invention, oral element 32 does not comprise wireless coupling element 74 . Instead, power source 72 of the oral element is coupled to circuitry 40 using a wire that passes through mucosa 58 . The techniques of this embodiment are generally more energy-efficient than wireless energy/data transfer techniques. As a result, the battery of power source 72 of oral element 32 may need to be replaced or recharged less frequently, or not at all. For some applications, oral element 32 is adapted to be implanted in a tooth of the subject. For some applications, the implanted oral element comprises a wireless communication element for external wireless communication, such as of data. For some applications, power source 72 comprises a rechargeable or a replaceable battery.
Reference is made to FIG. 9 , which is a schematic illustration of a contact-based energy transmission configuration of stimulation system 20 , in accordance with an embodiment of the present invention. In this embodiment, a proximal end of support element 36 of stimulator 30 comprises a contact 94 that protrudes slightly from mucosa 58 . Oral element 32 comprises a contact 96 , which is brought into physical contact with contact 94 for transmitting power and/or data to/from circuitry 40 . Contact 94 of stimulator 30 is typically in sealed contact with mucosa 58 , in a similar manner to pacemaker leads. For some applications, contact 94 is typically semi-spherical in shape, as shown in FIG. 9 . Alternatively, contact 94 is generally flat or concave in shape. The use of the contact-based techniques of this embodiment does not require alignment of oral element 32 with circuitry 40 . In addition, the contact-based techniques of this embodiment result in a uniform, predictable transfer of energy, and are generally more energy-efficient than wireless energy/data transfer techniques. As a result, the battery of power source 72 of oral element 32 may need to be replaced or recharged less frequently, or not at all.
FIG. 10 is a schematic illustration of a configuration of contact 94 , in accordance with an embodiment of the present invention. In this embodiment, contact 94 comprises positive and negative terminals 95 and 96 , each of which is coupled to a respective lead 84 . For some applications, support element 36 , at a portion thereof which passes through mucosa 58 , comprises a matrix 97 , which is adapted to promote mucosal tissue growth therein. The growth of mucosal tissue in the matrix generally reduces the likelihood of infection, and helps hold contact 94 in place. For some applications, contact 94 and/or matrix 97 is coated with an antiseptic substance, such as an antibacterial substance, to reduce the likelihood of infection passing from the oral cavity through the mucosa.
Reference is made to FIG. 11A , which is a schematic illustration of energy and data transmission paths between components of system 20 , in accordance with an embodiment of the present invention. Typically, wireless coupling element 74 of oral element 32 is adapted to wirelessly transmit energy to circuitry 40 of stimulator 30 , for powering the stimulator, as symbolically indicated by an arrow 100 . The close proximity of the wireless coupling elements of oral element 32 and stimulator 30 generally allows the use of relatively low energy levels and/or a small receiving element in circuitry 40 , e.g., a small coil or piezoelectric transducer.
In an embodiment of the present invention, the energy transmitted to circuitry 40 of stimulator 30 does not include the stimulation waveform to be applied using electrodes 38 . Instead, energy is typically transferred using a continuous wave (i.e., electromagnetic energy of constant amplitude and frequency). Circuitry 40 of stimulator 30 is configured to generate the stimulation waveform applied by electrodes 38 . Alternatively, the energy is transferred using a quasi-continuous wave, which encodes data, which data is used by circuitry to generate the stimulation waveform applied by electrodes 38 . The techniques of this embodiment may be employed, for example, with the configurations of stimulation system 20 described hereinabove with reference to FIGS. 1 and/or 8 , and/or hereinbelow with reference to FIGS. 12-14 and/or 15 . The transfer of energy only, in accordance with this embodiment, generally allows complete control of the waveform delivered by electrodes 38 , because the generation of the waveform is independent of the wireless coupling of oral element 32 and circuitry 40 of stimulator 30 . Furthermore, for some applications, circuitry 40 generates a bipolar waveform, which typically reduces the total accumulated charge in the tissue, thus improving safety and electrode life span.
For some applications, wireless coupling element 74 of oral element 32 is additionally configured to transmit and/or receive data to/from circuitry 40 of stimulator 30 , as indicated by an arrow 102 . Such data typically includes stimulation control signals, parameters, and/or feedback information. Such data is typically transmitted only periodically, rather than constantly during stimulation. Circuitry 40 of stimulator 30 configures at least a portion of the stimulation parameters based on the received information. For these applications, circuitry 40 of stimulator 30 is configured to generate the stimulation waveform applied by electrodes 38 , based on the configured parameters.
For some applications, wireless coupling element 74 of oral element 32 (either the same wireless coupling element used for transmitting and receiving data to and from circuitry 40 of stimulator 30 , or a separate wireless coupling element) is adapted to wirelessly relay the data to and receive data from external control unit 34 (as indicated by an arrow 104 ), which also comprises a wireless coupling element 106 . Typically, but not necessarily, substantive processing and generation of the data is performed exclusively by external control unit 34 , rather than by oral element 32 . For some applications, wireless coupling element 74 combines the data and the energy transmitted to circuitry 40 of stimulator 30 into a single signal, such as by modulating the data onto the carrier frequency of the transmitted energy, in which case circuitry 40 demodulates the received signal to obtain the data. Alternatively, wireless coupling element 74 transmits the data and the energy in separate signals. Alternatively, for some applications, circuitry 40 of stimulator 30 is configured to transmit and/or receive all or a portion of the data directly to/from external control unit 34 (as indicated by an arrow 108 ), bypassing oral element 32 , such as by using a VHF signal.
For some applications in which the energy is transferred using a continuous wave, the energy is transferred from outside the body of the subject, e.g., from a vicinity of the cheek or ear of the subject, rather than from oral element 32 . This is possible because the continuous wave generally has low peak power levels. For these applications, system 20 typically does not comprise oral element 32 .
In an embodiment of the present invention, circuitry 73 of oral element 32 generates the stimulation waveform, and wirelessly transmits the waveform to circuitry 40 of stimulator 30 . For these applications, circuitry 40 of stimulator 30 is generally passive, and simply relays the received waveform to electrodes 38 with minimal or no processing. Circuitry 40 typically comprises a simple circuit, including one or more rectifiers and capacitors. The techniques of this embodiment may be employed, for example, with the configurations of stimulation system 20 described hereinabove with reference to FIGS. 1 , 8 , and/or 9 .
For some applications, system 20 is configured to perform a calibration procedure in which the absolute energy level of the applied waveform is determined, and adjusted appropriately to achieve a desired stimulation level. Such calibration compensates for the patient-to-patient variability in energy transfer, caused, for example, by differences in placement and/or orientation of oral element 32 or circuitry 40 of stimulator 40 , and/or inter-patient anatomical differences, e.g., thickness of the mucosa.
Reference is made to FIG. 11B , which is a schematic illustration of energy and data transmission paths between components of system 20 , in accordance with an embodiment of the present invention. Except as described hereinbelow, this embodiment is similar to the embodiment described hereinabove with reference to FIG. 11A . In this embodiment, system 20 additionally comprises an external driver 110 , which comprises power source 72 and circuitry 73 . Oral element 32 comprises wireless coupling element 74 , but typically does not comprise power source 72 or circuitry 73 (the oral element and/or the wireless coupling element may comprise minimal circuitry, such as one or more rectifiers or capacitors). Oral element 32 is electrically coupled to external driver 110 by an elongated flexible coupling element 112 , which comprises one or more wires. Driver 110 is typically adapted to be physically coupled to a body of the subject, such as by being coupled to headset or a necklace.
Driver 110 typically comprises a wireless coupling element 114 , which the driver uses to wirelessly relay data to and receive data from external control unit 34 (as indicated by an arrow 116 ). For example, the data may be transmitted using the Bluetooth protocol or another wireless communication protocol, or using an infrared signal. Alternatively, driver 110 is coupled to external control unit 34 by one or more wires (configuration not shown).
Reference is made to FIG. 12 , which is a schematic illustration of a neural stimulation system 120 , in accordance with an embodiment of the present invention. Except as noted hereinbelow, elements of system 120 are the same as corresponding elements of system 20 having the same reference numerals. System 120 comprises implantable neural stimulator 30 and external control unit 34 . Stimulator 30 comprises elongated support element 36 , one or more electrodes 38 fixed to the support element in the vicinity of the distal end thereof, and an implantable submucosal antenna 122 coupled to the support element in a vicinity of the proximal end thereof. Submucosal antenna 122 is adapted to be implanted in the roof of oral cavity 52 between oral mucosa 58 and a palate, e.g., hard palate 50 and/or a soft palate 134 , and to generally conform to the shape of the palate.
FIG. 13 is a schematic illustration of implantable submucosal antenna 122 , in accordance with an embodiment of the present invention. Submucosal antenna 122 comprises a thin, flexible sheet 124 , which comprises at least one coil 126 . Sheet 124 comprises a flexible biocompatible material, such as silicone.
Reference is made to FIG. 14A , which is a schematic illustration of energy and data transmission paths between components of system 120 , in accordance with an embodiment of the present invention. System 120 typically lacks oral element 32 of system 20 . Instead, external control unit 34 is adapted to transmit power, typically using RF energy, directly to submucosal antenna 122 , for powering stimulator 30 , as indicated by an arrow 140 , and to transmit and/or receive data directly to/from the submucosal antenna, as indicated by an arrow 142 . Such data typically includes stimulation control signals, parameters, and/or feedback information. Such data is typically transmitted only periodically, rather than constantly during stimulation. Circuitry 40 of stimulator 30 is configured to generate the stimulation waveform applied by electrodes 38 , based on the configured parameters.
For some applications, wireless coupling element 106 combines the data and the energy into a single signal, such as by modulating the data onto the carrier frequency of the transmitted energy, in which case submucosal antenna 122 demodulates the received signal to obtain the data. Alternatively, wireless coupling element 106 transmits the data and the energy in separate signals. Alternatively, for some applications, stimulator 30 additionally comprises a wireless coupling element 144 , to/from which external control unit 34 transmits and/or receives data, such as by using a VHF signal. Typically, external control unit 34 is adapted to be placed in a vicinity of a head of the subject, such as in a vicinity of an ear of the subject. For some applications, external control unit 34 is adapted to be coupled to the ear. For example, the control unit may comprise or be integrated into a wired or wireless headset, such as a cellular phone headset.
Reference is made to FIG. 14B , which is a schematic illustration of energy and data transmission paths between components of system 120 , in accordance with an embodiment of the present invention. Except as described hereinbelow, this embodiment is similar to the embodiment described hereinabove with reference to FIG. 14A . In this embodiment, system 120 additionally comprises external driver 110 , which comprises power source 72 , circuitry 73 , and at least one wireless coupling element 128 . Driver 110 is typically adapted to be worn by the subject, such as by being coupled to headset or a necklace. Driver 110 is adapted to use wireless coupling element 128 to transmit power, typically using RF energy, directly to submucosal antenna 122 , for powering stimulator 30 , as indicated by an arrow 140 , and to transmit and/or receive data directly to/from the submucosal antenna, as indicated by an arrow 142 .
Driver 110 typically uses wireless coupling element 128 , or a separate wireless coupling element (not shown), to wirelessly relay data to and receive data from external control unit 34 (as indicated by an arrow 130 ). For example, the data may be transmitted using the Bluetooth protocol or another wireless communication protocol, or using an infrared signal. Alternatively, driver 110 is coupled to external control unit 34 by one or more wires (configuration not shown).
Reference is made to FIG. 15 , which is a schematic illustration of a configuration of stimulator 30 for use in stimulation system 120 , described hereinabove with reference to FIGS. 12-14 , in accordance with an embodiment of the present invention. In this embodiment, instead of submucosal antenna 122 , system 120 comprises a coil antenna 160 , at least a portion of which is coiled around at least a portion 162 of support element 36 . Alternatively, coil antenna 160 is an integral part of portion 162 . For some applications, coil antenna 160 comprises ferrite. For some applications, a sleeve is placed around all or a portion of coil antenna 160 and/or support element 36 (configuration not shown). Typically, the distal end of support element 36 comprises surgical punch 60 , described hereinabove with reference to FIG. 1 . For some applications, coil antenna 160 comprises a plurality of coils arranged in various orientations, which generally improves wireless coupling with wireless coupling element 106 of external control unit 34 . For example, the plurality of coils may comprise two or three coils oriented approximately orthogonally to one another. In the configuration shown in FIG. 15 , support element 36 and coil antenna 160 are typically adapted to be contained entirely within greater palatine canal 54 .
Reference is made to FIG. 16 , which is a schematic illustration of a configuration of electrodes 38 , in accordance with an embodiment of the present invention. In this embodiment, electrodes 38 comprise at least one (e.g., exactly one) cathode 150 , and at least one (e.g., exactly one) anode 152 . Cathode 150 is typically located closer to a distal tip 154 of support element 36 than is anode 152 . Typically, a length L 1 of anode 152 is greater than a length L 2 of cathode 150 , such as at least 200% of length L 2 . A closest distance D 1 between cathode 150 and anode 152 is typically greater than a closest distance D 2 between any portion of cathode 150 and any portion of SPG 56 .
In an embodiment of the present invention, a method for implanting stimulator 30 in greater palatine canal 54 comprises placing the stimulator in a bore of a needle having a sharp distal tip, passing the needle through mucosa 58 and greater palatine foramen 42 , into canal 54 , and withdrawing the needle, thereby leaving the stimulator implanted in the canal. Alternatively, the needle is first passed into canal 54 , and stimulator 30 is subsequently introduced into the bore of the needle. The needle is typically passed through mucosa 58 without requiring a prior surgical incision in the mucosa, i.e., without requiring the use of a surgical knife or other tool. Alternatively, prior to insertion of the needle into the canal, a submucosal surface on the hard palate is prepared, such as by raising a mucosal flap, and/or by creating a mucosal opening using a retractor.
Reference is made to FIGS. 17A-C , which are schematic illustrations of an array 190 of electrodes 38 , in accordance with an embodiment of the present invention. In this embodiment, stimulator 30 of system 20 or 120 comprises array 190 , which typically comprises between about 8 and about 32 electrodes 38 , such as about 32 electrodes. FIG. 17A shows array 190 in a flat, unrolled position. Typically, the array is organized in rows and columns, for example, between about 2 and about 8 rows, e.g., 8 rows, and between about 2 and about 4 columns, e.g., 4 columns. FIG. 17B shows array 190 encircling support element 36 (only a single column of electrodes 38 is visible in the figure). (For the sake of illustration, support element 36 is visible between electrodes 38 in FIG. 17B ; in actual applications, a portion of the support element may be concealed by structural elements of array 190 .) FIG. 17C is a cross-sectional top-view of one row of electrodes 38 . For some applications, array 190 is fabricated on a flat substrate 192 ( FIG. 17A ), which is wrapped around support element 36 ( FIG. 17B ). For some applications, substrate 192 extends longitudinally along all or a portion of the length of support element 36 , electrodes 38 are positioned in a distal region of the substrate, and circuitry of stimulator 30 , such as circuitry 40 , amplifier, and/or filters, is affixed to the substrate, e.g., in a proximal region of the substrate. For other applications, stimulator 30 does not comprise substrate 192 , and electrodes 38 are coupled directly to, or are integral with, support element 36 . It is noted that although stimulator 30 is generally shown in the figures as comprising array 190 of electrodes 38 , this is for the sake of illustration only; embodiments described and shown herein may use the electrode configuration described hereinabove with reference to FIG. 16 ; electrode configurations described in U.S. patent application Ser. No. 10/783,113, issued as U.S. Pat. No. 7,117,033 to Shalev et al., such as with reference to FIG. 12 , 13 , or 14 thereof; electrode configurations described in the other patent applications incorporated by reference hereinbelow; or electrode configurations known in the art of neural stimulation.
In an embodiment of the present invention, stimulator 30 comprises a plurality of electrodes, at least a portion of which are adapted to be separately activatable. System 20 or 120 is adapted to use a calibration algorithm to activate, during a plurality of calibration periods, respective different sets of one or more of electrodes 38 , in order to determine which set's activation causes a level of stimulation of the SPG closest to a desired level. For example, the desired level may be the maximum level that can be achieved for a given set of stimulation parameters. For some applications, the algorithm is alternatively or additionally used for setting a level of one or more stimulation parameters. System 20 or 120 typically uses the algorithm to determine the optimum set of electrodes after stimulator 30 has been implanted, so as to obviate the need to adjust the location of the stimulator after it has been implanted. Alternatively or additionally, the position of stimulator 30 is adjusted responsively to information derived using the algorithm. For some applications, during post-calibration (i.e., therapeutic) stimulation, the system activates different sets of electrodes at different times, such as in order to vary the level of stimulation applied to the SPG.
In an embodiment of the present invention, the level of stimulation of the SPG is determined by receiving feedback directly from the SPG, or from other neural tissue in a vicinity of the SPG, i.e., by using at least a portion of electrodes 38 to directly measure a level of stimulation of the SPG or the other neural tissue at or in a vicinity of the site(s) of the stimulation by the electrodes. For some applications, the at least a portion of electrodes 38 measure an electrical field of nervous tissue of the SPG or the other neural tissue induced by the electrical stimulation of the SPG. Typically, the signal generated by the sensed field is filtered to remove any artifacts in the signal generated by the stimulation applied by electrodes 38 .
For some applications, the same set of one or more electrodes applies stimulation and measures the achieved stimulation of the SPG, by measuring the level of stimulation of the SPG or the other neural tissue. For other applications, a first set of one or more electrodes applies the stimulation, and a second set of one or more electrodes measures the achieved stimulation. Typically, the second set of electrodes is located in a vicinity of the first set of electrodes, and/or adjacent to the first set of electrodes in array 190 .
Alternatively or additionally, for some applications, the level of stimulation of the SPG is determined by assessing an indirect physiological parameter of the subject related to the level of SPG stimulation, such as cerebral blood flow (CBF) and/or BBB permeability. For some applications, assessment techniques described hereinbelow are used. For some applications, a healthcare worker enters the values of the indirect physiological parameter into system 20 , while for other applications, a device for measuring the indirect physiological parameters is coupled to system 20 , and communicates the parameters to the system.
For some applications, system 20 is configured to select the desired set of electrodes 38 . Alternatively or additionally, system 20 comprises an output unit, such as a display, which presents the results of the calibration algorithm to a healthcare worker, who selects the desired set of electrodes.
In an embodiment of the present invention, stimulator 30 is autonomically powered, such as by utilizing temperature differentials within the subject, e.g., using techniques described in the above-mentioned U.S. Pat. No. 6,470,212 to Weijand et al. and U.S. Pat. No. 6,640,137 to MacDonald, mutatis mutandis, or other techniques known in the art for generating energy from biological processes for powering an implanted medical device. For some applications, circuitry 40 of stimulator 30 does not comprise a wireless coupling element, or the wireless coupling element is used only for data transmission, rather than for wirelessly receiving energy. In the latter case, data is typically transmitted from and/or to external control unit 34 .
In an embodiment of the present invention, electrodes 38 are located in a vicinity of a proximal end of support element 36 , such that the electrodes apply electrical stimulation to greater palatine nerve 66 in a vicinity of the proximal opening of greater palatine foramen 42 . For example, a closest distance between the electrodes and the proximal opening of the greater palatine foramen may be less than 10 mm, e.g., less than 5 mm. For some applications, upon implantation of stimulator 30 , electrodes 38 are contained entirely within greater palatine canal 54 , while for other applications, all or a portion of the electrodes are located submucosally outside of the canal and the foramen.
Although electrodes 38 have been described as being applied to an SPG of the subject, for some applications the electrodes are applied to another MTS of the subject, as defined hereinabove. For some of these applications, electrodes 38 are passed through the greater palatine canal to the MTS, while for other applications the electrodes are passed through only a portion of the greater palatine canal, or are advanced to the MTS by another route.
FIG. 18 a schematic pictorial view of a stimulation system 500 , for stimulation of a sphenopalatine ganglion (SPG) system, as defined hereinabove, and/or at least one other appropriate “modulation target site” (MTS), as defined hereinabove, such as SPG 56 , in accordance with an embodiment of the present invention. Stimulation system 500 comprises a support element 510 , which typically, but not necessarily, is generally rigid (i.e., it generally keeps its original shape during a placement procedure). A distal end 512 of support element 510 comprises one or more electrodes 514 . For some applications, electrodes 514 are recessed within support element 510 , as shown in the figure, while for other applications the electrodes are flush with the surface of the support element, or protrude therefrom. Alternatively, the electrodes are configured as shown in FIGS. 13 and 14 of U.S. patent application Ser. No. 10/783,113, issued as U.S. Pat. No. 7,117,033 to Shalev et al.
Support element 510 is adapted to be inserted into a vicinity of an MTS or an SPG system of the subject, as defined hereinbelow, via a greater palatine canal in a roof of an oral cavity of the subject. Typically, support element 510 is substantially straight. Support element 510 typically comprises one or more marks 516 that indicate the point at which the support element has been sufficiently inserted into the greater palatine canal. Alternatively or additionally, support element 510 comprises a stopper (not shown) in a vicinity of marks 516 , that mechanically prevents further insertion of the support element into the canal.
Stimulation system 500 further comprises a semi-flexible oral appliance 518 , which is physically coupled to support element 510 by flexible leads 520 . Oral appliance 518 comprises a neurostimulator 522 , which is electrically coupled to electrodes 514 via leads 520 . An upper surface 524 of oral appliance 518 is shaped to fit closely to the roof of the oral cavity, and is adapted to be coupled thereto. For example, oral appliance 518 may be shaped generally similarly to an orthodontic retainer. Neurostimulator 522 is typically battery-powered, and configurable to drive electrodes 514 to stimulate the MTS or SPG system. For some applications, the subject himself activates neurostimulator 522 . Stimulation system 500 is typically adapted to remain in the oral cavity for between several hours and about two days.
In an embodiment of the present invention, a stimulation system for application to a subject comprises an elongated support element having a length of between about 1.8 cm and about 4 cm, such as a length of between about 1.8 cm and about 3 cm. The support element comprises one or more electrodes fixed thereto in a vicinity of a distal end thereof. The stimulation system further comprises a control unit, coupled to the support element in a vicinity of a proximal end thereof. The control unit typically comprises a battery, and is adapted to drive the electrodes to apply an electrical current to tissue of the subject, such as the SPG system and/or at least one MTS. The control unit typically configures the current to have a pulse frequency of between about 10 Hz and about 50 Hz, an amplitude of between about 0.2 V and about 10 V, a pulse width of between about 50 microseconds and about 5 milliseconds, and, in alternation, on periods of between about 1 second and about 2 minutes, and off periods of between about 1 second and about 2 minutes. (Together, the on and off periods define a duty cycle.) For example, the control unit may drive the electrodes to apply the current having on periods of between about 60 seconds and about 105 seconds, and off periods of between about 30 seconds and 90 seconds, e.g., on periods of about 90 seconds, and off periods of about 60 seconds.
For some applications, the support element is semi-rigid. For example, the support element and the electrodes together may be similar to conventional concentric needle electrodes, such as Medtronic, Inc. needle electrode model DCN50, or Oxford Instruments Plc. needle electrode models X53153, X53155, X53156, X53158, or X53159.
For some applications, the stimulation system comprises an oral appliance, coupled to the support element, and shaped so as to define a surface that fits closely to a roof of an oral cavity. For example, the oral appliance may be similar to oral appliance 518 , described hereinabove with reference to FIG. 18 . For some applications, the control unit has a volume, including the battery, of less than about 3 cm 3 .
In an embodiment of the present invention, a stimulation system for application to a subject comprises an elongated support element having a length of between about 1.8 cm and about 4 cm, such as a length of between about 1.8 cm and about 3 cm. The support element comprises one or more electrodes fixed thereto in a vicinity of a distal end thereof, and a receiver, fixed to the support element in a vicinity of the proximal end thereof. The stimulation system further comprises a control unit, adapted to be coupled to the receiver. The control unit is adapted to drive the electrodes via the receiver to apply an electrical current to tissue of the subject, such as the SPG system and/or at least one MTS. The control unit typically configures the current to have a pulse frequency of between about 10 Hz and about 50 Hz, an amplitude of between about 0.2 V and about 10 V, a pulse width of between about 50 microseconds and about 5 milliseconds, and, in alternation, on periods of between about 1 second and about 2 minutes, and off periods of between about 1 second and about 2 minutes. (Together, the on and off periods define a duty cycle.) For example, the control unit may drive the electrodes to apply the current having on periods of between about 60 seconds and about 105 seconds, and off periods of between about 30 seconds and 90 seconds, e.g., on periods of about 90 seconds, and off periods of about 60 seconds.
For some applications, the receiver comprises an electrical contact site, and the control unit is adapted to be coupled to the receiver by being brought into physical contact with the electrical contact site. For example, the control unit may be brought into physical contact by positioning the control unit inside an oral cavity of the subject. For some applications, the stimulation system comprises an oral appliance, adapted to be fixed to the control unit, and shaped so as to define a surface that fits closely to a roof of an oral cavity. For example, the oral appliance may be similar to oral appliance 518 , described hereinabove with reference to FIG. 18 .
Alternatively, the receiver comprises a transducer, and the control unit comprises a wireless transmitter, which is adapted to couple the control unit to the receiver via wireless electromagnetic communication with the transducer. Typically, the transducer comprises a coil. For some applications, the control unit is adapted to be positioned outside of a head of the subject. Alternatively, the control unit is adapted to be placed in the oral cavity, such as by being fixed to an oral appliance. For some applications, the receiver has a volume of less than about 0.8 cm 3 , such as less than about 0.15 cm 3 .
For some applications, stimulator 30 is implanted using techniques described in a U.S. Pat. No. 7,636,597, entitled, “Surgical tools and techniques for stimulation,” which is assigned to the assignee of the present application and is incorporated herein by reference.
In the present patent application, “SPG system” means the SPG and associated neuroanatomical structures, including neural tracts originating in or reaching the SPG, including outgoing and incoming parasympathetic and sympathetic tracts, which tracts include preganglionic fibers of the SPG (e.g., fibers contained within the vidian nerve) and postganglionic fibers of the SPG (fibers that travel anterogradely from the SPG toward the brain vascular bed, including the retro-orbital branches of the SPG, which are fibers that connect the SPG with orbital neural structures).
In an embodiment of the present invention, during placement of electrodes 38 at an MTS, as defined hereinabove, at least one physiological indicator of cerebral blood flow (CBF) is observed or measured concurrently with or after placement. For some applications, optimization of placement of electrodes 38 onto the appropriate neural structure is performed by activating the stimulator, and generally simultaneously monitoring CBF while manipulating the electrodes, and/or adjusting at least one parameter of the applied stimulation, so as to increase or decrease CBF, as appropriate. Alternatively or additionally, this technique is used to verify the placement of electrodes 38 after implantation, and/or to select which combination of electrodes to use, such as by using the feedback algorithm described hereinabove. Alternatively or additionally, a similar optimization process is performed, either during or after placement of electrodes 38 , to determine parameters of the applied current so as to achieve a desired effect, e.g., on CBF or BBB permeability, as indicated by CBF.
Physiological indicators of CBF include, but are not limited to, the following:
a measure of vasodilation of blood vessels of the eye, determined by unaided visual inspection or by using an instrument, e.g., an instrument comprising machine vision functionality; transcranial Doppler ultrasonography measurements; a measure of forehead perfusion, measured, for example, using laser Doppler perfusion imaging (LDI) and/or using a temperature sensor; and/or near infrared spectroscopy (NIRS) measurements.
Other appropriate measurements indicative of CBF for use with these embodiments of the present invention will be apparent to those skilled in the art, having read the disclosure of the present patent application.
For some applications, one or more of the devices described hereinbelow with reference to FIGS. 18-21 are used for assessing a physiological indicator of CBF.
FIG. 19 is a schematic illustration of a vasodilation measurement instrument 230 , in accordance with an embodiment of the present invention. Instrument 230 comprises an image sensor 234 (e.g., a CCD or CMOS sensor, or another camera) and processing circuitry 238 , in order to provide machine vision functionality. Image sensor 234 is directed towards an eye 232 of the subject. The instrument measures the ratio of red to white in the sclera of eye 232 , or another indication of vasodilation.
FIG. 20 is a schematic illustration of a laser Doppler perfusion (LDI) device 270 , in accordance with an embodiment of the present invention. LDI device 270 comprises a laser source 271 , a scanner 272 , and a computer 281 . Scanner 272 is positioned near a forehead 241 of the subject for measuring forehead perfusion.
FIG. 21 is a schematic illustration of a thermometer 280 , in accordance with an embodiment of the present invention. Thermometer 280 is positioned touching a forehead 241 of the subject for measuring forehead perfusion.
FIG. 22 is a schematic illustration of a transcranial Doppler ultrasonography device 284 , in accordance with an embodiment of the present invention. Transcranial Doppler ultrasonography device 284 is positioned touching a head 288 of the subject for measuring CBF.
For some applications, the measurement device, such as those described hereinabove with reference to FIGS. 18-21 , comprises an output unit 236 , such as a numeric display, tone generator, color display, or other output device, for outputting a signal indicative of the measured physiological parameter. Alternatively or additionally, instrument 230 is coupled to an internal or external control unit of system 20 or 120 , and communicates the signal directly to the control unit.
In an embodiment of the present invention, during placement of electrodes 38 at an MTS, as defined hereinabove, penetration of a systemically administered dye into an eye of the subject is observed or measured concurrently with or after placement, as an indication of a level of increased permeability of the BBB. For example, the dye may include fluorescein dye. For some applications, optimization of placement of electrodes 38 onto the appropriate neural structure is performed by activating the stimulator, and generally simultaneously monitoring the penetration of the dye while manipulating the electrodes, and/or adjusting at least one parameter of the applied stimulation, so as to increase or decrease permeability of the BBB, as appropriate. Alternatively or additionally, this technique is used to verify the placement of electrodes 38 after implantation, and/or to select which combination of electrodes to use, such as by using the feedback algorithm described hereinabove. Alternatively or additionally, a similar optimization process is performed, either during or after placement of electrodes 38 , to determine parameters of the applied current so as to achieve a desired effect, e.g., on CBF or BBB permeability, as indicated by BBB permeability.
In an embodiment of the present invention, one or more of the above-described CBF-based assessment techniques are used by a healthcare worker after implantation to assess (a) whether electrodes 38 retain appropriate placement and contact with the MTS, and/or (b) whether parameters of the applied current (e.g., magnitude, frequency, duration, scheduling) continue to achieve the desired effect, e.g., on CBF or BBB permeability. For example, such an assessment may be performed periodically during post-implantation follow-up care.
In an embodiment of the present invention, the CBF-based assessment techniques described hereinabove are used to assist in determining the effective dosage and/or other parameters for presenting odorants to an air passage of the patient, as described in U.S. patent application Ser. No. 10/512,780, published as US Patent Application Publication 2005/0266099, filed Oct. 25, 2004, which is assigned to the assignee of the present application and is incorporated herein by reference.
In an embodiment of the present invention, chemical stimulation of at least one MTS is achieved by presenting chemicals, for example in a liquid or gaseous state, to an air passage of the subject, such as a nasal cavity or a throat, or in a vicinity thereof. The temporal profile and other quantitative characteristics of such chemical modulation are believed by the present inventors to have a mechanism of action that has a neuroanatomical basis overlapping with that of the electrical modulation of the MTS. For some applications, chemical-presentation techniques described herein are practiced in combination with techniques described in U.S. patent application Ser. No. 10/512,780, published as US Patent Application Publication 2005/0266099, filed Oct. 25, 2004, and/or U.S. patent application Ser. No. 10/952,536, published as US Patent Application Publication 2005/0159790, filed Sep. 27, 2005, both of which are assigned to the assignee of the present patent application and are incorporated herein by reference. In these chemical-presentation applications, an extent to which the chemical has achieved the desired effect (e.g., increased permeability of the BBB, or increased or decreased CBF) is determined by monitoring real-time changes in CBF, and adjusting the dose of the chemical responsive thereto.
Chemicals that may increase or decrease cerebral blood flow and/or the permeability of the blood-brain barrier (e.g., via modulation of SPG-related fibers), include, but are not limited to, propionic acid, cyclohexanone, amyl acetate, acetic acid, citric acid, carbon dioxide, sodium chloride, ammonia, menthol, alcohol, nicotine, piperine, gingerol, zingerone, allyl isothiocyanate, cinnamaldehyde, cuminaldehyde, 2-propenyl/2-phenylethyl isothiocyanate, thymol, and eucalyptol. The chemicals reach the appropriate neural structures and induce vasodilatation, vasoconstriction and/or cerebrovascular permeability changes.
In an embodiments of the present invention, chemical stimulation is applied to at least one MTS, using (a) a nasal applicator adapted to deliver the stimulating chemical to an upper region of the nasal cavity, or (b) a transpalatine applicator inserted via the greater palatine canal.
In some embodiments of the present invention, stimulation of at least one MTS is achieved by applying a neuroexcitatory agent to the MTS. Suitable neuroexcitatory agents include, but are not limited to, acetylcholine and urocholine. For some applications, the MTS is stimulated by applying a neuroinhibitory agent, such as atropine, hexamethonium, or a local anesthetic (e.g., lidocaine). In these agent-application embodiments, an extent to which the agent has achieved the desired effect (e.g., increased permeability of the BBB, or increased or decreased CBF) is determined by monitoring real-time changes in CBF, and adjusting the dose of the agent responsive thereto.
In an embodiment of the present invention, stimulation of the MTS is achieved by applying mechanical stimulation to the MTS, e.g., vibration. An extent to which the mechanical stimulation has achieved the desired effect (e.g., increased permeability of the BBB, or increased or decreased CBF) is determined by monitoring real-time changes in CBF, and adjusting the extent of the mechanical stimulation (e.g., magnitude, frequency, or duration) responsive thereto.
It is also to be appreciated that whereas some embodiments of the present invention are described with respect to implanting the electrical stimulator, for some applications the stimulator is temporarily inserted into the subject, and techniques described herein are used to optimize the temporary placement of the stimulator.
In an embodiment of the present invention, bilateral stimulation is applied, in which a first electrode is applied to a first MTS, and a second electrode is applied to a second MTS. Such bilateral stimulation may be applied using techniques described in U.S. Provisional Patent Application 60/604,037, filed Aug. 23, 2004, which is assigned to the assignee of the present application and is incorporated herein by reference, and/or in PCT Patent Application PCT/IL2005/000912 (published as PCT Publication WO 06/021957), filed Aug. 23, 2005,” entitled, “Concurrent bilateral SPG modulation,” which is assigned to the assignee of the present application and is incorporated herein by reference.
FIG. 23A is a schematic illustration of a nasal magnetic induction device 400 , in accordance with an embodiment of the present invention. Nasal magnetic induction device 400 generates a magnetic field in the vicinity of an MTS. The magnetic field induces an electric current in the MTS, which temporarily depolarizes neurons therein, thereby electrically stimulating the MTS. Nasal magnetic induction device 400 typically comprises a wire coil 410 adapted to be insertable into the nasal cavity, and a control unit 412 coupled to the coil. As appropriate, the coil may be compressed during insertion and expand at the target site, or it may be retracted during insertion within a supporting element 414 of device 400 , and released when at the target site. Typically, coil 410 has a diameter D of between about 3 mm and about 12 mm, and comprises between about 4 and about 30 loops of wire. The wire typically has a diameter of between about 50 micrometers and about 200 micrometers. Upon activation, the control unit generates a pulsed electric current in the coil. Because of the close proximity of the coil to an MTS, e.g., an SPG, the control unit typically outputs power sufficient to stimulate the SPG but generally insufficient to substantially stimulate surrounding peripheral or brain tissue. For some applications, the nasal magnetic induction device further comprises a cooling element (e.g., a thermoelectric cooling element, a liquid cooling mechanism, or an air cooling mechanism), which is adapted to prevent excessive heating of the coil.
FIG. 23B is a schematic illustration of a nasal magnetic induction device 420 , in accordance with an embodiment of the present invention. Nasal magnetic induction device 420 is similar to nasal magnetic induction device 400 , described hereinabove with reference to FIG. 23A , except that nasal magnetic induction device 420 comprises a figure-eight-shaped wire coil 430 , which may, for example, enhance focusing of the induced field. Alternatively, nasal magnetic induction device 420 comprises a 4-leaf-shaped wire coil, such as described in the above-cited article to Roth B J et al.
FIGS. 24A and 24B are schematic illustrations of an external magnetic induction device 440 , in accordance with an embodiment of the present invention. External magnetic induction device 440 comprises (a) one or more (typically two) magnetic coils 450 adapted to be placed in a vicinity of a temporomandibular joint 452 of a subject, in a vicinity of an MTS, e.g., an SPG, and (b) a control unit 454 coupled to the coils. Typically, each coil 450 has a diameter of between about 30 mm and about 120 mm, and comprises between about 4 and about 30 loops of wire.
In an embodiment of the present invention, an external magnetic induction device comprises a coil adapted to be placed partially or completely around a head of the subject (not necessarily in the configuration shown in FIGS. 24A and 24B ), and a control unit coupled to the coil. Typically, the coil has a diameter of between about 3 cm and about 12 cm, and comprises between about 4 and about 30 loops of wire. The coil is configured to focus the generated magnetic field on at least one MTS, e.g., the SPG.
FIG. 25 is a schematic pictorial view of an electrical stimulation system 310 comprising an implantable stimulator 312 , for stimulation of a “modulation target site” (MTS), as defined hereinabove, such as a sphenopalatine ganglion (SPG) 322 , in accordance with an embodiment of the present invention. In FIG. 25 , a human nasal cavity 320 is shown, and stimulator 312 is implanted between the hard palate and the mucoperiosteum (not shown) of the roof of the mouth. Branches of parasympathetic neurons coming from SPG 322 extend to the middle cerebral and anterior cerebral arteries (not shown). Typically, one or more relatively short electrodes 326 extend from stimulator 312 to contact or to be in a vicinity of an MTS, such as SPG 322 .
For some applications, stimulator 312 is implanted on top of the bony palate, in the bottom of the nasal cavity. Alternatively or additionally, the stimulator is implanted at the lower side of the bony palate, at the top of the oral cavity. In this instance, one or more flexible electrodes 326 originating in the stimulator are passed through the palatine bone or posterior to the soft palate, so as to be in a position to stimulate the SPG or another MTS. Further alternatively or additionally, the stimulator may be directly attached to the SPG and/or to another MTS.
For some applications, stimulator 312 is delivered to a desired point within nasal cavity 320 by removably attaching stimulator 312 to the distal end of a rigid or slightly flexible introducer rod (not shown) and inserting the rod into one of the patient's nasal passages until the stimulator is properly positioned. As appropriate, the placement process may be facilitated by fluoroscopy, x-ray guidance, fine endoscopic surgery (FES) techniques or by any other effective guidance method known in the art, or by combinations of the aforementioned. Typically, skin temperature and/or cerebral blood flow (CBF) is measured concurrently with insertion. CBF may be measured with, for example, a laser Doppler unit positioned at the patient's forehead or transcranial Doppler measurements. Verification of proper implantation of the electrodes onto the appropriate neural structure may be performed by activating the device, and generally simultaneously monitoring CBF.
For some applications, stimulator 312 is implanted using techniques described in U.S. patent application Ser. No. 10/535,024, filed Dec. 27, 2005, which issued as U.S. Pat. No. 7,636,597, entitled, “Surgical tools and techniques for stimulation,” which is assigned to the assignee of the present application and is incorporated herein by reference, and/or in the above-mentioned PCT Publication WO 04/043218. For some applications, techniques described herein are performed in combination with apparatus and/or methods that are described in U.S. patent application Ser. No. 11/349,020, filed Feb. 7, 2006, which issued as U.S. Pat. No. 7,561,919, entitled, “SPG stimulation via the greater palatine canal,” which is assigned to the assignee of the present application and is incorporated herein by reference.
FIG. 26 is a schematic illustration of a stimulator control unit 330 positioned external to a patient's body, in accordance with an embodiment of the present invention. At least one flexible electrode 332 typically extends from control unit 330 , through a nostril of the patient, and to a position within the nasal cavity that is adjacent to SPG 322 .
In an embodiment of the present invention, techniques described herein are performed in conjunction with techniques described in US Patent Application Publication 2004/0220644 (issued as U.S. Pat. No. 7,117,033), which is assigned to the assignee of the present application and is incorporated herein by reference. For example, the substantially rigid support element described therein may be initially quickly inserted into the stimulation site for acute treatment, and an implantable stimulator 312 may be subsequently implanted for longer-term treatment.
It is to be understood that electrodes 326 ( FIG. 25) and 332 ( FIG. 26 ) may each comprise one or more electrodes, e.g., two electrodes, or an array of microelectrodes. For applications in which stimulator 312 comprises a metal housing that can function as an electrode, typically one electrode 326 is used, operating in a monopolar mode. Regardless of the total number of electrodes in use, typically only a single or a double electrode extends to SPG 322 . Other electrodes 326 or 332 or a metal housing of stimulator 312 are typically temporarily or permanently implanted in contact with other parts of nasal cavity 320 .
Each of electrodes 326 and/or 332 typically comprises a suitable conductive material, for example, a physiologically-acceptable material such as silver, iridium, platinum, a platinum iridium alloy, titanium, nitinol, or a nickel-chrome alloy. For some applications, one or more of the electrodes have lengths ranging from about 1 to 5 mm, and diameters ranging from about 50 to 100 microns. Each electrode is typically insulated with a physiologically-acceptable material such as polyethylene, polyurethane, or a co-polymer of either of these. The electrodes are typically spiral in shape, for better contact, and may have a hook shaped distal end for hooking into or near the SPG. Alternatively or additionally, the electrodes may comprise simple wire electrodes, spring-loaded “crocodile” electrodes, or adhesive probes, as appropriate.
Reference is made to FIG. 27 , which is a graph 600 illustrating electrical stimulation protocols, in accordance with an embodiment of the present invention. Excitatory stimulation of an MTS (e.g., the SPG) induces changes in CBF, induces the release of one or more neuroprotective substances, such as neuromodulators (e.g., nitric oxide (NO) and/or vasoactive intestinal polypeptide (VIP)), and/or modulates permeability of the blood-brain barrier (BBB). The inventors have found that excitatory stimulation of an MTS at at least a minimum threshold strength increases CBF, and that the increase in CBF is related to the strength of the stimulation. The inventors have also found that at a sufficiently high strength, such stimulation modulates the permeability of the BBB, in addition to increasing CBF.
“Strength,” as used in the present application, including the claims, means a total charge applied to an MTS in a given time period, e.g., one minute, one hour, or one day. Strength is increased or decreased by changing one or more parameters of the applied stimulation, such as the amplitude, number of cycles in a given time period, frequency, pulse width, or duty cycle (e.g., ratio of “on” to “off” time within a given cycle), as described hereinbelow in greater detail.
The y-axis of graph 600 indicates the strength of the stimulation of an MTS. The strength of the stimulation is determined by the values of the parameters of the stimulation, such as voltage, current, frequency, cycles per time period, and duty cycle. Stimulation at at least a minimum CBF-increasing strength 602 increases CBF. Stimulation at such a strength also typically induces the release of one or more neuroprotective substances, such as NO and/or VIP. A maximum CBF-increasing strength 606 is the strength at which CBF is maximally increased, i.e., further increases in strength do not further increase CBF. The BBB is opened, i.e., the permeability of the BBB to larger molecules or substances that do not cross the intact BBB is significantly increased, by stimulation having a strength in a range 608 between a minimum BBB-opening strength 610 and maximum BBB-opening strength 612 (beyond which increased strength does not result in additional opening of the BBB). Although minimum BBB-opening strength 610 is shown in graph 600 as being greater than maximum CBF-increasing strength 606 , this is not necessarily the case.
In the present application, including the claims, stimulation of an MTS is considered capable of inducing a “significant” increase in the permeability of the BBB if the stimulation is capable of inducing at least one of the following:
(a) an increase in concentration of Evans blue (EB) in brain tissue of a subject, such as a rat, of at least 100% compared to a baseline concentration measured in a control rat. To determine the increase, permanent middle cerebral artery occlusion (pMCAO) is induced in the rat, such as using techniques described hereinbelow with reference to FIG. 30 . Three hours after pMCAO, stimulation is applied to the MTS, and a bolus of EB 2% at 1 ml per kg body weight of the rat is administered intravenously. The rat is sacrificed one hour after application of the stimulation and administration of the EB. To determine the baseline concentration, pMCAO is induced in a control rat, three hours after pMCAO an identical EB bolus is administered intravenously, but no stimulation is applied, and the control rat is sacrificed one hour after the administration of the EB; and
(b) a serum S100beta level of the subject (indicative of clearance of the protein from the brain into the systemic circulation), at a measurement time 45 minutes after initiation of MTS stimulation, that is at least 30% greater than a serum S100beta level of the subject measured at the beginning of the MTS stimulation.
Although the above are indications of the “significance” of an increase in permeability of the BBB, use of the apparatus and performance of the methods described and claimed herein typically do not include measuring any of these indications. In particular, indication (a) is generally only possible to measure in an animal model; if it were desired to conduct a human experiment, different techniques would likely be used, such as measuring the concentration in the brain of a radioactive isotope that is normally excluded by the BBB.
For some applications, it is desirable to apply stimulation to an MTS, and configure the stimulation to have a strength that induces an increase in permeability of the BBB that is even lower than a “significant” increase, as defined above. Such a “sub-significant” increase in permeability of the BBB is considered to occur if the stimulation is capable of inducing at least one of the following: (i) an increase in concentration of EB, under the conditions defined in indication (a) above, of at least 20%, such as at least 30%, e.g., at least 50%; and (ii) a serum S100beta level, under the conditions defined in indication (b) above, that is at least 10%, e.g., at least 20%, greater than the level of the subject measured at the beginning of the MTS stimulation.
For some applications, it is useful to define increased CBF as a percentage increase in CBF over a baseline level of CBF, which increase has at least a certain duration, e.g., at least 5 minutes. Typically, the baseline CBF level is either: (a) a normal baseline level for a subject, i.e., prior to an adverse brain event, such as a cerebrovascular event, e.g., a stroke, or (b) a post-event baseline level, prior to stimulation using the techniques described herein, and, optionally, prior to other treatment of the event. CBF is typically expressed as volume of blood flow per time per mass of the subject, e.g., ml/min/100 g. For some applications, increased CBF is expressed as an area under the curve (AUC) of CBF with respect to baseline over a certain time interval.
In an embodiment of the present invention, electrical stimulation system 310 is configured to apply excitatory electrical stimulation to at least one MTS of a subject, and to configure the stimulation to increase CBF of the subject and/or induce the release of neuroprotective substances, without substantially opening the BBB of the subject. In other words, the system sets the strength of stimulation equal to less than minimum BBB-opening strength 610 , such as less than 90% of minimum BBB-opening strength 610 , e.g., less than 80%, 70%, or 60% of minimum BBB-opening strength 610 . For some applications, the system is configured to increase CBF of the subject and/or induce the release of neuroprotective substances without increasing the permeability of the BBB to a level that produces a measurably-harmful clinical effect for the subject.
For some applications, system 310 sets an acute strength 622 equal to a level appropriate for treatment of an acute condition, such as an adverse brain event (e.g., a cerebrovascular event), for which increased CBF and/or release of neuroprotective substances is beneficial, but for which opening the BBB is not indicated. For example, the system may set acute strength 622 equal to at least about 20% of minimum BBB-opening strength 610 , e.g., at least about 50%, 60%, 70%, or 80% of minimum BBB-opening strength 610 .
In an embodiment of the present invention, system 310 is used for rehabilitative treatment after an adverse brain event, such as a cerebrovascular event, e.g., a stroke, or for rehabilitative treatment of a non-acute cerebrovascular condition. Such rehabilitative stimulation induces the release of neuroprotective substances and/or maintains a slightly elevated level of blood flow, typically over an extended period of time, such as at least 24 hours, at least one week, at least two weeks, at least four weeks, or at least three months. As a result, such stimulation typically rehabilitates damaged tissue, improves perfusion of the rehabilitating brain, and/or accelerates angiogenesis. (See, for example, the above-mentioned article by Zhang R et al. (2001), which reports that NO donors administrated 24 hours after stroke significantly increased angiogenesis in the ischemic boundary regions.) For some applications, the system is configured to apply such rehabilitative stimulation intermittently, such as during one session per day, having a duration of between 1 minute and 6 hours, such as at least 5 minutes or at least 15 minutes, or between 2 and 4 hours, e.g., about 3 hours or about 6 hours, or more than 6 hours. Alternatively, the system is configured to apply such stimulation generally constantly, i.e., 24 hours per day. Further alternatively, the rehabilitative stimulation is applied less frequently than every day, such as once every other day (e.g., at least one minute during every 48 hours), or more frequently than once per day, such as during two sessions per day. For some applications, such stimulation is applied beginning at least one hour after the adverse brain event, such as a cerebrovascular event, e.g., a stroke, such as beginning at least 3 hours, at least 6 hours, at least 9 hours, at least 12 hours, at least 24 hours, or at least 48 hours after the brain event. For some applications, NO released by stimulation at rehabilitation strength 622 is of particular neuroprotective benefit during rehabilitation.
For some applications, such rehabilitative stimulation is applied during a plurality of stimulation periods which includes at least first and last stimulation periods. System 310 sets an inter-period interval between initiation of the first period and initiation of the last period to be at least 24 hours. For example, the first stimulation period may occur from 1:00 P.M. to 4:00 P.M. on a Monday, and the last stimulation period may occur from 1:00 P.M. to 4:00 P.M. on a Tuesday of the same week. Optionally, stimulation is applied during at least one additional stimulation period between the first and last periods. For example, stimulation may be additionally applied from 1:00 A.M. to 4:00 A.M. on the Tuesday. For some applications, the first period concludes simultaneously with the initiation of the last period, i.e., the stimulation is applied constantly from the beginning of the first period until the conclusion of the last period. For example, the stimulation may be applied constantly from 1:00 P.M. on Monday, January 1 to 4:00 P.M. on Tuesday, January 2, or constantly from 1:00 P.M. on Monday, January 1 to 4:00 P.M. on Monday, January 29. Alternatively, the initiation of the last stimulation period occurs after a conclusion of the first stimulation period, such that the stimulation is not applied during at least one non-stimulation period between the conclusion of the first stimulation period and the initiation of the last stimulation period.
For some applications, the system sets the inter-period interval to be at least 48 hours, such as at least one week, at least two weeks, or at least four weeks. When using such greater inter-period intervals, the system typically, but not necessarily, applies stimulation during at least several additional stimulation periods between the first and last stimulation periods. For some applications, such additional stimulation periods may include a plurality of daily stimulation periods, applied on every day between the initiation of the first stimulation period and the initiation of the last stimulation period. For example, the first stimulation period may occur from 1:00 P.M. to 4:00 P.M. on Monday, January 1, the last stimulation period may occur from 1:00 P.M. to 4:00 P.M. on Monday, January 8, and the additional daily stimulation periods may occur from 1:00 P.M. to 4:00 P.M. on each day from Tuesday, January 2 through Sunday, January 7, inclusive. For some applications, stimulation is applied for at least 30 minutes every day (e.g., at least 60 minutes every day) between the initiation of the first stimulation period and the initiation of the last stimulation period. For some applications, stimulation is applied during a plurality of non-continuous stimulation periods during each 24-hour period between the initiation of the first stimulation period and the initiation of the last stimulation period. For example, the first stimulation period may occur from 1:00 P.M. to 4:00 P.M. on Monday, the last stimulation period may occur from 1:00 P.M. to 4:00 P.M. on Wednesday, and stimulation may be applied during additional stimulation periods from (a) 1:00 A.M. to 4:00 A.M. on Tuesday, (b) from 1:00 P.M. to 4:00 P.M. on Tuesday, and (c) from 1:00 A.M. to 4:00 A.M. on Wednesday, such that stimulation is applied during two stimulation periods during the 24-hour period from 1:00 P.M. on Monday to 1:00 P.M. on Tuesday, and during two stimulation periods during the 24-hour period from 1:00 P.M. on Tuesday to 1:00 P.M. on Wednesday.
For some applications, the system is configured to set the inter-period interval to be no more than a maximum value, such as three, six, nine, or twelve months. For some applications, the system comprises a user interface, which enables a healthcare worker to enter a value for the inter-period interval. The system typically rejects values that are greater than the maximum value, such as by requiring the healthcare worker to enter another value, or by using the maximum value instead of the entered value. Alternatively, the system notifies the healthcare worker if the entered value is greater than the maximum value; optionally, the system allows the healthcare worker to override the notification.
For some applications, the system is configured to store a maximum total time of stimulation per each time period having a given duration, and to apply the stimulation no more than the maximum total time per each time period having the given duration. For example, the given duration of each time period may be 24 hours. Typical values for the maximum total time of stimulation per 24-hour period include one hour, three hours, six hours, ten hours, and twelve hours. For some applications, the maximum total time of stimulation is predetermined, e.g., by the manufacturer of the system, while for other applications, a healthcare worker enters the maximum total time of stimulation into the system.
As used in the present application, including the claims, a “stimulation period” includes an entire period during which stimulation is applied, even though current is applied to the site only during a portion of the period, because of the duty cycle, on/off periods, and/or frequency of the current, for example.
For some applications, system 310 sets the strength of stimulation during such long-term rehabilitation to a rehabilitation strength 620 , such as between about 10% and about 40% of minimum BBB-opening strength 610 , e.g., between about 20% and about 30% of minimum BBB-opening strength 610 , or such as between about 10% and about 40% of maximum CBF-increasing strength 606 , e.g., between about 20% and about 30% of maximum CBF-increasing strength 606 . Alternatively or additionally, system 310 sets rehabilitation strength 620 to a level that causes an increase in CBF equal to less than about 40% of a maximum CBF increase that system 310 is capable of inducing.
In an embodiment of the present invention, system 310 sets the strength of stimulation to a preventive strength appropriate for preventing an occurrence of a brain event, typically a secondary brain event, e.g., a secondary stroke. For example, such strength may be between about 5% and about 50% of the minimum BBB-opening strength 610 . For some applications, NO released by stimulation at the preventive strength is of particular neuroprotective benefit during prevention, and has an anti-thrombolytic, vasodilatory, and/or anti-inflammatory effect.
In an embodiment of the present invention, system 310 is configured to treat a complication of subarachnoid hemorrhage (SAH), such as a cerebral vasospasm. The currently-preferred conventional treatment for SAH includes a surgical procedure in which a medical vehicle is used to treat the SAH. The medical vehicle may comprise, for example: (a) a tool for treating the SAH such as by clipping the aneurysm that caused the SAH, and/or (b) a pharmaceutical treatment. However, the presence of blood in the subarachnoid space sometimes causes increased sensitization of large cerebral arteries, resulting at a later time in cerebral vasospasms. These late-onset vasospasms, in turn, cause brain ischemia and often irreversible damage (see the above-mentioned article by Van Gijn J et al.). Therefore, the stimulation of the MTS of this embodiment of the present invention is typically applied in conjunction with such a treatment (e.g., before, during or after the treatment), typically to the SPG, in order to counteract the reduced CBF sometimes caused by blood passage into the subarachnoid space.
Typically, for treating the complication of SAH, system 310 configures the stimulation to increase CBF of the subject and/or induce the release of neuroprotective substances, without substantially opening the BBB of the subject. Typically, system 310 is configured to set the strength of stimulation to at least acute strength 622 , but no more than maximum CBF-increasing strength 606 , so as not to substantially open the BBB. For some applications, the stimulation of the MTS is initiated at a time after the treatment when the hemorrhage has already been substantially reduced (at which time, in the absence of MTS stimulation, CBF is frequently reduced below desired levels). Alternatively, the stimulation of the MTS is initiated prior to this point, but generally has its strongest elevating effect on CBF once the hemorrhage has been substantially reduced.
Reference is again made to FIG. 27 . In an embodiment of the present invention, electrical stimulation system 310 is configured to apply staged treatment of a brain event, such as an ischemic event (e.g., a stroke). The system configures the stimulation to dilate cerebral vessels, thereby increasing CBF to affected brain tissue and tissue in a vicinity thereof, and/or to induce the release of one or more neuroprotective substances, such as neuromodulators (e.g., nitric oxide (NO) and/or vasoactive intestinal polypeptide (VIP)). Such increased CBF and/or release of neuroprotective substances decrease damage caused by the brain event. The system is typically configured to adjust at least one parameter of the applied stimulation responsively to an amount of time that has elapsed since the occurrence of the brain event. For some applications, system 310 calculates the elapsed time responsively to an estimated time of occurrence of the brain event, which is entered into the system by a healthcare worker, typically early in the treatment of the event. In these applications, the system typically automatically progresses from stage to stage based on the elapsed time from the occurrence of the event. Alternatively, for some applications, a healthcare worker manually selects the stages.
System 310 is typically configured to apply the stimulation in two or more stages. For some applications, during a first, acute stage 630 , the system sets the parameters of stimulation to acute strength 622 , which is sufficient to cause a high level of cerebral vessel dilation and/or a release of neuroprotective substances, but insufficient to substantially open the BBB. Such stimulation is primarily intended to arrest the spreading of the initial ischemic core, such as by restoring blood flow to the penumbra in order to prevent damage to cells therein, and/or by releasing neuroprotective substances, such as NO and/or VIP. Such stimulation may also save some cells within the ischemic core, such as neuronal cells. The first stage of stimulation is typically appropriate during the period beginning at the time of the event, and ending at about 4 to 8 hours after the time of the event, such as at about 6 hours after the event. Alternatively, the first stage of stimulation is appropriate until about 24 hours after the time of the event. (See, for example, the above-cited articles by Davis S M et al. and Phan T G et al.) For some applications, VIP released by stimulation at acute strength 622 is of particular neuroprotective benefit. For some applications, hypoperfused areas of the brain are identified, such as by using MRI or PET, which can potentially be saved using the stimulation techniques described herein.
During a second, rehabilitative stage 636 , system 310 reduces the strength of the stimulation to rehabilitation strength 620 , and typically applies the stimulation intermittently, such as during one session per day, having a duration of between 1 minute and 6 hours, such as between 2 and 4 hours, e.g., about 3 hours, or more than 6 hours. This rehabilitative level of stimulation continues to induce the release of neuroprotective substances, and/or maintains a slightly elevated level of blood flow. This stage of stimulation is typically applied during the period beginning at the conclusion of acute stage 630 , and lasting at least one week, such as at least two weeks, at least one month, at least three months, or at least six months. Alternatively, the rehabilitative stimulation is applied generally constantly, i.e., 24 hours per day. Further alternatively, the rehabilitative stimulation is applied less frequently than every day, such as once every other day, or more frequently than once per day, such during two sessions per day.
For some applications, system 310 is configured to apply stimulation during an additional, post-acute stage 632 , between acute stage 630 and rehabilitative stage 636 . During post-acute stage 632 , the system reduces the strength of the stimulation to a post-acute strength 634 , between acute strength 622 and rehabilitation strength 620 . This post-acute strength is sufficient to maintain an increased level of blood flow to and/or release of neuroprotective substances to the ischemic core and the penumbra. The lower strength is less likely to cause potential side effects, such as aneurysm, that might occur if the system maintained the higher level of stimulation of the first stage. Typically, post-acute strength 634 is equal to between about 20% and 70% of minimum BBB-opening strength 610 , such as between about 40% and 60%. Post-acute stage 632 typically begins at the conclusion of acute stage 630 , and ends at about 16 to 30 hours after the time of the event, such as about 24 hours after the event.
The following table shows exemplary parameter ranges for some of the stimulation strengths and treatment protocols described hereinabove.
TABLE 1
Pulse
No. of
Cycle
Signal
width
Cycles
on/off time
Indication
amplitude
Hz
(μsec)
per hour
(sec)
Acute
0.5-10
mA
10-30
100-500
1-10
60/12,
treatment
4/15,
Rehabilitation
0.5-10
mA
10-30
30/60
Prevention
0.5-10
mA
10-30
of
recurrence
Minimum
1-3.5
V
10-30
100-500
1-100
45/45,
BTB
45/90,
Minimum
1-4
V
10-30
90/60, 4/15,
BBB
2/8
Maximum
3.5-8
V
10-50
BBB
As indicated in Table 1, for some applications system 310 provides stimulation by applying a plurality of cycles of stimulation, each cycle including an “on” period (e.g., between 2 and 90 seconds) followed by an “off” period (e.g., between 8 and 90 seconds). Such cycles are applied a certain number of times per hour, typically spaced evenly throughout the hour. For example, if the cycles are applied four times per hour, the four cycles may be applied at the beginning of the hour, 15 minutes into the hour, 30 minutes into the hour, and 45 minutes into the hour, respectively. For some applications, each stimulation is applied in sets of two or more cycles. For example, if the stimulation is applied four times per hour, a set of two cycles may be applied at the beginning of the hour, 15 minutes into the hour, 30 minutes into the hour, and 45 minutes into the hour, respectively.
For some applications, in order to apply different strengths for the different brain event protocols (acute treatment, post-acute treatment, rehabilitation, and prevention of recurrence of the event), system 310 changes the amplitude of the applied signal and/or the number of cycles per hour. Alternatively or additionally, the system changes the frequency, pulse width, duration of the “on” periods, duration of the “off” periods, ratio of duration of the “on” to the “off” periods, number of cycles per set of cycles, or at least one other parameter of the stimulation.
Nitric oxide (NO) influences infarct size after focal cerebral ischemia and also regulates neurogenesis in the adult brain. These observations suggest that therapeutic approaches to stroke that target NO signaling may provide neuroprotection and also enhance brain repair through cell replacement (see Zhang R et al. (2001) and Sun Y et al., cited hereinabove). Utilizing a rat model, Zhang R et al. (2001) demonstrated that treatment of stroke with nitric oxide (NO) donors reduces functional neurological deficits. Zhang F et al. (cited hereinabove) demonstrated that NO donors increase CBF to the ischemic territory and reduce the tissue damage resulting from focal ischemia. The protective effect may result from an increase in CBF to the ischemic territory, probably the ischemic penumbra. NO and VIP have been found to be potent neuroprotectants in cell culture models (see the above-mentioned article by Sandgren K et al.). Khan M et al. (cited hereinabove), using S-nitrosothiols, a nitric oxide (NO) donor, demonstrated that administration of NO provided neuroprotection in a rat model of focal cerebral ischemia. Ziche M et al. (cited hereinabove) discuss the role of NO, as a factor responsible for vasodilation, in physiological and pathological angiogenesis. The inventors hypothesize that the release of NO induced by the stimulation techniques described herein may have therapeutic benefits, even if such stimulation is applied beginning several hours, or even several days, after the stroke.
In an embodiment of the present invention, stimulation during acute stage 630 and/or post-acute stage 632 is performed using a needle-like electrode, which is inserted, using a simple procedure, into a subject recently admitted to a hospital after a stroke. For example, the device described with reference to FIGS. 1-4B and/or FIGS. 17A-C of the above-mentioned U.S. patent application Ser. No. 11/349,020 (issued as U.S. Pat. No. 7,561,919) may be used for the acute and/or post-acute stages. Upon completion of one or both of these stages, and/or stabilization of the subject, the needle-like electrode is removed, and a longer-term stimulator is implanted and used for rehabilitative stage 636 and/or the preventive stage. For example, the device described with reference to FIGS. 5A-D , 12 - 14 B, and/or 17 A-C of the '020 application may be used for the rehabilitative and/or preventive stages.
Reference is made to FIG. 28 , which is a graph 650 showing a rehabilitation protocol for treating stroke, in accordance with an embodiment of the present invention. In accordance with this protocol, system 310 is configured to alternatingly apply stimulation at a first, rehabilitative level of strength, and at a second BBB-opening level of strength in conjunction with administration of a drug for rehabilitation from stroke. For example, the drug may include a growth factor, such as BDNF, GDNF, or NGF. Typically, the first rehabilitative level is rehabilitation strength 620 , described hereinabove with reference to FIG. 27 , and the second BBB-opening level falls within BBB-opening range 608 , such as maximum BBB-opening strength 612 , described hereinabove with reference to FIG. 27 . System 310 is typically configured to apply the rehabilitative stimulation intermittently, such as during one session per day, having a duration of between about 1 and about 6 hours, such as between about 2 and about 4 hours day, e.g., about 3 hours. Alternatively, the rehabilitative stimulation is applied less frequently than every day, such as once every other day, or more frequently than once per day, such as during two sessions per day.
System 310 is typically configured to apply the BBB-opening stimulation intermittently, such as for between about 0.5 and about 1 hour per day, or for between about 3 and about 6 hours per day, e.g., about 4 hours per day. Alternatively, the BBB-opening stimulation is applied less frequently than every day, such as once every other day, or more frequently than once per day, such as twice per day, or 24 times per day. The drug administered in conjunction with applying the BBB-opening stimulation is typically administered systematically, before and/or during application of the BBB-opening stimulation. For some applications, the rehabilitative stimulation is applied immediately before or after the BBB-opening stimulation (as shown in FIG. 28 ), while for other applications the rehabilitative and BBB-opening stimulations are applied non-contiguously (not shown in FIG. 28 ).
Reference is made to FIG. 29 , which is a graph showing changes in CBF vs. baseline using three different SPG stimulation protocols, measured in accordance with an embodiment of the present invention. 16 naïve rats were anesthetized with a ketamine-xylazine combination, and a plastic holder was affixed to the skull for CBF measurement. A bipolar electrode was brought into contact with the SPG and connected to a controller. The SPG was stimulated for five minutes beginning after CBF stabilization, using the following signal parameters: 3.5 volts, 10 Hz, and a 500 μsec pulse width. The rats were divided into four groups, one of which served as a control, and the other three received stimulation having different duty cycles: 4 seconds on/15 seconds off, 60 seconds on/12 seconds off, and 90 second on/60 second off. As can be seen in FIG. 29 and in Table 2 below, CBF significantly increased in two of the stimulation groups (4/15 and 60/12) vs. CBF baseline. The maximum increase in CBF vs. baseline (193%) was observed in the 60/12 stimulation group after two minutes of SPG stimulation. CBF in this group remained elevated even 10-15 minutes after termination of SPG stimulation. The minimum increase in CBF vs. baseline (141%) was observed in the 90/60 stimulation group. It is clear from these results that SPG stimulation at the described parameters significantly increases CBF, and that such increase was stable at 10 minutes following SPG stimulation.
TABLE 2
CBF at 2 minutes
[% change
Group
from baseline]
4/15 (n = 5)
157
60/12 (n = 6)
193
90/60 (n = 5)
141
Reference is made to FIGS. 30-35C , which are graphs showing in vivo experimental results, measured in accordance with respective embodiments of the present invention. These animal experiments were performed to test the efficacy of the SPG stimulation techniques described hereinabove for treating stroke. The experiments described with reference to FIGS. 30-35C used a rat middle cerebral artery occlusion (MCAO) model of stroke. As described in detail hereinbelow, these experiments demonstrated that:
SPG stimulation starting three hours following MCAO occlusion significantly improved cerebral blood flow (CBF), decreased infract size, and improved neuromuscular function; SPG stimulation reduced mortality; SPG stimulation for one or three hours per day for three days, beginning 24 hours after MCAO, improved neuromuscular functions for nine days following the insult; and SPG stimulation for six hours per day for six days, beginning 24 hours after MCAO improved neuromuscular function at 13 and 28 days following occlusion.
Reference is made to FIG. 30 , which is a graph showing the effect of SPG stimulation beginning three hours after permanent MCAO (pCMAO) in male rats, measured in accordance with an embodiment of the present invention. The graph shows changes in CBF vs. baseline, in an experimental group (n=12) and in a control group (n=12). The Sprague Dawley® (SD) rats were anesthetized with a ketamine-xylazine combination (85 mg/kg and 5 mg/kg respectively), and pMCAO was performed as follows. The right common carotid artery (CCA) was exposed through a midline neck incision and carefully dissected free from surrounding nerves and fascia, from its bifurcation to the base of the skull. The occipital artery branches of the external carotid artery (ECA) were then isolated, and these branches were dissected and coagulated. The ECA was dissected further distally and coagulated together with the terminal lingual and maxillary artery branches, which was then divided. The internal carotid artery (ICA) was isolated and carefully separated from the adjacent vagus nerve, and the pterygopalatine artery was ligated close to its origin with a 5-0 nylon suture. A 4-0 silk suture was tied loosely around the mobilized ECA stump, and a 4 cm length of 4-0 monofilament nylon suture (the tip of the suture was blunted by using a flame, and the suture was coated with silicone, prior to insertion) was inserted through the proximal ECA into the ICA, and from there into the circle of Willis, effectively occluding the MCA. The surgical wound was closed and the rats were returned to their cages to recover from anesthesia. These techniques for performing pMCAO are similar to those described in the above-mentioned article by Schmid-Elsaesser R et al.
SPG stimulation was initiated at three hours following pMCAO. The stimulation regime included a duty cycle of 60 seconds on/12 seconds off, at 2 mA and 10 Hz, with a 500 μsec pulse width. The stimulation was applied for five minutes every 30 minutes, for a period of 10 hours. As can be seen in FIG. 30 , SPG stimulation markedly and significantly increased CBF levels in rats after pMCAO. The greatest increase was observed at 6 hours following MCAO.
FIGS. 31 and 32 are graphs showing results of an in vivo experiment assessing the effect of SPG stimulation performed three hours following stroke, measured in accordance with an embodiment of the present invention. A rat pMCAO model of stroke was used to evaluate the neuroprotective benefits of SPG stimulation following stroke using techniques described herein. A three-hour delay prior to applying stimulation was chosen to simulate the relatively late-stage intervention common in clinical settings. The results of this experiment demonstrate that SPG stimulation provided significant neuroprotection. SPG stimulation reduced mortality, significantly improved neuromuscular function, and increased CBF.
32 SD rats were divided into an experimental group (n=15), and a control group (n=17). pMCAO was performed using the techniques described hereinabove. A bipolar electrode was brought into contact with the SPG ipsilateral to the pMCAO, and connected to a controller.
Three hours after pMCAO and prior to commencement of stimulation, all of the rats were subjected to the first of three neuroscoring (behavioral) tests. Additional neuroscoring was performed at 24 and 48 hours post-pMCAO. SPG stimulation was initiated at three hours following pMCAO occlusion. The stimulation regime included a duty cycle of 60 seconds on/12 seconds off, at 2 mA and 10 Hz, with a 500 μsec pulse width. The stimulation was performed for five minutes every 30 minutes, for a period of 10 hours. Forty-eight hours following pMCAO, the rats were sacrificed, and their brains were removed for triphenyltetrazolium chloride (TTC) staining. Infarct volume was quantified at each coronal level in the area of the contralateral hemisphere and the ipsilateral spared hemisphere. The volume of the total infarct was measured. The infarct volume was quantified by computerized morphometric analysis using an imaging program.
As can be seen in FIG. 31 and in Table 3 below, SPG stimulation increased CBF levels in the experimental group vs. the control group. SPG stimulation also decreased the sub-cortical and cortical infarct volume in the experimental group vs. the control group, as measured at forty-eight hours following pMCAO, as can be seen in FIG. 32 , which shows the infarct volume as a percentage of the total volume of both hemispheres, and in Table 3. Mortality was lower in the experimental group than in the control group, and neuroscore was higher in the experimental group than in the control group, as is shown in Table 3.
TABLE 3
CBF
(at 6 hours after
Infarct
MCAO)
volume (at
Neuroscore
[ml/min/
Mortality
48 hours)
(at 24 hours)
Group
100 g]
[%]
[%]
[arbitrary units]
Control
99.3
47.1
38.3
3.3
Experimental
141.7
26.7
25.3
3.6
FIGS. 33A-C are graphs showing the results of in vivo experiments assessing the effect of SPG stimulation performed three hours following stroke, measured in accordance with respective embodiments of the present invention. A rat pMCAO model of stroke was used to evaluate the neuroprotective benefits of SPG stimulation following stroke using techniques described herein. Other than as described below, these experiments were conducted in the same manner as those described hereinabove with respect to FIGS. 31 and 32 and Table 3. 24 SD rats were divided into an experimental group (n=17), and a control group (n=12).
As can be seen in FIG. 33A , SPG stimulation increased CBF levels in the experimental group vs. the control group. SPG stimulation also decreased the sub-cortical and cortical infarct volume in the experimental group vs. the control group, as measured at forty-eight hours following pMCAO, as can be seen in FIG. 33B , which shows the infarct volume as a percentage of the total volume of both hemispheres. Neuroscore was slightly lower in the experimental group than in the control group at 3 hours after pMCAO, but was significantly (P<0.05) higher in the experimental group at 24 hours after pMCAO, as shown in FIG. 33C (neuroscore was assessed on a scale of 0 to 12, with 12 representing the best performance).
Reference is made to FIG. 34 , which is a graph showing results of an in vivo experiment assessing the effect of rehabilitative SPG stimulation, measured in accordance with an embodiment of the present invention. A rat MCAO (middle cerebral artery occlusion) model of stroke was used to evaluate the neuromuscular benefits of rehabilitative SPG stimulation using the techniques described herein. 47 rats were divided into three groups: a control group (n=18); a first experimental group (n=16), which received one hour of SPG stimulation per day; and a second experimental group (n=13), which received three hours of SPG stimulation per day. pMCAO was performed using the techniques described hereinabove with reference to FIG. 30 . A bipolar electrode was brought into contact with the SPG ipsilateral to the pMCAO, and connected to a controller. SPG stimulation was initiated at 24 hours after pMCAO, in order to demonstrate the potential rehabilitative effects of such stimulation, rather than the acute benefits. The first and second experimental groups each received SPG stimulation at 24 hours, 48 hours, and 72 hours after pMCAO. The stimulation regime included a duty cycle of 60 seconds on/12 seconds off, at 2 mA and 10 Hz, with a 500 μsec pulse width. As mentioned above, the stimulation was performed for one hour per day in the first experimental group, and three hours per day in the second experimental group.
At 24, 48, 72, 96, and 216 hours after pMCAO, the rats were tested using a modified neuroscore battery, which assessed the severity of damage on a scale of 0 to 10, with 10 representing the greatest deficit. As can be seen in FIG. 34 , the rats in both the first and second experimental groups achieved better (lower) neuroscores than the control group at all tested time periods after pMCAO, with statistical significance achieved for the second (3 hour stimulation) experimental group at nine days after pMCAO.
Reference is made to FIGS. 35A-C , which are graphs showing results of an in vivo experiment assessing the effect of rehabilitative SPG stimulation, measured in accordance with an embodiment of the present invention. A rat MCAO model of stroke was used to evaluate the benefits, including neuromuscular benefits, of rehabilitative SPG stimulation using the techniques described herein. 29 rats were divided into an experimental group (n=16) and a control group (n=13). Transient MCAO (tMCAO) was performed as follows. The right common carotid artery (CCA) was exposed through a midline neck incision and carefully dissected free from surrounding nerves and fascia, from its bifurcation to the base of the skull. The occipital artery branches of the external carotid artery (ECA) were isolated, and these branches were dissected and coagulated. The ECA was further dissected distally and coagulated together with the terminal lingual and maxillary artery branches, which were divided. The internal carotid artery (ICA) was isolated and carefully separated from the adjacent vagus nerve, and the pterygopalatine artery was ligated close to its origin with a 5-0 nylon suture. A 4-0 silk suture was tied loosely around the mobilized ECA stump, and a 4 cm length of 4-0 monofilament nylon suture (the tip of the suture was blunted using a flame, and the suture was coated with silicone, prior to insertion) was inserted through the proximal ECA into the ICA, and from there into the circle of Willis, effectively occluding the MCA. The suture was placed for three hours and thereafter removed. The surgical wound was closed, and the animals were returned to their cages to recover from the procedure. These techniques for performing tMCAO are similar to those described in the above-mentioned article by Schmid-Elsaesser R et al. On the day of the tMCAO procedure, a bipolar electrode was implanted in contact with the SPG ipsilateral to the tMCAO, and connected to a controller.
At 24 hours after tMCAO, and prior to commencement of the first stimulation, neurological evaluation was performed on the rats using the modified Neurological Severity Score (mNSS) scale. Only animals with an overall score of at least 12 were included in the experiment. The rats in the experimental group received SPG stimulation for 6 hours per day for 6 days, beginning 24 hours after tMCAO. The stimulation regime included a duty cycle of 60 seconds on/12 seconds off, at 2 mA and 10 Hz, with a 500 μsec pulse width. Neuroscores were assessed at days 6, 13, and 28 after tMCAO, using behavioral tests aimed at studying neuromuscular function. FIGS. 35A and 35B show results obtained at days 13 and 28, respectively (the mNSS scale ranges from 0 to 12, with best performance indicated by a 12 ). A significant improvement in neuromuscular function can be seen at both days 13 and 28. FIG. 35C shows the results of a stepping test for the left and right paws. A significant improvement in motor function in the experimental group compared with the control group can be seen for the contralateral (left) paw.
Reference is made to FIGS. 36A-H , which are graphs showing results of an in vivo experiment assessing the effect of long-term rehabilitative SPG stimulation, measured in accordance with an embodiment of the present invention. A rat tMCAO model of stroke was used to evaluate the benefits, including neuromuscular, motility, cognitive, somatosensory, somatomotor, infarct volume benefits, of rehabilitative SPG stimulation using the techniques described herein. The stimulation was applied for seven consecutive days beginning at 24 hours after reperfusion in the tMCAO model.
94 male Sprague Dawley (SD) rats were divided into six groups, as shown in Table 4:
TABLE 4
Hours of stimulation
Group
No. of rats
per day
1 - Control
18
N/A
2 - Sham
10
N/A
3
17
1
4
16
3
5
17
6
6
16
10
Prior to performance of any surgical procedure on the rats, the rats were trained using a series of behavior tests. Five parameter categories were evaluated using one or more tests, as follows:
Neuromuscular function—rotarod motor test, mNSS test, beam walking and balance test, stepping test, and staircase skilled reaching test; Motility—open field test; Learning memory (cognitive)—water maze test; Somatosensory sensation—adhesive removal test; and Somatomotor sensation—corner turn test.
Transient MCAO (tMCAO) was performed on the right hemisphere of all of rats except those of the sham group, using the techniques described hereinabove with reference to FIGS. 35A-C . Three hours after the occlusion, reperfusion was allowed in all groups. On the day of tMCAO, the rats were anesthetized, and a bipolar electrode was implanted in contact with the SPG ipsilateral to the pMCAO (i.e., the right SPG), and connected to a controller. At 24 hours post-tMCAO (just prior to stimulation), the rats were subjected to neuroscoring using the mNSS scale, which has a score range of 0-18, where 0 represents normal and 18 represents maximum neurological defect. Rats scoring less than or equal to 9 were excluded from the experiment.
SPG stimulation was applied for seven consecutive days beginning at 24 hours post-tMCAO, using the following regime: a duty cycle of 60 seconds on/12 seconds off, with two cycles every 15 minutes, at 2 mA and 10 Hz, with a 500 μsec pulse width. The stimulation was applied for fifteen minutes every 60 minutes. The number of hours of stimulation per day was as shown in Table 4 above.
In order to assess rehabilitation, on days 8, 14, and 35 post-tMCAO, (with limited exceptions for specific tests), the rats were subjected to the same pre-procedure behavior tests used in the training, as described hereinabove. One day after the last behavior testing, the rats were sacrificed and perfused. Their brains were harvested, infarct volume was measured, and neurons were counted.
The results of the experiment included the following:
Mortality in the SPG-stimulated groups was lower than in the non-stimulated control group. SPG stimulation generally improved neuromuscular functions (rotarod, mNSS, beam walk and balance, stepping and staircase tests) in comparison to the non-stimulated control group. SPG stimulation improved cognitive capabilities (water maze test) in comparison to the non-stimulated control group. There was a trend towards increased motility (open field test) in the SPG-stimulated groups. Somatosensory sensations were enhanced in the SPG-stimulated groups in comparison to the non-stimulated control group. Somatomotor competence was superior in the SPG-stimulated groups than in the non-stimulated control groups. SPG stimulation resulted in higher neurons counts in cortical layer V of the ipsilateral stimulated side in comparison to the non-stimulated control group.
In summary, in the present experiment, SPG stimulation initiated 24 hours after tMCAO had advantageous results for all five parameter groups evaluated. In addition, SPG stimulation increased the number of neurons in all regions counted.
FIG. 36A is a graph showing neuroscores (mNSS test) of all six groups, measured at 24 hours, 8 days, 14 days, and 35 days after tMCAO, measured in accordance with an embodiment of the present invention. As can be seen in the graph, mNSS scores of the SPG-stimulated rats decreased in a time-dependent manner post-tMCAO, indicating the occurrence of an active restorative, rehabilitative process. SPG stimulation markedly and significantly (p<0.05) improved neurological function measured at days 8, 14, and 35 in all SPG-stimulated groups.
FIG. 36B is a graph showing the results of the stepping test performed on the left foreleg in all six groups, measured pre-tMCAO and at 8 days, 14 days, and 35 days after tMCAO, measured in accordance with an embodiment of the present invention. As can be seen in the graph, there was a significant (p<0.05) increase in left (impaired) foreleg stepping in all SPG-stimulated rats in comparison to the non-stimulated control group (with the exception of the 10-hour stimulated group at day 35). Maximum improvement was evident in the 3- and 6-hour stimulation groups at days 14 and 35, respectively.
FIGS. 36C-F are graphs showing the results of the Morris water maze (WM) task, measured in accordance with an embodiment of the present invention. The Morris WM task is a standard test of learning in which the animal repeatedly searches for a rest platform hidden beneath the surface in a pool. The test is especially sensitive to hippocampal and cortical damage, and reflects attention, memory, and learning strategy. The Morris WM task was performed on days 14 and 35 following tMCAO.
FIG. 36C is a graph showing the latency to the first occurrence in the Old Zone (as described below) in first and second trials at 14 days after tMCAO, measured in accordance with an embodiment of the present invention. This parameter assesses the rats' functional memory. The rest platform was moved from the Old Zone (its position during training) to the New Zone (its position during testing), and the rats were expected to seek the Old Zone. The first trial showed that the SPG-stimulated rats (3-, 6-, and 10-hour stimulation) returned to the Old Zone significantly (p<0.05) more quickly than the non-stimulated rats in the control group. The second trial showed, although non-significantly, that the SPG-stimulated rats returned to the Old Zone faster than the non-stimulated controls, even though introduced to the New Zone rest platform in the first trial. The second trial thus confirmed that the SPG-stimulated rats showed enhanced remnants of functional memory.
FIG. 36D is a graph showing time spent in the Old Zone at day 14 after tMCAO, measured in accordance with an embodiment of the present invention. This parameter also assesses the rats' functional memory. As can be seen in the graph, the 3-, 6-, and 10-hour SPG-stimulated groups spent significantly (p<0.05) more time seeking the rest platform in the Old Zone in comparison to the non-stimulated control group.
FIG. 36E is a graph showing the latency to the first occurrence in the New Zone in first and second trials at day 35 after tMCAO, measured in accordance with an embodiment of the present invention. This parameter also assessed the rats' functional memory. In the first trial, the 3-, 6-, and 10-hour SPG-stimulated groups demonstrated superior, although non-significant, results in finding the New Zone, compared with the non-stimulated control group. In the second trial, all of the SPG-stimulated groups achieved better results than the non-stimulated control group. These results were significant (p<0.05) only in the 3-hour stimulated group.
FIG. 36F is a graph showing the distance moved to find the rest platform in the New Zone in first and second trials at day 35 after tMCAO, measured in accordance with an embodiment of the present invention. This parameter assessed the rats' long-term learning capability. In both trials the SPG-stimulated rats demonstrated better performance than the control group. These results were significant (p<0.05) only in the 3-hour stimulated group during the first trial.
The staircase test (results not shown) was performed to assess the rehabilitation of foreleg fine motorics. At day 14 after tMCAO the SPG-stimulated groups demonstrated better performance in the left impaired foreleg than the control group (1-, 3-, and 6-hour stimulation, significant (p<0.05) in the 3- and 6-hour stimulated rats only). At day 35 after tMCAO the SPG-stimulated groups demonstrated better performance in the left impaired foreleg, significant (p<0.05) in the 3-hour stimulated rats only.
The rotarod test (results not shown) was performed to assess the rats' ability to remain on a rotating rod. It requires a high degree of sensorimotor coordination and is sensitive to damage in the basal ganglia and the cerebellum. The only significant (p<0.05) results were in the 3-hour stimulated rats on the 35 day assessment, which remained on the rotarod significantly longer than the control group.
FIG. 36G is a graph showing the time required for the rats to remove an adhesive patch from the left foreleg, measured in accordance with an embodiment of the present invention. This test assessed both cutaneous sensitivity and sensor motor integration, and is analogous to human neurological tests used clinically in stroke patients. In the left impaired foreleg, the SPG-stimulated rats showed better results than the non-stimulated controls at all assessment days (8, 14, and 35 days). These results were significant (p<0.05) at all three assessment days in the 3- and 6-hour stimulated groups only.
The corner test (results not shown) was performed to evaluate the rats' tendency to favor a turn in the direction of the ipsilateral side of the tMCAO (i.e., the right side in the experiment). On all three assessment days (8, 14, and 35 days), all SPG-stimulated groups showed a decrease in right side turns in comparison to the non-stimulated control group. This decrease was significant (p<0.05) only on day 35 in the 1- and 6-hour stimulated rats.
The beam walk test (results not shown) was performed to evaluate sensor motor integration, specifically hind limb function. In general, all SPG-stimulated groups showed improved results in comparison to the non-stimulated control group. These results were significant (p<0.05) only on day 35 only in the 3-hour stimulated group.
The beam balance test (results not shown) was performed to assess gross vestibulomotor function, by requiring the rats to balance steadily on a narrow beam. This test is sensitive to motor cortical insults. On all assessment days (days 8, 14, and 35), all of the SPG-stimulated groups (except the 1-hour stimulated group on day 8) performed better than the non-stimulated control group. These results were significant (p<0.05) only on day 14 in the 3-hour stimulated group.
The open field test (results not shown) was performed to assess the following four parameters indicative of hippocampal and basal ganglia damage, as well as hind limb dysfunction:
Total distance moved, which decreases in cerebrally-insulted animals. All of the SPG-stimulated groups achieved enhanced movement compared to the control group on day 14 after tMCAO. These results were significant (p<0.05) only in the 3- and 6-hour stimulated groups. Velocity, which is diminished in cerebrally-insulted animals. All of the SPG-stimulated groups achieved enhanced velocity compared to the control group on day 14 after tMCAO. These results were significant (p<0.05) only in the 3- and 6-hour stimulated groups. Latency of first occurrence in center zone. All of SPG-stimulated groups (except the 10-hour stimulated group on day 14) showed quicker entry into the center zone in comparison to the non-stimulated control group. These results were significant (p<0.05) only on day 35 in the 1- and 3-hour stimulated groups. Total distance moved in center zone. On day 14, the 3- and 10-hour stimulated groups achieved significantly (p<0.05) greater distance moved than the control group.
FIG. 36H is a graph showing the number of neurons in cortical layer V and measured in accordance with an embodiment of the present invention. Neuron counting was performed in cortical layers V and II-III in the non-stimulated control group and in the 3- and 6-hour SPG-stimulated groups. The number of neurons in cortical layer V was significantly (p<0.05) greater in both of these SPG-stimulated groups compared to the non-stimulated group. In cortical layers II-III there was no significant difference between the stimulated and non-stimulated groups.
There were no significant differences in body weigh between the SPG-stimulated groups and the non-stimulated control group.
The inventors are currently performing an in vivo experiment to compare the application of SPG stimulation for 28 days with the application of SPG stimulation for 7 days, as applied in the experiment described hereinabove with reference to FIGS. 36A-H . The experimental protocol is similar to that of this above-mentioned experiment. Preliminary results of this current experiment indicate that application of SPG stimulation for the longer 28-day period has greater therapeutic benefits than application of the stimulation for 7 days:
Table 5 shows the results of an in vivo experiment performed to test whether long-term stimulation of the SPG using a protocol appropriate for treating stroke damages the BBB, measured in accordance with an embodiment of the present invention. 31 rats (males, Wistar™, 12 weeks, average body weight 300 g) were divided to three groups: an SPG stimulation group (n=13), which had an SPG stimulator implanted; a first control group (n-12), which was not stimulated, and had a sham operation; and a second control group (n=6), which had a sham operation, and was exposed to an RF electromagnetic field for 24 hours. The SPG stimulation group received 24 hours of continuous SPG stimulation with a stimulation regime that included a duty cycle of 90 seconds on/60 seconds off, at 5 V and 10 Hz, with a 1 millisecond pulse width. Upon completion of stimulation, a marker (Evans blue (EB) (2%)), which normally does not cross the BBB, was intravenously (2 ml) injected into the rats. 48 hours following the EB administration, 500 ml of cold saline was used for perfusion of blood and EB from the rats' circulation. Thereafter, the rats' brains were removed, the left and right hemispheres were homogenized, and brain EB concentration was determined using an Elisa Reader at 630 nm. As can be seen in Table 5, stimulation for 24 hours did not cause leakage of EB into the brain, indicating that the stimulation did not cause damage to the BBB.
TABLE 5
Right
Left
Group
Hemisphere
Hemisphere
First Control (non-stimulated) (n = 12)
0.04 ± 0.03
0.02 ± 0.02
Second Control (RF-exposed) (n = 6)
0.03 ± 0.02
0.04 ± 0.02
Experimental (stimulated) (n = 13)
0.03 ± 0.02
0.02 ± 0.02
The inventors performed in vivo experiments in rats to assess the safety of SPG stimulation techniques described herein. These experiments showed that stimulation did not break down the BBB, and that stimulation was found to be safe in a battery of motor and cognitive tests, which were in general agreement with histological analysis.
In an embodiment of the present invention, a calibration procedure is performed, in which a test molecule is injected into the systemic blood circulation of the subject, and a threshold stimulation strength is determined by stimulating at least one MTS, and gradually increasing the stimulation strength until the BBB is opened (e.g., as determined using a radioactive scanning technique). System 310 applies therapeutic stimulation to an MTS using a strength equal to a certain percentage of the threshold strength, typically less than 100%.
Reference is made to FIG. 37 , which is a graph 660 showing a protocol for treating a brain tumor, in accordance with an embodiment of the present invention. In accordance with this protocol, a method for treating a brain tumor comprises: (a) during a first period of time 670 , applying excitatory electrical stimulation to at least one MTS at a first, relatively low strength 652 , in conjunction with administration of a chemotherapeutic drug at a first, relatively high dosage 674 ; and (b) during a second period of time 676 , applying the stimulation at a second strength 678 greater than first strength 652 , in conjunction with administration of the drug at a second dosage 680 lower than first dosage 674 . Alternatively, the drug is administered only at the first dosage, and the stimulation is applied at second strength 678 after the level of the drug in the systemic circulation has dropped because of ordinary metabolic drug clearance from the circulation. For some applications, the protocol shown for second period 676 is applied after first period 670 (as shown). For other applications, the protocol shown for the second period is applied before the protocol shown for the first period. Alternatively, two different chemotherapeutic drugs are applied during the first and second periods, respectively, not necessarily at different dosages.
The blood-tumor barrier (BTB) of the core and tissue near the core of a growing brain tumor is generally damaged by the natural progression of the tumor. During first period 670 , stimulation applied at first strength 672 is thus sufficient to further open the BTB of the core and tissue near the core, but not sufficient to open the BBB of the periphery of the tumor or of other cells in the brain. In other words, first strength 672 is between a BTB opening strength 673 and maximum BBB-opening strength 612 . As a result, high dosage 674 of the chemotherapeutic drug is targeted at the core and tissue near the core of the tumor, since the drug is substantially unable to enter other brain cells, because of their intact BBB and the large molecular size of the drug. During second period 676 , stimulation at higher second strength 678 opens the BBB of other brain cells, including tumor cells in the periphery of the core and/or other areas of the brain. For some applications, second strength 678 is greater than or equal to maximum BBB-opening strength 612 , as shown in FIG. 37 . Alternatively or additionally, second strength 678 is sufficient to induce a significant increase in the permeability of the BBB. Second dosage 680 is low enough not to substantially damage non-tumor cells. For some applications, the dosage is set to the highest level that does not cause systemic and/or brain toxicity; this level is higher during first period 670 than during second period 676 , because of the lower level of MTS stimulation during the first period than during the second period. For some applications, only the protocol for the first period is applied, when this is deemed sufficient to facilitate delivery of the drug to the core and tissue near the core while generally avoiding facilitating delivery of the drug into other brain cells. For some applications, in order to determine the appropriate parameters for increasing the permeability of the BTB and/or BBB for this embodiment, a calibration procedure is performed in which the uptake of a substance across the BTB and/or BBB is measured at a plurality of stimulation parameters (e.g., using a radioactive isotope or other marker known in the art).
In an embodiment of the present invention, bipolar stimulation is applied, in which a first electrode is applied to a first MTS, and a second electrode is applied to a second MTS.
In an embodiment of the present invention, an SPG of the subject is indirectly activated by stimulating a branch of cranial nerve V of the subject, including, for example, afferent fibers of cranial nerve V, either electrically, magnetically, or electromagnetically. A reflex response to such stimulation leads to activation of the SPG. Typically, the stimulation is performed while the subject is under general anesthesia or sedation. For some applications, cranial nerve V is stimulated by non-invasively attaching electrodes to the surface of the face of the subject, typically using techniques commonly used for transcutaneous electrical nerve stimulation (TENS).
In an embodiment of the present invention, an SPG of the subject is indirectly activated by stimulating afferent fibers of the trigeminal nerve (cranial nerve V) of the subject, either electrically, magnetically, or electromagnetically. A reflex response to such stimulation leads to activation of the SPG. (For example, the maxillary branch of the trigeminal nerve directly contacts the SPG.) Typically, but not necessarily, such stimulation is performed while the subject is under general anesthesia or sedation. For some applications, cranial nerve V is stimulated by non-invasively attaching electrodes to the surface of the face of the subject, typically using techniques commonly used for transcutaneous electrical nerve stimulation (TENS). For example, TENS may be applied to a cheek or a tip of a nose of a subject. In an embodiment of the present invention, an oral appliance is provided that is configured to be brought into contact with a mucous membrane of a palate of an oral cavity of a subject. The appliance comprises one or more electrodes, which are driven to apply transmucosal electrical stimulation to nerve fibers within or immediately above the mucous membrane, which fibers directly innervate an SPG of the subject. Typically, but not necessarily, such stimulation is performed while the subject is under general anesthesia or sedation. Such transmucosal stimulation may require less current than the transcutaneous stimulation described hereinabove.
In some embodiments of the present invention, techniques described herein are practiced in combination with techniques described in one or more of the references cited in the Background of the Invention section hereinabove and/or in combination with techniques described in one or more of the patent applications cited hereinabove.
The scope of the present invention includes embodiments described in the following patent applications, which are assigned to the assignee of the present patent application and are incorporated herein by reference. In an embodiment of the present invention, techniques and apparatus described in one or more of the following applications are combined with techniques and apparatus described herein:
U.S. Provisional Patent Application 60/203,172, filed May 8, 2000, entitled, “Method and apparatus for stimulating the sphenopalatine ganglion to modify properties of the BBB and cerebral blood flow” U.S. patent application Ser. No. 10/258,714, filed Oct. 25, 2002, which issued as U.S. Pat. No. 7,120,489, entitled, “Method and apparatus for stimulating the sphenopalatine ganglion to modify properties of the BBB and cerebral blood flow,” or the above-referenced PCT Publication WO 01/85094 U.S. Provisional Patent Application 60/364,451, filed Mar. 15, 2002, entitled, “Applications of stimulating the sphenopalatine ganglion (SPG)” U.S. Provisional Patent Application 60/368,657, filed Mar. 28, 2002, entitled, “SPG Stimulation” U.S. Provisional Patent Application 60/376,048, filed Apr. 25, 2002, entitled, “Methods and apparatus for modifying properties of the BBB and cerebral circulation by using the neuroexcitatory and/or neuroinhibitory effects of odorants on nerves in the head” U.S. Provisional Patent Application 60/388,931, filed Jun. 14, 2002, entitled “Methods and systems for management of Alzheimer's disease,” PCT Patent Application PCT/IL03/000508, filed Jun. 13, 2003, claiming priority therefrom, and which published as PCT Publication WO 03/105658, and U.S. patent application Ser. No. 10/518,322, filed Dec. 14, 2004 in the national stage thereof, which issued as U.S. Pat. No. 7,640,062 U.S. Provisional Patent Application 60/400,167, filed Jul. 31, 2002, entitled, “Delivering compounds to the brain by modifying properties of the BBB and cerebral circulation” U.S. Provisional Patent Application 60/426,180, filed Nov. 14, 2002, entitled, “Surgical tools and techniques for sphenopalatine ganglion stimulation,” PCT Patent Application PCT/IL03/000966, filed Nov. 13, 2003, which claims priority therefrom, and which published as PCT Publication WO 04/043218, and U.S. patent application Ser. No. 10/535,024, filed May 11, 2005 in the national stage thereof, which issued as U.S. Pat. No. 7,636,597 U.S. Provisional Patent Application 60/426,182, filed Nov. 14, 2002, and corresponding PCT Patent Application PCT/IL03/000967, which claims priority therefrom, filed Nov. 13, 2003, which published as PCT Publication WO 04/044947, entitled, “Stimulation circuitry and control of electronic medical device,” and a US patent application filed May 11, 2005 in the national stage thereof U.S. patent application Ser. No. 10/294,310, filed Nov. 14, 2002, which issued as U.S. Pat. No. 7,146,209, entitled, “SPG stimulation for treating eye pathologies,” and PCT Patent Application PCT/IL03/000965, filed Nov. 13, 2003, claiming priority therefrom, which published as PCT Publication WO 04/043217 PCT Patent Application PCT/IL03/000631, filed Jul. 31, 2003, which published as PCT Publication WO 04/010923, entitled, “Delivering compounds to the brain by modifying properties of the BBB and cerebral circulation,” and U.S. patent application Ser. No. 10/522,615, filed Jan. 31, 2005 in the national stage thereof U.S. Pat. No. 6,853,858 to Shalev U.S. patent application Ser. No. 10/783,113, filed Feb. 20, 2004, which issued as U.S. Pat. No. 7,117,033, entitled, “Stimulation for acute conditions” U.S. Provisional Patent Application 60/426,181, filed Nov. 14, 2002, entitled, “Stimulation for treating ear pathologies,” PCT Patent Application PCT/IL03/000963, filed Nov. 13, 2003, which claims priority therefrom, and which published as PCT Publication WO 04/045242, and U.S. patent application Ser. No. 10/535,025, filed May 11, 2005 in the national stage thereof U.S. Provisional Patent Application 60/448,807, filed Feb. 20, 2003, entitled, “Stimulation for treating autoimmune-related disorders of the CNS” U.S. Provisional Patent Application 60/461,232 to Gross et al., filed Apr. 8, 2003, entitled, “Treating abnormal conditions of the mind and body by modifying properties of the blood-brain barrier and cephalic blood flow” PCT Patent Application PCT/IL03/00338 to Shalev, filed Apr. 25, 2003, which published as PCT Publication WO 03/090599, entitled, “Methods and apparatus for modifying properties of the BBB and cerebral circulation by using the neuroexcitatory and/or neuroinhibitory effects of odorants on nerves in the head,” and U.S. patent application Ser. No. 10/512,780, filed Oct. 25, 2004 in the national stage thereof, which published as US Patent Application 2005/0266099 U.S. Provisional Patent Application 60/506,165, filed Sep. 26, 2003, entitled, “Diagnostic applications of stimulation” U.S. patent application Ser. No. 10/678,730, filed Oct. 2, 2003, which published as US Patent Application Publication 2005/0074506, entitled, “Targeted release of nitric oxide in the brain circulation for opening the BBB,” and PCT Patent Application PCT/IL04/000911, filed Oct. 3, 2004, claiming priority therefrom, which published as PCT Publication WO 05/030118 PCT Patent Application PCT/IL04/000897, filed Sep. 26, 2004, entitled, “Stimulation for treating and diagnosing conditions,” which published as PCT Publication WO 05/030025 U.S. Provisional Patent Application 60/604,037, filed Aug. 23, 2004, entitled, “Concurrent bilateral SPG modulation” PCT Patent Application PCT/IL05/000912, filed Aug. 23, 2005, entitled, “Concurrent bilateral SPG modulation,” which published as PCT Publication WO 06/021957 U.S. patent application Ser. No. 10/952,536, filed Sep. 27, 2004, entitled, “Stimulation for treating and diagnosing conditions,” which published as US Patent Application Publication 2005/0159790 (now abandoned) U.S. Provisional Patent Application 60/709,734, filed Aug. 19, 2005, entitled, “Stimulation for treating brain events and other conditions” U.S. patent application Ser. No. 11/349,020, filed Feb. 7, 2006, which issued as U.S. Pat. No. 7,561,919, entitled, “SPG stimulation via the greater palatine canal” U.S. Pat. No. 7,561,919 to Shalev et al. U.S. Pat. No. 8,055,347 to Lamensdorf et al.
In an embodiment of the present invention, system 20 and/or 120 comprises circuitry described in one or more of the above-mentioned applications.
In an embodiment of the present invention, electrical stimulation system 310 comprises circuitry described in one or more of the above-mentioned applications.
In an embodiment of the present invention, an MTS is stimulated using the magnetic stimulation apparatus and methods described in the above-mentioned U.S. patent application Ser. No. 10/783,113.
As used in the present application and in the claims, the BBB comprises the tight junctions opposing the passage of most ions and large molecular weight compounds between the blood and brain tissue. As used in the present application and in the claims, the BTB comprises a barrier opposing the passage of many ions and large molecular weight compounds between the blood and tissue of a brain tumor.
It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes both combinations and subcombinations of the various features described hereinabove, as well as variations and modifications thereof that are not in the prior art, which would occur to persons skilled in the art upon reading the foregoing description. For example, elements which are shown in a figure to be housed within one integral unit may, for some applications, be disposed in a plurality of distinct units. Similarly, apparatus for communication and power transmission which are shown to be coupled in a wireless fashion may, alternatively, be coupled in a wired fashion, and apparatus for communication and power transmission which are shown to be coupled in a wired fashion may, alternatively, be coupled in a wireless fashion.
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A method for treating a subject is provided, including applying electrical stimulation to a site of the subject selected from the group consisting of: a sphenopalatine ganglion (SPG), a greater palatine nerve, a lesser palatine nerve, a sphenopalatine nerve, a communicating branch between a maxillary nerve and an SPG, an otic ganglion, an afferent fiber going into the otic ganglion, an efferent fiber going out of the otic ganglion, an infraorbital nerve, a vidian nerve, a greater superficial petrosal nerve, and a lesser deep petrosal nerve. The stimulation is configured to excite nervous tissue of the site at a strength sufficient to induce at least one neuroprotective occurrence selected from the group consisting of: an increase in cerebral blood flow (CBF) of the subject, and a release of one or more neuroprotective substances, and insufficient to induce a significant increase in permeability of a blood-brain barrier (BBB) of the subject.
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BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to marine fenders. More particularly, this invention is directed to an improved marine fender having high energy absorbtion capacity and low reaction force and a shape and structure which eliminates expensive framework and external support material subject to snagging and frequent maintenance.
2. Description of the Prior Art
Marine fenders are used to absorb the impact energy between two ships, a ship and a quay or pier, a vessel and an off-shore oil platform, and other similar situations. Many types of fenders have been used for these various purposes, including bundles of rope and wood floats.
Currently most existing fender systems fall into one or more of three broad categories: (1) solid elastomeric shapes, (2) shock cells, and (3) low pressure fendering.
Solid elastomeric fenders include extruded or molded rubber shapes which will absorb a large amount of energy, but, because of the high compressive resistance of the elastomers, have small deflection and high reaction force. The high reaction force of this type fender generally limits its use to areas where vessel approach velocities are low or where vessels are small. Normally this type of fender is used with vessels, piers and docks in protected waters or for small boat landing on off-shore oil platforms.
Shock cell fenders usually incorporate solid elastomeric fenders on a metal frame with shock cells between the frame and the structure being fendered. The shock cells may be bodies of elastomeric material or may employ hydraulics, pneumatics, springs, etc. Shock cells generally absorb large amounts of enegy but also have high reaction forces. This type of fendering requires extensive metal framework and frequent maintenance, particularly in the case of pneumatic or hydraulic shock cells. Shock cell fenders are usually limited to use in fixed locations such as on off-shore oil platforms.
Low pressure fenders generally consist of an elastomeric skin filled with pressurized air or resilient foam. Usually these fenders operate at a contact pressure between 5 psi and 75 psi compared to several hundred psi for solid elastomeric and shock cell fenders. Low pressure fenders are usually contained within nets made of chain or wire rope and frequently incorporate used tires or rubber extensions as part of the net. The net is necessary to provide means for handling the fender or for transmitting loads from the fender to the rigging attaching the fender to the structure.
Low pressure fenders filled with air pressure require frequent monitoring of the inflation pressure and are subject to exploding or deflating if punctured. Both air and foam filled fenders require maintenance of the nets which are subject to snagging and wear. This type of fender is in widespread use in ship-to-ship and ship-to-dock applications, but is little used on off-shore oil platforms.
The fender of the invention combines many of the advantages of the three types of prior art fenders while eliminating their disadvantages. The unique design provides a fender having the high energy absorption capacity of solid elastomeric fenders and shock cell fenders and the low reaction force of the low pressure fenders. The fender design eliminates external nets common to low pressure fenders thus reducing maintenance and eliminating wear and snagging problems. The conical shape of the ends of the fender reduces the potential for snagging the fender on structure or vessel overhang, a common problem with cylindrical-shaped fenders.
While the fender of the invention has the high energy absorption capacity of solid elastomeric fenders, it is generally of larger diameter than the solid fenders thereby providing more stand-off distance between the vessel and the structure being fendered. In most instances this is advantageous, particularly with large vessels and in rough-sea situations such as for off-shore oil platforms.
Unlike shock cell fenders, the invention does not require an extensive steel framework and separate shock cells, thereby reducing the cost of the fendering system and the maintenance required. Furthermore, although providing energy absorption comparable to a shock cell fender, the invention is more versatile in use since it does not have the extensive structural framework; it may be easily relocated or removed and replaced.
SUMMARY OF THE INVENTION
The objects and advantages of the invention are set forth in part in the description which follows and in part will be obvious from the description, or may be learned by practice of the invention. The 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.
In accordance with the purpose of the invention, as embodied and broadly described herein, the fender of this invention comprises a resilient core for absorbing energy upon repeated compression having a cylindrical central portion tapering at each opposed end thereof to a truncated cone-shaped end portion and having an axial bore; a fitting secured to each end portion including a tubular central member disposed coaxially with the axial bore, an annular seat integral with one end of the central member proximate the core having a diameter greater than the central member, and an annular flange secured to the other end of the central member; flexible strength means disposed in the axial bore and the bores of the opposed central members cooperating with the flange of each fitting for interconnecting the fittings and adjustably biasing the fittings axially toward each other; and a flexible elastomeric skin enclosing the core and the central member and seat of each fitting to protect the core from wear and abrasion and to distribute impact loads evenly over the core and fittings.
In a preferred embodiment, an elastomeric collar is disposed around the portion of the skin enclosing the central member and seat of each fitting for protecting the skin from abrasion and for absorbing compressive impact energy.
Preferably the fender core is formed of a resilient plastic foam having a density in a range of 2-60 lbs/cu.ft.
It is also preferred that the fender further comprise elongated reinforcing fibers embedded within the skin and encircling the core and fittings at an angle to the longitudinal axis of the core. The elongated reinforcing fibers may be arranged in overlapping swaths each comprising a plurality of substantially parallel fibers, the swaths intersecting each other at approximately 45° and being wrapped around the core, the fittings and back around the core.
Preferably each of the opposed ends of the strength means is adjustably attached to a respective flange secured to the respective fitting, and means for attaching the fender to a structure is also secured to one or both of the opposed flanges.
Also in accordance with the invention, a method of manufacturing the marine fender comprises applying resilient plastic foam material around an elongated mandrel; shaping the foam material to form a core having a substantially cylindrical central section tapering at each opposed end to a truncated cone-shaped end portion and having an axial bore around the mandrel; placing a fitting around the mandrel at each end of the core, the fitting having a tubular central member located around the mandrel coaxial with the bore, an annular seat integral with one end of the central member abutting the core, and an annular flange secured to the other end of the central member; axially securing each fitting to the mandrel by means of a lock collar secured to the mandrel; while rotating the mandrel, core and fittings around their common axis, concurrently applying liquid elastomeric material to form an elastomeric skin around the core and the central member and seat of each fitting and wrapping swaths of elongated reinforcing fibers around the core and the central member and seat of each fitting to embed the fibers in the skin; removing the mandrel; inserting a flexible strength means in the bore and central member of each fitting; adjustably securing each end of the flexible strength means to a respective annular flange; and securing to at least one flange means for external attachment of the fender to a structure.
Preferably, the method further includes, prior to removing the mandrel, the step of molding an elastomeric collar around the skin enclosing the central member and seat of each fitting.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one embodiment of the invention and, together with the description, serve to explain the principles of the invention.
FIG. 1 is a partial cutaway side view of the fender of the invention.
FIG. 2 is an elevation view of the fender of FIG. 1 mounted in place.
FIG. 3 is a top view of another mounting method for the fender of the invention.
FIG. 4 is a cross-sectional view of one end of an embodiment of the invention.
FIG. 4A is a top view of the fender depicted in FIG. 4.
FIGS. 5A-D and plan views of components of the fitting of an embodiment of the invention.
FIG. 6 depicts the structure used in manufacture of the fender.
FIG. 7 depicts the lock ring used in manufacture of the fender.
FIG. 8 schematically represents the method of manufacture of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings.
In accordance with the invention, the marine fender comprises a resilient core for absorbing energy upon repeated compression having a cylindrical central portion tapering at each opposed end thereof to a truncated cone-shaped end portion and having an axial bore.
As here embodied and depicted in FIG. 1, the marine fender 10 comprises a resilient core 12 having a cylindrical central portion 14 tapering at each opposed end thereof to a truncated cone-shaped end portion 16 and having an axial bore 18.
Preferably the resilient core 12 is formed of a resilient, plastic foam having a density of from 2 to 60 pounds per cubic foot. The plastic foam may be polyethylene, ethylene vinyl acetate, vinyl urethane, styrene butadiene, or such other plastics or elastomers or copolymers or alloys of such.
The foam may be arranged in slabs around the bore 18 and shaped to form the central portion 14 and truncated cone-shaped end portions 16.
In accordance with the invention, a fitting is disposed at each end portion of the core. Each fitting includes a tubular central member coaxial with the bore of the core, an annular seat integral with one end of the central member proximate the core with a diameter greater than the central member, and an annular flange means secured to the other end of the central member.
As embodied herein and depicted in FIGS. 1 and 4, a fitting 20 is disposed at each end portion of the core 12. Each fitting 20 includes a tubular central member 22 coaxial with the bore 18 of the core 10. An annular seat 24 integral with one end of the central member 22 has a diameter greater than the central member 22 and is disposed proximate the respective end portion 16 of the core 12. Annular flange means 26 is secured to the other end of the central member 22.
Preferably the annular seat 24 has a substantially truncated cone shape and is secured to the outer periphery of the one end of the central member 22 coaxial with the bore of the central member 22. The annular seat 24 may be an annular flange having truncated cone shape welded to the central member 22 with the base of the flange being substantially coplanar with the end of the central member.
Each fitting 20 is disposed such that the base of the annular seat 24 is in abutting relationship with the truncated apex of the respective end portion 16.
In accordance with the invention, flexible strength means is disposed in the co-axial bores of the core and opposed central members cooperating with the flange means of the fittings for interconnecting the fittings and adjustably biasing the fittings axially toward each other.
Preferably, flange means 26 includes means for permitting external attachment of the fender 10 to a structure. As depicted in the embodiment of FIG. 4, flange means 26 comprises flange 30 welded around the end of the central member 22 in a plane substantially parallel to the base of the annular seat 24, first plate 32 disposed on flange 30 and over the open end of central member 22, and second plate 34 disposed on first plate 32.
As seen in FIGS. 4 and 5A, flange 30 has a central opening 36 for receiving the end of the central member 22 and a plurality of holes 38 spaced around the central opening 36.
First plate 32 (FIGS. 4 and 5B) has a central opening 40 disposed coaxial with the bore of central member 22 and a plurality of holes 42 disposed coaxial with holes 38 in flange 30.
Second plate 34 (FIGS. 4 and 5C) has a central opening 44 coaxial with central opening 40 in first plate 32 and a plurality of holes 46 coaxial with holes 42 in first plate 32.
As seen in the embodiment depicted in FIG. 4, flexible strength means may be a chain 28. Preferably, at each end of chain 28 is a threaded element 48 which cooperates with first plate 32 of each fitting for interconnecting the fittings and adjustably biasing the fittings toward each other. The flexible strength means may also be wire or synthetic rope having a threaded element at each end thereof. The flexible strength means permits biasing fittings 20 toward each other and permits transmitting forces from one end of fender 10 to the other end.
Each threaded element 48 is slidably received in central opening 40 of the each respective first plate 32 and secured to the respective first plate 32 by nut 50. Central opening 40 in first plate 32 had a diameter large enough to slidably receive threaded element 48 but small enough to permit tightening of nut 50 to bias fittings 20 together. The central opening 44 in second plate 34 has a diameter sufficiently large to receive nut 50. Tightening of nut 50 biases fittings 20 toward each other, thus placing core 12 in compression.
First plate 32 is sandwiched between flange 30 and second plate 34. Bolts 52 in coaxial holes 38,42 and 46 in flange 30, first plate 32 and second plate 34, respectively, secure the first and second plates 32,34 to flange 30. The holes 38 in flange 30 may be threaded for receiving the threaded end of bolts 52. Preferably, nuts 54 are welded to the bottom of flange 30 coaxial with holes 38 for threadably receiving to threaded ends of bolts 52 to secure first and second plates 32,34 and flange 30 together.
Second plate 34 also provides means for permitting external attachment of fender 10 to a structure. In the embodiment depicted in FIGS. 4 and 4A, second plate 34 secures swivel plate assembly 56 to at least one fitting 20. Swivel plate 56 carries shackle 58 which provides means for securing fender 10 to a structure. A shackle 58 may be located at one or both ends of fender 10.
Swivel plate assembly 56 includes swivel plate 60 having a central opening 62 and a pair of opposed, parallel clevis plates 64 secured to the swivel plate 60. First plate 32 has a diameter less than that of second plate 34 and flange 30 and fits in central opening 62 of swivel plate 60. Swivel plate assembly 56 is secured to fender 10 by securing swivel plate 60 between flange 30 and second plate 34 proximate their periphery. Bushing 65 are located between first and second plates 32,34 permitting rigid attachment of the first and second plates to flange 30 while leaving space between second plate 34 and flange 30 at their peripheries to permit rotation of swivel plate 60 around the fender axis. Shackle 58 is rotatably carried on rod 66 secured between clevis plates 64.
Alternatively, attachment to the fender 10 may be to a single clevis plate 68 secured to the center of second plate 34 of one or both fittings 20. As seen in FIGS. 2, 5C and 5D, clevis plate 68 is welded transverse second plate 34. The bottom of clevis plate 68 has a notch 70 permitting access to nut 50 disposed in central opening 44 of second plate 34. In this embodiment the diameter of first plate 32 may be the same as flange 30 and second plate 34.
A second alternative for securing fender 10 to a structure is depicted in FIG. 3. In this embodiment two clevis plates 72 are secured to swivel plate 60 in position to permit attachment of fender 10 to a structure through both clevis plates 72. Fender 10 may rotate about its axis due to the structure discussed with respect to FIG. 4 which permits swivel plate 60 to rotate about the fender axis.
In accordance with the invention, a flexible elastomeric skin encloses the core and the central member and seat of each fitting to protect the core and fittings from wear and abrasion and to distribute impact loads evenly over the core and fittings.
In a preferred embodiment (FIGS. 1 and 4), flexible elastomeric skin 74 covers the core 12 and central member 22 and annular seat 24 of both fittings 20. The skin 74 abuts the bottom of flange 30 and also covers nuts 54 which are secured to the bottom of flange 30. By enclosing central member 20 and annular seat 24 of each fitting within the skin 74 the fittings are held captive within the skin and forces are evenly transmitted from fittings 20 to skin 74. The skin may be an elastomer such as polyurethane, natural rubber, synthetic rubber or vinyl.
Preferably, elongated reinforcing fibers 76 are embedded in skin 74 and encircle core 12 and fittings 20 at an angle to the axis of fender 10. It is preferred that the fibers 76 be substantially continuous and embedded in the skin in overlapping swaths comprising a plurality of substantially parallel fibers. The swaths of fibers intersect to each other at approximately 45°, as seen in FIG. 1, and are wrapped around core 12, fittings 20 and back around core 12 to strengthen the entire structure and to distribute loads over the entire core and both fittings. The fiber 76 may be, for example, nylon, polyester or aromatic polyamide.
In the preferred embodiment, an elastomeric collar surrounds the portion of the skin enclosing the central member and seat of each fitting for protecting the skin from abrasion and for absorbing compressive impact energy. As depicted in FIGS. 1, 2 and 4, collar 78 is a molded annular member encircling central member 22, substantially all of annular seat 24 and flange 30 of each fitting 20 outside skin 74. Collar 78 may be made of molded polyurethane, natural rubber or synthetic rubber and may have a diameter 40 to 50% of the diameter of central portion 14 of core 12.
In accordance with the invention, the method of manufacturing the fender comprises applying resilient, plastic foam material around an elongated mandrel and shaping the foam material to form a core having a substantially cylindrical central section tapering at each opposed end thereof to a truncated cone-shaped end portion and having an axial bore around the mandrel.
As depicted in FIG. 6, slabs of foam material 80 are secured to each other around a mandrel 82. The mandrel 82 creates a bore in the core formed by the foam material 80. It may be preferred to place a cylindrical liner around the mandrel and securing the foam to the liner. The liner would serve to protect the interior of the bore from abrasion by a flexible strength means such as chain placed in the bore. After the slabs of foam 80 are secured in place, the core is shaped to form a substantially cylindrical central portion tapering at each end to truncated-cone shaped end portions.
In accordance with the invention, the method further comprises the steps of placing a fitting around the mandrel at each end of the core, each fitting having a tubular central member located around the mandrel coaxial with the core bore, an annular seat integral with one end of the central member abutting the core, and an annular flange secured to the other end of the central member. Each fitting is axially secured to the mandrel by means of a lock collar secured to the mandrel.
In the preferred method, a fitting 84 is placed around mandrel 82 at each end of the foam 80 forming the core. Fitting 84 includes central member 86 located around mandrel 82 coaxial with the core, annular seat 88 integral with one end of central member 86 abutting the core at each end thereof, and annular flange 90 secured to the other end of the central member 86. It may be preferred to place a cylindrical layer of foam material 92 around the mandrel inside each central member 86. This compensates for the diameter of the central member 86 which is greater than the base of the core.
A lock collar 94 (FIGS. 6 and 7) is secured around the mandrel 82 at each end thereof abutting the central member 86 and flange 90 for axially securing each fitting 84 in place.
In accordance with the invention, the method further comprises the steps of concurrently applying liquid elastomeric material to form an elastomeric skin around the core and each fitting and wrapping swaths of elongated reinforcing fibers around the core and fittings to embed the fibers in the skin while rotating the mandrel, core, and fittings around their common axis. Preferably the skin with embedded fibers is continuous between the opposed flanges of the opposed fittings. As seen in FIG. 8, liquid elastomeric material 100 is applied to core and fittings 84 and swaths of fibers 102 are wrapped around core and fittings 84 while mandrel 82 is rotated as depicted by arrow 104.
After the skin material has dried, an elastomeric collar may be molded around the skin enclosing the central member and seat of each fitting. Preferably, each collar may be molded to also encircle the flange secured to each fitting.
The method of the invention further includes the steps of removing the mandrel, inserting flexible strength means in the bore of the core and central member of each fitting, adjustably securing each end of the flexible strength means to a respective flange, and securing to each flange means for attaching the fender to a structure.
More particularly, referring to FIGS. 4 and 6, the method includes, after forming the core 16 and fixing the fittings 84 to the mandrel 82, applying skin 74 and fibers 76 while rotating the mandrel 82, core and fittings 84. Mandrel 82 is then removed by removing lock collars 94. The cylindrical layer of foam material 92, if used, should be removed with the mandrel 82.
Chain 28 is inserted in bore 18 and central members 22. Flange means 26 is then assembled and swivel plate assembly 56 and threaded element 48 are secured to the flange means 26.
In the preferred method, before mandrel 82 is removed and after skin 74 dries, collar 78 may be molded in place around each fitting 84.
It will be apparent to those skilled in the art that various modifications and variations could be made in the fender and manufacturing method of the invention without departing from the scope or spirit of the invention.
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A marine fender having high energy absorption capacity, low reaction force, a smooth exterior surface and no extensive exterior support structure to preclude snagging and reduce maintenance is provided. The fender comprises a resilient core having a cylindrical central portion tapering at each end to a truncated cone-shaped end portion, a fitting at each end of the core disposed coaxially with an axial bore in the core, flexible strength member in the axial bore interconnecting the fittings and providing means for adjustably biasing the fittings toward each other, and a flexible elastomeric skin enclosing the core and substantial portions of each fitting to protect the core from wear and abrasion and to distribute impact loads evenly over the core and fittings.
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[0001] This application is a Continuation-in-Part application of co-pending application Ser. No. 09/259068, filed Feb. 26, 1999 entitled SOLID GEL MEMBRANE.
FIELD OF THE INVENTION
[0002] This invention relates generally to rechargeable electrochemical cells and more particularly to rechargeable electrochemical cells in which an ionic-conducting polymer-based solid gel membrane is used as a separator.
BACKGROUND OF THE INVENTION
[0003] Electrochemical devices generally incorporate an electrolyte source to provide the anions or cations necessary to produce an electrochemical reaction. A zinc/air system, for example, requires the diffusion of hydroxide anions, and typically will incorporate an aqueous potassium hydroxide solution as the electrolyte. The lifetime of this battery is however, limited for several reasons. First, the naked zinc anode is corroded by both the aqueous electrolyte and air. Second, the air channels of the air cathode gradually become blocked by water from the electrolyte solution and third, the electrolyte solution becomes contaminated with zinc oxidation product that diffuses from the anode.
[0004] Various methods have been used to address the many problems associated with the use of aqueous electrolytes in zinc anode based systems such as zinc/air fuel cells. Additives, for example, have been introduced into the electrolyte solution to extend its lifetime and to protect the anode from corrosion. U.S. Pat. No. 4,118,551 discloses the use of inorganic additives such as mercury, indium, tin, lead, lead compounds, cadmium or thallium oxide to reduce corrosion of a zinc electrode. Many of these additives however, are expensive and more significantly, are very toxic. U.S. Pat. No. 4,378,414 discloses the use of a multi-layer separator between the positive and negative electrodes to reduce corrosion of the anode and contamination of the electrolyte by zinc oxidation products. In addition, hydrophobic materials have been introduced into zinc/air devices to prevent water permeation into the air channels of the cathode. Introduction of hydrophobic materials is however, a difficult process and may result in decreased performance of the cathode.
[0005] In addition to zinc/air systems, other metal/air systems, such as aluminum/air, lithium/air, cadmium/air, magnesium/air, and iron/air systems, also have the potential for many different applications due to their theoretically high ampere-hour capacity, voltage, and specific energy. In actual practice however, these very promising theoretical values are greatly reduced due to the corrosion of the metal anode in the electrolyte.
[0006] A solid state hydroxide conductive electrolyte polybenzimidazole (“PBI”) film is disclosed in U.S. Pat. No. 5,688,613 and comprises a polymeric support structure having an electrolyte active species dispersed therein, wherein the polymer structure is in intimate contact with both the anode and the cathode. This PBI film, however, does not absorb water and therefore, does not hold water within the membrane, causing it to dry out quickly.
[0007] U.S. Pat. No. 3,871,918 discloses an electrochemical cell embodying an electrode of zinc powder granules suspended in a gel comprised of methylenebisacrylamide, acrylic acid and acrylamide. Potassium hydroxide serves as the electrolyte, and is contained within the gel.
[0008] With regard to devices that rely on the conduction of cations, while there has been a significant amount of research in this area, most proton conducting membranes are very expensive to produce and typically do not function at room temperature. In the 1970's for example, a fully fluorinated polymer membrane, NAFION® (DuPont, Wilmington, Del. USA) was introduced and has served as the basis from which subsequent proton conducting membranes have evolved.
[0009] U.S. Pat. No. 5,468,574 discloses a proton conductive membrane that is characterized as a highly sulfonated polymeric membrane composed of block copolymers of sulfonated polystyrene, ethylene and butylene blocks. In 1997, NASA's Jet Propulsion Laboratory disclosed the development of an improved proton conductive membrane composed of sulfonated poly (ether ether ketone), commonly known as H-SPEEK.
[0010] The separator in a cell or battery physically separates and electrically insulates electrodes of different polarity. While serving as a barrier to the transport of active materials of the different electrodes, a separator should also provide ionic conduction. Good ionic conductivity is necessary to ensure that an electrochemical cell/battery is capable of delivering usable amounts of power for a given application.
[0011] In a rechargeable electrochemical cell, a separator is also used to prevent short circuiting caused by metal dendrite penetration during recharging. For example, in rechargeable zinc/air cells, zinc on the surface of the negative zinc electrode (anode) is dissolved as zincate ion into the electrolyte solution during discharge. Then, during the charge, when the charging current is typically below 20 mA/cm 2 , depending on the particular anode used, the zincate ion forms dendritic zinc, which is needle-like and grows from the negative electrode toward the charging electrode. Unfortunately, these needle-like structures can pierce through conventional separators causing an internal short circuit. The service life of the cell is consequently terminated. In addition to preventing dendrite penetration, the separator must allow for the exchange of electrolytic ions during both discharging and charging of the cell.
[0012] The most commonly used separators in rechargeable cells are porous insulator films of polyolefins, polyvinyl alcohol (PVA), nylon, or cellophane. Acrylic compounds may also be radiation-grafted onto these separators to make them more wettable and permeable to the electrolyte. Although much work has been done to improve the performance of separators, dendrite penetration problems are frequently encountered with these and other conventional separators, as well as problems involving diffusion of reaction products such as the metal oxide to remaining parts of the cell.
[0013] With conventional separators, controlling the pore size of the separator is the only effective way to avoid dendrite penetration and prevent product diffusion. By doing this, however, the ionic conductivity of the separator is also greatly reduced. This creates a bottleneck for high charging-discharging current density operations, important considerations for use in some applications, such as in electrical vehicles.
[0014] U.S. Pat. No. 5,549,988 discloses an electrolyte system separator disposed between the cathode and anode of a rechargeable electrochemical battery. The electrolyte system includes a polymer matrix prepared from polyacrylic acid or derivatives thereof. An electrolyte species, such as KOH or H 2 SO 4 , is then added to the polymer matrix to complete the system. However, as reported in the patent, the measured ionic conductivities of the disclosed electrolyte-polymer films are low, ranging from 0.012 S/cm to 0.066 S/cm. Although these conductivities are acceptable for some applications, they are inadequate for other high rate operations including electrical vehicles.
[0015] An electrochemical reaction is also involved in the function of electrochromic devices (ECD's). Electrochromism is broadly defined as a reversible optical absorption change induced in a material by an electrochemical redox process. Typically, an electrochromic device contains two different electrochromic materials (ECM's) having complementary properties; the first is generally reduced, undergoing a color (1)-to-color (2) transition during reduction, while the second material is oxidized, undergoing a similar transition upon the loss of electrons.
[0016] Basically, there are two types of electrochromic devices, depending upon the location of the electrochromic materials within the device. In a thin-film type device, the two ECM's are coated onto the two electrodes and remain there during the redox coloration process. In a solution-phase device, both ECM's are dissolved in an electrolyte solution and remain their during the coloration cycle. The solution-phase device is typically more reliable and has a longer lifetime, however, in order to maintain the colored state, an external power source must be continuously applied. As the thin-film type device does not need an external power source to maintain its colored state, power consumption is greatly reduced, making this an advantage for such energy-saving applications as smart windows. The drawback of the thin-film type device is that it has a short lifetime. After a certain number of cycles, ECM films can lose contact with the electrode, or they may no longer be capable of phase change and the device expires.
[0017] With regard to solution-phase devices, U.S. Pat. No. 5,128,799, for example, discloses a method of reducing the current required to maintain the colored state which involves the addition of gel into the device. While reducing energy consumption however, the addition of the gel into the device also greatly reduces the switching speed of the device. With regard to thin-film devices, attempts to extend the lifetime of the device have included changes to the crystal structure of the film. While such changes have increased the lifetime of thin-film devices to an extent, the typical lifetime of such devices is still not satisfactory.
[0018] The foregoing problems thus present major obstacles to the successful development and commercialization of fuel cell technology, a green energy source, and of electrochromic devices such as smart windows and flat panel displays, which have several energy-saving, decorative, and information display applications. With respect to the problems associated with rechargeable electrochemical cells, it is clear that there is a great need for a separator that can provide improved ionic conductivity while providing an effective barrier against the penetration of metal dendrites and the diffusion of reaction products.
SUMMARY OF THE INVENTION
[0019] The present invention provides polymer-based solid gel membranes that contain ionic species within the gel's solution phase and that are highly conductive to anions or cations. In accordance with the principles of the invention, solid gel membranes may be produced for use in such power sources as, for example, metal/air (e.g. zinc/air, cadmium/air, lithium/air, magnesium/air, iron/air, and aluminum/air), Zn/Ni, Zn/MnO 2 , Zn/AgO, Fe/Ni, lead-acid, Ni/Cd, and hydrogen fuel cells, as well as for use in electrochromic devices, such as smart windows and flat panel displays. Additionally, the instant polymeric solid gel membranes are useful in rechargeable electrochemical cells, wherein the solid gel membrane is employed as a separator between the charging electrode and the anode.
[0020] With respect to a zinc/air fuel cell battery, for example, conductive membranes of the present invention may be used to protect the anode, as well as the cathode. In such a system, the ionic species is contained within the solution phase of the solid gel membrane, allowing it to behave as a liquid electrolyte without the disadvantages. The gel membrane protects the anode from corrosion (by the electrolyte as well as by air) and prevents zinc oxidation product from the anode from contaminating the electrolyte. With regard to the cathode, as the membrane is itself a solid, there is no water to block the air channels of the cathode. As a result, the system will have an extended lifetime.
[0021] As used herein, the term “anode” refers to and is interchangeable with the term “negative electrode”. Likewise, “cathode” refers to and is interchangeable with the term “positive electrode”.
[0022] The present invention also includes rechargeable electrochemical cells that use the solid gel membrane as a separator between the anode and charging electrode. Such a separator provides many advantages that conventional separators lack. For example, it provides a smooth impenetrable surface that allows the exchange of ions for both discharging and charging of the cell while preventing fast dendrite penetration and the diffusion of reaction products such as metal oxide to remaining parts of the cell. Furthermore, the measured ionic conductivities of the present solid gel membranes are much higher than those of prior art solid electrolytes or electrolyte-polymer films. For example, the observed conductivity values for the present separators are surprisingly about 0.10 S/cm or more. Even more surprisingly, ionic conductivities as high as 0.36 S/cm have been measured, and it is possible that higher values still may be observed. Thus, these unique and unprecedented properties distinguish the separator of the present invention from previous designs that merely trap dendrite growth and slow penetration.
[0023] Accordingly, the principles of the present invention relate, in one aspect, to a rechargeable electrochemical cell comprising a separator, an anode, a cathode, and a charging electrode. Optionally, a liquid electrolyte, such as one of those mentioned herein and/or commonly known by those of skill in the art, may also be included in the rechargeable cell. The liquid (aqueous) electrolyte contacts the separator, each electrode, and a porous spacer, if employed. The separator comprises an ion-conducting polymer-based solid gel membrane which includes a support onto which a polymer-based gel having an ionic species contained within a solution phase thereof is formed. The support may be a woven or nonwoven fabric or one of the electrodes.
[0024] The polymer-based gel comprises a polymerization product of one or more monomers selected from the group of water soluble ethylenically unsaturated amides and acids. The polymer-based gel also includes a water soluble or water swellable polymer, which acts as a reinforcing element. In addition, a chemical polymerization initiator (listed below) may optionally be included. The ionic species is added to a solution containing the polymerization initiator (if used), the monomer(s), and the reinforcing element prior to polymerization, and it remains embedded in the polymer gel after the polymerization.
[0025] Polymerization is carried out at a temperature ranging from room temperature to about 130° C., but preferably at an elevated temperature ranging from about 75° to about 100° C. Higher heating temperatures, such as those ranging from about 95° to about 100° C., provide a stiffer polymer surface, which is a desirable property in rechargeable cell applications. Optionally, the polymerization may be carried out using radiation in conjunction with heating. Alternatively, the polymerization may be performed using radiation alone without raising the temperature of the ingredients, depending on the strength of the radiation. Examples of radiation types useful in the polymerization reaction include, but are not limited to, ultraviolet light, γ-rays or x-rays.
[0026] In the rechargeable cell, the cathode and charging electrode may be a single bifunctional electrode or may be individual and separate electrodes. The separator is positioned between the anode and charging electrode. In alkaline systems, the hydroxide ionic species typically comes from an aqueous alkaline solution of potassium hydroxide, sodium hydroxide, lithium hydroxide, or combinations thereof. Preferably in a potassium hydroxide solution, for example, the base has a concentration ranging from about 0.1 wt. % to about 55 wt. %, and most preferably about 37.5 wt. %. In acidic systems, the proton comes from an aqueous acidic electrolyte solution, such as a solution of perchloric acid, sulfuric acid, hydrochloric acid, or combinations thereof. The concentration of perchloric acid, for example, preferably ranges from about 0.5 wt. % to about 70 wt. %, and most preferably about 13.4 wt. %. The membrane separator may also be used in neutral systems, wherein the ionic species comes from a saturated aqueous neutral solution of ammonium chloride and potassium sulfate; a saturated solution of ammonium chloride, potassium sulfate, and sodium chloride; or a saturated neutral solution of potassium sulfate and ammonium chloride.
[0027] When the cathode and charging electrode are individual and separate electrodes, the charging electrode is positioned between the separator and cathode, and a porous spacer is optionally positioned between the charging electrode and cathode.
[0028] In another aspect, the invention is a rechargeable electrochemical cell comprising a separator, a metal anode (preferably zinc), an air cathode, and a charging electrode. In this system, the separator is a hydroxide conducting polymer-based solid gel membrane comprising a support onto which a polymer-based gel having a hydroxide species contained within a solution phase thereof is formed. The polymer-based gel comprises polysulfone as a reinforcing element and a polymerization product of a polymerization initiator, methylenebisacrylamide, acrylamide, and methacrylic acid. The hydroxide species comes from an aqueous alkaline solution (ranging from about 0.1 wt. % to about 55 wt. % potassium hydroxide, sodium hydroxide, lithium hydroxide, or a mixture thereof), which is added to the polymerization initiator, methylenebisacrylamide, acrylamide, methacrylic acid, and polysulfone prior to polymerization. The air cathode and charging electrode may be a single bifunctional electrode or may be individual and separate electrodes. The separator is positioned between the metal anode and charging electrode. The ionic conductivity of the separator typically ranges from about 0.10 S/cm to about 0.36 S/cm, but may be higher.
[0029] In another aspect, the present invention is an electrochemical cell comprising first and second electrodes and one or more polymer based solid gel membranes disposed there between. In one embodiment, the electrochemical cell is a zinc/air cell having an anode protective solid gel membrane and a hydroxide conducting solid gel membrane disposed between the zinc anode and the air cathode. In another embodiment of a zinc/air system, both the anode and cathode are protected by a solid gel membrane of the present invention, and an aqueous electrolyte is disposed between the two.
[0030] In a further embodiment of this aspect of the invention, the electrochemical cell is an aluminum/air cell, wherein a hydroxide conductive solid gel membrane is applied to the aluminum anode to protect it from corrosion.
[0031] In yet a further embodiment of this aspect of the invention, the electrochemical cell is an aluminum/air cell, wherein a hydroxide conductive solid gel membrane is disposed between the aluminum anode and the air cathode.
[0032] Accordingly, the principles of the present invention also provide a method of inhibiting corrosion of a metal anode in a metal/air fuel cell system comprised of a metal anode and an air cathode. The method comprises disposing one or more polymer based solid gel membranes between said anode and said cathode.
[0033] In yet a further embodiment of the invention, the electrochemical cell is a proton or hydroxide conducting power source, such as a hydrogen fuel cell system. In this embodiment, a proton or hydroxide conductive solid gel membrane may be sandwiched between the hydrogen anode and the air cathode, thus separating the hydrogen and the air, while allowing the diffusion of proton or hydroxide ions. This embodiment provides several advantages over prior art proton conducting membranes in that the solid gel membranes of the present invention are much easier and less expensive to produce than earlier membranes and, more importantly, unlike previous membranes, the solid gel membranes of the present invention will function efficiently at room temperature.
[0034] The principles of the present invention may also be applied to electrochromic devices. Here, the electrochromic materials of the device are contained within solid gel membranes, thus providing the device with the reliability and long lifetime associated with solution phase EC systems, and also the energy-saving memory properties associated with thin-film EC systems.
[0035] Accordingly, yet another embodiment of the present invention is an electrochromic device wherein electrochromic materials are contained within polymer based solid gel membranes. Typically, such a device will involve two electrode substrates and electrochromic materials contained within solid gel membranes sandwiched there between. The device may optionally include an aqueous or a solid electrolyte disposed between the solid gel membranes. The electrode substrates may be comprised of such materials as, for example, platinum, gold, conductive glass, such as indium-tin oxide glass, and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] Numerous other advantages and features of the present invention will become readily apparent from the following detailed description of preferred embodiments when read in conjunction with the accompanying drawings, wherein:
[0037] [0037]FIG. 1 is a schematic depiction of a zinc/air fuel cell incorporating an anode protective membrane and a hydroxide conducting membrane of the present invention;
[0038] [0038]FIG. 2 is a schematic depiction of another embodiment of a zinc/air fuel cell incorporating both an anode and a cathode protective membrane of the present invention;
[0039] [0039]FIG. 3 is a schematic depiction of an aluminum/air fuel cell incorporating a hydroxide conductive membrane of the present invention;
[0040] [0040]FIG. 4 is a schematic depiction of a hydrogen/air fuel cell incorporating a proton or hydroxide conductive membrane of the present invention;
[0041] [0041]FIG. 5 is a schematic depiction of an electrochromic device wherein the electrochromic materials are contained within membranes of the present invention;
[0042] [0042]FIG. 6 is a schematic depiction of a rechargeable metal/air battery having three electrodes, a porous spacer, and a solid gel membrane incorporated as a separator in accordance with the present invention; and
[0043] [0043]FIG. 7 is a schematic depiction of a rechargeable metal/air battery having an anode, a bifunctional electrode, and a solid gel membrane incorporated as a separator in accordance with the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0044] Referring now to the drawings, FIG. 1 depicts a typical zinc/air fuel cell, wherein two polymer-based solid gel membranes ( 1 , 2 ) are disposed between the zinc anode ( 3 ) and the air cathode ( 4 ). The first is an anode protective membrane ( 1 ) and the second is a hydroxide conductive membrane ( 2 ). The membranes are not only the source of ionic species, and are highly conductive to that species, but they also provide a protective layer to the electrodes to prevent the usual sources of cell destruction. The membranes prevent diffusion of zinc oxidation product into the electrolyte solution phase, they prevent corrosion of the zinc anode by either the electrolyte solution or air, and they prevent blockage of the cathode air channels by water from the electrolyte solution. The zinc/air system of FIG. 2 includes a protective and conductive solid gel membrane ( 5 , 6 ) on the surface of the zinc anode ( 3 ) and the air cathode ( 4 ), and an aqueous electrolyte ( 7 ) between the two.
[0045] Referring now to FIG. 3, an aluminum/air fuel cell system incorporating a solid gel hydroxide conductive membrane ( 8 ) between the aluminum anode ( 9 ) and the air cathode ( 10 ) is depicted. As in the zinc/air system, the solid gel membrane of this embodiment serves to prevent the corrosion problems associated with the use of pure liquid electrolyte and also serves as the ionic conducting media.
[0046] As illustrated in FIG. 4, when applied to the art of hydrogen fuel cells, the principles of the present invention provide a proton or hydroxide conductive membrane that is easy to produce, much less expensive than existing proton conductive membranes and that functions well at room temperature. Because the actual conducting media remains in aqueous solution within the polymer gel backbone, the conductivity of the membrane is comparable to that of liquid electrolytes, which at room temperature is significantly high. In this embodiment of the invention, a proton or hydroxide conductive solid gel membrane ( 11 ) is sandwiched between the hydrogen anode ( 12 ) and the air cathode ( 13 ), thereby separating the hydrogen and the air.
[0047] As shown in FIG. 5, the principles of the present invention may also be applied to electrochromic systems. Here, the electrochromic materials are dispersed within the solution phase of the polymer gel backbone of a solid gel membrane. Since the ECM's are in solution, the device exhibits the superior reliability and long life of a solution phase device and in addition, because the ECM's are physically confined, they can not diffuse into the device's bulk electrolyte and the device therefore also exhibits the superior memory of a thin-film type device. As shown, the device includes two electrode substrates ( 14 , 15 ) having solid gel membrane encapsulated electrochromic materials ( 16 , 17 ) there between. As illustrated, the device optionally includes an aqueous or solid electrolyte ( 18 ) disposed between solid gel membranes ( 16 , 17 ).
[0048] Referring to FIG. 6, there is illustrated therein a rechargeable electrochemical cell ( 100 ) fabricated from three electrode assemblies, ( 20 , 30 , 40 ) and contained within housing ( 90 ). Electrode ( 20 ) represents the negative electrode or metal anode; electrode ( 40 ) is the positive electrode, i.e. air cathode; and electrode ( 30 ) is a porous charging electrode. In this embodiment, cathode ( 40 ) and charging electrode ( 30 ) are separate electrodes, and charging electrode ( 30 ) is positioned between cathode ( 40 ) and the solid gel separator. As shown in the drawing, the three electrodes ( 20 , 30 , 40 ) are disposed in spaced apart, parallel relationships with one another. Rechargeable electrochemical cell ( 100 ) optionally includes liquid (aqueous) electrolyte ( 80 ) in contact with each electrode, separator ( 60 ), and porous spacer ( 50 ) (when employed) typically by immersion.
[0049] Metal anode ( 20 ) is made of an oxidizable metal, preferably zinc, cadmium, lithium, magnesium, iron, or aluminum, but metal anode ( 20 ) is most preferably zinc. Air cathode ( 40 ) preferably has a current density of at least 200 mA/cm 2 . An exemplary air cathode is disclosed in copending, commonly assigned U.S. patent application entitled ELECTROCHEMICAL ELECTRODE FOR FUEL CELL, filed on Oct. 8, 1999 and corresponding to Attorney Docket No. 1101.006, which is incorporated herein by reference in its entirety. Other air cathodes may instead be used, however, depending on the performance capabilities thereof, as will be obvious to those of skill.
[0050] As shown in FIG. 6, porous charging electrode ( 30 ) is positioned in parallel relationship between metal anode ( 20 ) and air cathode ( 40 ). Any inert conductive porous material may be used to form porous charging electrode ( 30 ). Examples include, but are not limited to platinum, nickel, nickel oxide, perovskite and its derivatives, carbon, and palladium. In addition, apertures or holes may be drilled into charging electrode ( 30 ) to aid with the passage of ions. It is important that the electrodes do not physically contact each other, and a distance therebetween sufficient to form a gap for the electrolyte must be provided.
[0051] In addition, it is sometimes desirable to position porous spacer ( 50 ) between charging electrode ( 30 ) and air cathode ( 40 ) as a means of ensuring sufficient distance between the two electrodes. When porous spacer ( 50 ) is included in rechargeable electrochemical cell ( 100 ), a gap is formed for the electrolyte on each side of porous spacer ( 50 ) and each electrode ( 30 ) and ( 40 ). However, the invention is not limited to structures which include porous spacer ( 50 ). Any means of preventing physical contact between the two electrodes may be employed, such as anchoring the electrodes apart in the housing. However, when porous spacer ( 50 ) is used, it is typically made of a porous plastic material, such as nylon, and typically has a thickness ranging from about 0.1 mm to about 2 mm.
[0052] As depicted, separator ( 60 ) is disposed in spaced apart, parallel relationship with electrodes ( 20 , 30 , 40 ) and is positioned between charging electrode ( 30 ) and metal anode ( 20 ). A gap for the electrolyte is provided on each side of separator ( 60 ). Alternatively, but not illustrated, when the separator is radiation-grafted onto one of the three electrodes, the electrode provides a support for the separator, and thus no gap exists between the separator and the electrode on which it is formed. In accordance with the present invention, separator ( 60 ) functions, in part, to prevent shorting between air cathode ( 40 ) and metal anode ( 20 ).
[0053] Separator ( 60 ) comprises an ion-conducting, polymer-based solid gel membrane. This membrane comprises, in part, a support material or substrate, which is preferably a woven or nonwoven fabric, such as a polyolefin, polyvinyl alcohol, cellulose, or a polyamide, such as nylon. Alternatively, the substrate/support may be the anode, charging electrode, or cathode (not illustrated). A polymer-based gel having an ionic species contained within a solution phase thereof, which has been formed on the support material, completes separator ( 60 ). More particularly, the polymer-based gel or film portion of the membrane includes an electrolyte in solution with the polymerization product of a polymerization initiator and one or more water-soluble ethylenically unsaturated amide or acid monomers, preferably methylenebisacrylamide, acrylamide, methacrylic acid, acrylic acid, 1-vinyl-2-pyrrolidinone, or combinations thereof. Other suitable monomers are listed below.
[0054] Prior to initiating the polymerization, the ingredients are dissolved in water, and, in this embodiment, an aqueous hydroxide electrolyte solution (e.g. KOH) having a hydroxide ion concentration ranging from about 0.1 wt. % to about 55 wt. %, but preferably about 37.5 wt. %, is added to produce the ionic species. Suitable hydroxide electrolytes include, for example, potassium hydroxide, sodium hydroxide, lithium hydroxide, or combinations thereof. Alternatively, the ionic species may come from a neutral aqueous solution prepared from combinations of ammonium chloride, potassium sulfate, and/or sodium chloride. The electrolyte is added to the monomer solution prior to polymerization and remains in solution after the polymerization.
[0055] Also prior to the polymerization process, an ionic polymer, such as polysulfone (anionic) or poly(sodium-4-styrenesulfonate) is added to the monomer solution as a reinforcing element. The addition of the reinforcing element enhances the ionic conductivity and mechanical strength of the separator. Optionally, a crosslinking agent, such as methylenebisacrylamide or ethylenebisacrylamide may also be employed during the polymerization. Other crosslinkers and reinforcing element polymers may be used instead, such as one of those listed below, as would be obvious to those of skill.
[0056] To form separator ( 60 ) depicted in FIG. 6 (and indicated as reference number ( 61 ) in FIG. 7 below), a piece of woven or nonwoven fabric, such as nylon (i.e. a polyamide), for example, is provided as the support, and the selected fabric is soaked in the monomer solution. The solution-coated fabric is cooled, and ammonium persulfate, for example, is optionally added as a polymerization initiator. Other suitable chemical initiators include alkali metal persulfates and peroxides. The fabric coated with the monomer film solution is then placed between glass and polyethylene teraphthalate (PET) film. After heating, the monomer solution is further polymerized by irradiating the “sandwiched” plastic/monomer film with UV light, for example, and the polymer-based gel membrane or separator is produced. The hydroxide ion (or other ions) remains in solution after the polymerization. Thus, polymerization is preferably carried out at an elevated temperature (up to 130° C.) using a chemical polymerization initiator and radiation. However, polymerization to form the polymer-based gel can also be carried out by one of these alternative methods: heating and using a chemical polymerization initiator (no radiation) or heating plus radiation (no chemical initiator); or radiation at room temperature, depending on the strength of the radiation.
[0057] Separator ( 60 ), thus formed, has a thickness that is typically about 0.3 mm. Preferably, the separator will be as thin as 0.1 mm. However, the invention is not limited to separators ranging in thickness from 0.1 to 0.3 mm. It will be obvious to those of skill whether a particular separator is too thick or too thin, based on its effectiveness in a particular application. The separator provides a source of hydroxide (or other) ions and is highly conductive to that ionic species.
[0058] It is important to note that unexpectedly high ionic conductivities (up to 0.36 S/cm thus far), but not previously observed in prior art systems have been achieved using the solid gel membrane separator in the rechargeable electrochemical cells of the present invention. This is, in part, because the electrolyte is added to the monomer solution prior to polymerization. After polymerization, the ionic species remains in solution as part of the polymer-based solid gel, which is disposed on the support or fabric to form the polymer-based solid gel membrane separator ( 60 ) (or ( 61 ) in FIG. 7). This solid gel membrane or separator also prevents penetration of dendritic metal through the separator and therefore protects the negative electrode from dendrite formation during charging. Furthermore, the solid gel separator also prevents destruction of the cell by preventing diffusion of the metal oxidation product into the electrolyte solution.
[0059] [0059]FIG. 7 shows rechargeable electrochemical cell ( 110 ) of the present invention wherein the cathode and charging electrode form single bifunctional electrode ( 41 ), i.e. the electrode is used both as the positive electrode and for charging the battery. Optionally, liquid (aqueous) electrolyte ( 81 ) may also be included within the housing of the cell. Separator ( 61 ) is disposed between anode ( 21 ) and bifunctional electrode ( 41 ). Electrochemical cell 110 also includes housing ( 91 ).
[0060] This dual electrode/separator configuration depicted in FIG. 7 may be used for several different types of rechargeable battery systems. For example, anode ( 21 ) may be an oxidizable metal, such as one of those previously listed in connection with FIG. 6 (preferably zinc), and bifunctional electrode ( 41 ) may be the previously described air cathode. In another embodiment, anode ( 21 ) is zinc or zinc oxide, and bifunctional electrode ( 41 ) is nickel oxide, manganese dioxide, silver oxide, or cobalt oxide. Alternatively, anode ( 21 ) may be iron or cadmium, and single bifunctional electrode ( 41 ) is nickel oxide. In these systems, the ionic species contained in polymer-based gel membrane separator ( 61 ) preferably comes from one of the above-listed aqueous alkaline hydroxide solutions and associated hydroxide concentration. However, in the rechargeable metal/air cells of the present invention, a neutral membrane separator ( 61 ) can alternately be employed wherein the ionic species comes from one of the above-listed neutral aqueous solutions.
[0061] An acidic membrane may be used as separator ( 61 ) in acidic systems such as in rechargeable lead-acid batteries wherein anode ( 21 ) is lead and bifunctional electrode ( 41 ) is lead oxide. In this embodiment, the ionic species contained in separator ( 61 ) comes from an aqueous solution of perchloric acid, sulfuric acid, hydrochloric acid, phosphoric acid, or combinations thereof.
[0062] In other rechargeable electrochemical cell configurations, not depicted, but mentioned above, the ion-conducting polymer-based solid gel may be grafted directly onto the anode, charging electrode, cathode, or bifunctional electrode, when one is used. In this case, support for the separator or membrane is provided by the electrode substrate on which the polymer-based solid gel is formed.
[0063] The shape of the electrolyte solution volume or housing, which is shown as reference number ( 90 ) in FIG. 6 and ( 91 ) in FIG. 7, is not constrained to be square or rectangular. It can be circular, elliptical, polygonal, or any desired shape. In addition, the cell housing may be fabricated from any strong chemically inert insulation material, such as plastic conventionally used in electrochemical cells and alkaline batteries.
[0064] When in operation, conducting wires (not shown), usually copper strips, are adhered to exposed portions of the metal anode, charging electrode, and cathode and/or bifunctional electrode. These conducting wires are used to apply an external voltage to the cell to recharge the anode. An insulating epoxy is typically used to cover the exposed joints.
EXAMPLES
[0065] Preferred embodiments of the present invention are hereinafter described in more detail by means of the following examples that are provided by way of illustration and not by way of limitation. The reactants and reagents used in the reactions described below are readily available materials. Such materials can be conveniently prepared in accordance with conventional preparatory procedures or obtained from commercial sources.
Example 1
[0066] The following procedure was used to prepare a strong polymer film for use in the present invention. 0.75 grams methylenebisacrylamide, 0.56 g acrylamide, 4.70 g methacrylic acid, and 0.25 g poly(sodium 4-styrenesulfonate) were dissolved in 10 milliliters water and then 20 ml 40% KOH was added to the resulting solution, which was maintained at room temperature. 0.05 g ammonium persulfate was then added to the solution. A piece of fabric was soaked in the resulting monomer solution and then sandwiched between a piece of glass and a piece of PET transparent film. This was heated on a 75° C. hotplate for 1 minute and then irradiated under strong UV light for 5 minutes, whereby a strong polymer film was formed.
[0067] The resulting film is highly conductive of hydroxide ions, making it suitable for use in an alkaline hydrogen fuel cell. Here, the membrane film is sandwiched between an air cathode and a hydrogen anode, separating the air and hydrogen, while allowing the diffusion of hydroxide ions.
Example 2
[0068] In this example, a polymer based solid gel membrane was prepared in accordance with the principles of the invention and applied to the surface of a cathode. 0.75 g Methylenebisacrylamide, 0.56 g acrylamide, 4.70 g methacrylic acid, and 1.5 g polysulfone (anionic) were dissolved in 10 ml water and then 20 ml 40% KOH was added to the resulting solution, which was maintained at room temperature. 0.038 g ammonium persulfate dissolved in 1 ml water was added and the resulting solution was poured onto the surface of an air cathode. The cathode was then covered by a piece of PET film and heated on a 75° C. hotplate for 1 minute and then irradiated under strong UV light, whereby a strong polymer film was formed.
[0069] This cathode may be used with an anode prepared as in Example 3, below, or it may be used directly with a plain metal sheet, such as zinc, aluminum, cadmium, lithium, magnesium, or lead, in the formation of a corresponding metal/air fuel cell battery. Alternatively, the cathode on which the solid gel is grafted, as in Example 2, may form a separator/bifunctional electrode in a rechargeable electrochemical cell (metal/air) in accordance with the present invention, or it may be positioned next to the charging electrode in the rechargeable cell, as mentioned above.
Example 3
[0070] A polymer based ion conducting membrane was prepared and applied to the surface of an anode according to the principles of the present invention. 0.75 g methylenebisacrylamide, 1.5 g poly(sodium 4-styrenesulfonate), 5.18 g 1-vinyl-2-pyrrolidinone, and 3.36 g acrylic acid were dissolved in 30 ml NH 4 Cl and K 2 SO 4 saturated aqueous solution, followed by the addition of 0.1 g ammonium persulfate. The solution was spread onto the anode surface, and covered by a PET film and then irradiated under strong UV light, whereby a strong polymer film was formed for use as a separator grafted onto the anode. In a fuel cell, the separator/anode is positioned next to the cathode, and in a rechargeable electrochemical cell, it is positioned next to the charging electrode or next to a single bifunctional electrode, when one is employed.
Example 4
[0071] A polymer-based solid gel membrane was prepared according to the present invention and processed to form a proton conducting film. 6.4 g 70% perchloric acid, 0.75 g methylenebisacrylamide, 5.18 g acrylic acid, and 0.1 g potassium sulfite (reducing agent) were dissolved in 27 ml water and then 0.1 g ammonium persulfate was added to the solution. A piece of fabric was soaked in the resulting monomer solution and then sandwiched between a piece of glass and a piece of PET transparent film. This was heated on an 85° C. hotplate for 1 minute and then irradiated under strong UV light for 8 minutes, whereby a strong polymer film was formed.
[0072] The resulting film is highly conductive of protons (hydrogen ions), making it suitable for use in a hydrogen fuel cell or for use as a separator in an acidic rechargeable electrochemical cell, such as in a rechargeable lead-acid battery. In a hydrogen fuel cell, the membrane film is sandwiched between an air cathode and a hydrogen anode, separating the air and hydrogen while allowing the diffusion of hydrogen ions.
Example 5
[0073] The principles of the present invention may also be applied to electrochromic devices. For example, one or several electrochromic materials are dissolved in an aqueous monomer solution which is then applied to an electrode substrate. The substrate may be comprised of such materials as for example, platinum, gold, conductive glass, e.g., indium-tin oxide glass, or other electro-conductive materials. The solution is polymerized according to either of the above methods wherein the ECM's are contained within the polymer membrane formed on the surface of the substrate. Two such modified electrodes, containing the same or different ECM's, are used in the electrochromic device with one acting as the anode and the other as the cathode. The electrodes may be packed together as a complete display device or they may be separated by a liquid or solid electrolyte.
Example 6
[0074] The following procedure was used to prepare a strong polymer film for use as a separator in a rechargeable electrochemical cell. One and a half grams (1.5 g) polysulfone (anionic), 0.75 g methylenebisacrylamide, 0.56 g acrylamide, and 4.70 g methacrylic acid was dissolved in 10 mL water, and maintained at room temperature. Twenty (20) mL 50% KOH was added to the resulting solution. A piece of nylon fabric commercially available from Frendenberg Nonwovens as FS2213E was then soaked in the monomer solution. The solution was placed in an ice bath, and 0.10 g ammonium persulfate was added to the solution. The separator was then taken out of the solution and sandwiched between transparent PET film and glass. The ‘sandwiched’ separator was then heated on a hot plate at 90° C. for 20 minutes on each side, then irradiated under strong UV light for 7 minutes on each side. The conductivity of the resulting membrane was 0.11 S/cm.
[0075] Examples of other monomers that may be used in the formation of a solid gel membrane and separator of the invention include any water-soluble ethylenically unsaturated amides or acids, including, but not limited to, N-isopropylacrylamide, fumaramide, fumaric acid, N, N-dimethylacrylamide, 3,3-dimethylacrylic acid, and the sodium salt of vinylsulfonic acid.
[0076] Other cross-linking agents include, for example, any water-soluble N,N'-alkylidene-bis(ethylenically unsaturated amide).
[0077] Examples of polymers other than poly(sodium 4-styrenesulfonate) that may be used as reinforcing elements within the solid gel electrolyte may include any water-soluble or water-swellable polymers, such as, for example, carboxymethyl cellulose, polysulfone (anionic), sodium salt of poly(styrenesulfonic acid-co-maleic acid), and corn starch.
[0078] Suitable fabrics onto which the monomer solution may be applied include, for example, woven or non-woven fabrics such as polyolefins, polyamides, polyvinyl alcohol, and cellulose.
[0079] With regard to initiation of the polymerization reaction chemical initiators such as, ammonium persulfate, alkali metal persulfates or peroxides may optionally be used in combination with radical generating methods such as radiation, including for example, ultraviolet light, X-ray, γ-ray, and the like. However, the chemical initiators need not be added if the radiation alone is sufficiently powerful to begin the polymerization. As stated above, the polymerization may be conducted at temperatures ranging from room temperature up to about 130° C.
[0080] This invention has been described in terms of specific embodiments, set forth in detail. It should be understood, however, that these embodiments are presented by way of illustration only, and that the invention is not necessarily limited thereto. The principles of the present invention may, for example, also be applied in the preparation of a solid gel membrane for use in such other electrochemical systems as for example, Ni/Cd and Zn/MnO 2 cells. Additionally, other monomers, polymers, chemical polymerization initiators, reducing agents, and the like, other than those particularly disclosed herein might be used. Modifications and variations in any given material or process step will be readily apparent to those skilled in the art without departing from the true spirit and scope of the following claims, and all such modifications and variations are intended to be included within the scope of the present invention.
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Rechargeable electrochemical cells that employ a highly conductive polymer-based solid gel membrane separator disposed between the anode and charging electrode are disclosed. The separator comprises a support or substrate and a polymeric gel composition having an ionic species contained in a solution phase thereof. In preparing the separator, the ionic species is added to a monomer solution prior to polymerization and remains embedded in the resulting polymer gel after polymerization. The ionic species behaves like a liquid electrolyte, while at the same time, the polymer-based solid gel membrane provides a smooth impenetrable surface that allows the exchange of ions for both discharging and charging of the cell. Advantageously, the separator reduces dendrite penetration and prevents the diffusion of reaction products such as metal oxide to remaining parts of the cell. Furthermore, the measured ionic conductivity of the separator is much higher than those of prior art solid electrolytes or electroyte-polymer films. The disclosed rechargeable electrochemical cells include, for example, metal/air, Zn/Ni, Zn/MnO 2 , Zn/AgO, Fe/Ni, and lead-acid systems.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 09/908,983, filed Jul. 19, 2001, which claims the benefit of priority from U.S. Provisional Application No. 60/219,294, filed Jul. 19, 2000, the disclosures of which are hereby incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to information processing system organization and in particular, to an interactive user interface to information processing systems. More particularly, the present invention relates to an activity-oriented user interface that allows a user to create and define customized groupings of several kinds of different objects created by information processing, communication and/or web applications, as opposed to the prior art of grouping like objects together in separate and distinct object groupings.
BACKGROUND OF THE INVENTION
A computer screen user interface provides the user with certain tools to organize the objects he or she is working with. The most common and typical way of organizing the objects in a computer is a hierarchical structure of directories or folders (hereinafter called folder structure). The user interface typically includes some default initial folder structure, which the user can eventually change by adding new folders and subfolders. Such default or user defined folder structure is used to simplify finding, retrieving and working with the objects, provided the user employs and memorizes certain individual conventions and rules, when the user creates, saves or moves the objects to certain folders or subfolders. Typically, the user tries to create and name folders and subfolders in such a way, that later, whenever necessary, it would be easier for him or her to understand, memorize or logically deduce, what kind of objects should be saved to or retrieved from, a certain folder. An example is the Microsoft Windows Explorer, which presents a folder structure and contents of each folder.
In addition to the folder structure, typically there is a special location, such as a desktop, root directory, special folder or location bar (hereinafter called desktop), to store most frequently used, new, temporary or uncategorized objects. For a reasonable number of objects, such locations provide a faster access for the user. Therefore, as the number of objects in such desktop grows, all but a limited number of the most frequently used objects should be eventually moved into the folder structure. The examples are Microsoft Windows Desktop, which can contain a certain spatially limited number of object icons, and the default My Documents folder in Microsoft Windows 95/98/2000.
In addition to the folder structure and desktop, some computer applications, software or programs (hereinafter called applications), provide their own default locations to store and retrieve user's objects, with or without folder structure, with or without user's capability to manipulate such folder structure, and with or without access to the general folder structure or desktop. In such cases the user has to organize his or her objects, using a separate set of rules and conventions, specific to such application, and in some cases an additional effort is needed to find, retrieve and work with these objects, other than through such particular application, if it is possible at all to do so. In addition, some applications allow access to the general folder structure for some types of objects, but not for the others. An example is Netscape Messenger, all versions up to the present date, which, for storing email messages, provides its default folder structure, which can be manipulated by the user. Netscape Messenger allows saving some types of objects, such as attached document files, but not the email messages themselves, in a general folder structure. Other examples are Netscape Navigator and Microsoft Internet Explorer, which allow storing the bookmarks or favorites respectively within a special folder structure, but not in a general folder structure.
There are several problems with the above prior approaches. In order to use Windows Explorer to organize objects, the user must be aware of it and learn about its features. Windows Explorer doesn't open automatically, and is merely included as one of many other components of the Windows operating system. Furthermore, Windows Explorer, once opened, doesn't clearly show the features of creating, renaming and manipulating the folders, those features being initially available from inside the cascading menus. As a result, many users, especially novices, cannot easily organize the objects they work with, and waste extra time and expend extra effort to find objects, sometimes unsuccessfully, and in general fail to use the computer in an efficient and convenient way.
In contrast, the Windows Desktop or default My Documents folder are presented very evidently in the user interface (the latter by being a default save location for some applications), and many users, especially novices, use them to store the objects. However, as mentioned above, eventually these locations become cluttered, and, without inherent hierarchical structure, inefficient in organizing the user's objects, as they grow in number.
Among the various types of computer usage, the most common for a computer user are: information processing (e.g. documents, files), communication (e.g. email, messages, contacts), web browsing (e.g. websites, bookmarks). Email clients and web browsers, which handle the second and third types of usage, do not use the same general folder structure-nor do they allow the user to organize the objects they generate into the same general folders—as are used with the information processing, with a few particular exceptions for some specific types of objects. Instead, the user is presented with a specific separate folder structure for each type of the object.
The email clients provide the user with two specific folder structures, one for the email messages, and another one for contacts and email addresses. The document attachments to email messages, however, can be stored in a general folder structure.
The web browsers provide the user with a specific folder structure for bookmarks or favorites. However, the individual bookmarks or favorites subfolders can be saved or copied to a general folder structure.
Not being able to use the general folder structure for all types of objects requires a user to create a multiplicity of several separate folder structures. In addition, a user must maintain and memorize separate folder structures in order to organize the most common everyday objects. Very often, these different types of objects relate to one activity, project, client, matter, etc. as categorized in the mind of the user. For example, if the user is working on a certain Project A, he or she very likely has a number of files and documents related to project A, plus a number of email messages related to project A, plus a number of email addresses for contacts involved in Project A, plus a number of Internet bookmarks for Project A. The prior systems and methods require the user to look for and work with these four types of objects in four separate and different folder structures. Even though the most organized of users may try to coordinate and conform the four different folder structures, every time the user looks for a different type of object, she still needs to access another folder tree, even if conformed. Typically, though, each of the four separate folder structures would be created at different times, and would contain more or less detail than the others, have different names for the folders and subfolders, and as a result, display a great deal of nonconformity in the different objects that are nonetheless related to the same user activity. Efficiency in processing different types of objects within the same activity demands the user to memorize several folder structures, their folder and subfolder names, and consistently follow rules and conventions for each in storing and manipulating the objects. As the number of activities, projects, clients, tasks grows, so does the burden and inefficiency in maintaining parallel folder structures.
In addition, inability to use the same folder structure for all objects of the same activity leads to other inefficiencies in using the computer besides an increase in file maintenance. For example, an email message with an attachment may contain at least three different types of objects: a contact name and email address; text message in the body of the email; and one or several attached files. Except for certain limited numbers of attached file types, which can be viewed inside the email (i.e. images, html documents), the attached files are opened by other applications, which files may be edited and then must be saved in the general folder structure, while the original email message remains in the email folder structure. This separation of the e-mail into different objects has several drawbacks that the present inventors have identified: (1) It is hard for the user to delete an attached file without deleting the text message, (2) Disk space is wasted by keeping two copies of the same attached file; one in the email client and one in the general file structure, (3) The general folder structure fails to contain information about senders/recipients of the attached file.
As referred above, a disadvantage of the prior email clients is that they indicate in their list of communications only the sender of the sent messages, instead of the recipient of the sent messages. In most cases, the sender of the sent messages is the user. A disadvantage of prior user interfaces is their drag-and-drop technique by which a user directs a mouse to move objects within the folder structure and the interface in general. A user has to keep the mouse button pressed while navigating the interface. If a user ceases to press the button during a command operation, he or she loses the ability to complete the operation and has to start all over. Such movement is ergonomically inefficient and taxing, especially to a user who moves objects within and across various folder structures.
The present inventors have perceived drawbacks to piecemeal approaches to the above problems. The present invention provides solutions, thereby giving the user advantageous ways to keep track of multiple sets of information, which otherwise would require additional physical and more complex effort.
SUMMARY OF THE INVENTION
Features
The present invention increases efficient use of user time and effort by providing an information processing system and method by which a user groups and accesses different kinds of objects related to the same activity together in a general user-defined folder. Specifically, the present invention provides a user interface that allows a user to group and access different kinds of objects together in a general user-defined folder. The different kinds of objects that may be placed together in and accessed from the same folder include: application files and documents; contacts such as address book entries, including e-mail addresses and fax numbers; communication files such as e-mails and faxes; web browsing objects, such as favorites or bookmarks; and web pages.
The prior art permits data files to be organized in a file structure. According to one aspect of the present invention, files containing activity-relevant email, URLs, documents and contact information are easily placed in a logical organization in the same directory folder, by which they are more readily associated with each other for retrieval and manipulation. The present invention lets a user store and access all of these functionalities and files directly through the same user interface so that each functionality is constantly available to the user. This is done without exiting the interface. In a particular embodiment of the present invention, manipulation of the files is accomplished without the need exit the interface in order to invoke separate program applications.
The methods of the present invention may be implemented in an information handling system, which includes one or more processors, memory, and input/output means. One of the embodiments of the invention is a set of instructions resident in an information handling system.
The present invention also provides an article of manufacture in the form of a computer-readable medium on which is stored a computer-readable software program capable of performing the foregoing method. Further, the present invention provides a computer system having preloaded therein a software program that allows a user to place different kinds of objects that he or she defines as related to the same activity together within a user-defined folder of a general folder structure. The computer system includes a processor and a display device coupled to the processor. The display device is used to display the user interface that allows a user to place different kinds of objects related to the same activity together within a user-defined folder of a general folder structure. The computer system also includes storage devices, such as a local or remote memory storage device, coupled to the processor. The memory storage device maintains the program module and data.
It is a feature of the present invention that application files, communication messages, email addresses and fax numbers of contacts, web bookmarks or favorites, and web sites can be stored together in and accessed from the same folder of the activity-oriented interface.
It is also a feature of the present invention that communications containing attachment(s) are separated on arrival to the recipient into a text message file and attachment file(s), each attachment file bearing an indication of the sender and/or recipient. A further feature of the present invention identifies such attachments with a visible icon denoted as a sticker note, which indicates the subject of the email message that the attachment accompanied. Text message files and attachment files are also annotated with the specific date and time received or sent. In this way, the user can relate and group within the general folder structure email messages with their attachments and yet is still able to process and perform operations on the attachments without having to so process the email messages.
It is also a feature of the present invention to provide visible icons by which the user can create and rename user-defined folders of a general folder structure into which the user may store together application files, communication messages, email address and fax numbers of contacts, web bookmarks or favorites and websites. The visible icons provided by the current invention presents a powerful user interface that displays a user's own folders, which a user creates to organize and group files and correspondence, along with shortcuts to installed software applications and to the utilities of the software of the present invention.
It is an important feature that the present invention couples the above features with a private email server. In so doing, a user, using the email functionality resident in a software program of the present invention, may send and receive emails directly within the user interface of the present invention upon connecting to an Internet Service Provider (ISP) of choice. Alternatively, a user may continue to send and receive emails from a server other than the private server, which is connected to the user's ISP server.
Coupled to the compound features of email functionality and the direct access of different kinds of objects within the same user-defined folder is a feature that provides automatic encryption and decryption in handling a user's email messages, both transparent processes to the user. Additionally, encrypted files are compressed. Once the encryption module of the present invention is configured by the user, the user does not have to deal directly with encryption keys setup or management and is thereby freed from learning the encryption software.
The present invention also features automatic archiving of files or messages left by the user in the general desktop folder at the end of a work session.
In addition, an important feature of the present invention is a pick-and-drop technique by which a user moves objects within the activity-oriented interface. In a “pick-and-drop” technique, a user clicks a mouse button once to select an object or objects, moves the object(s) around the interface without having to keep a mouse button continuously depressed, and then drops the object(s) where needed by pressing a mouse button once again, which action de-selects the object(s). With this feature, a user, with a minimum of mouse clicks, may open a file, copy it to a different location, fax or email it, depending on the context. Using the pick-and-drop technique, a user may send a message by dropping the message onto any contact name that is displayed within the same folder. Further, a variant of the pick-and-drop technique may be used to save web links or web pages, to “drop” them to a contact file or to send them to a contact.
Moreover, the pick-and-drop technique is well-suited for use with portable and handheld computerized systems in that it allows a user to execute commands and operations with a trackball and touchpad with greater precision.
Advantages
It is an advantage of the present invention that files and/or communications in various forms, such as e-mails and faxes, can be sent to the contacts listed in the same folder of the activity-oriented interface. It is a further advantage that all communications have a smart indication of a sender for the received files, and a recipient for the sent files.
A further advantage is that an implementation of the present invention not only allows a user to avoid excessive clicking on a mouse but also does away with double clicking. Importantly, for those users relying on a mouse, the user no longer needs to continuously depress a mouse button to keep the object selected during the dragging of an object. Unlike dragging a selected object, performing an operation involving a selected object in the present invention may be interrupted (such as by a telephone call) and then may be continued. The greatly reduced mouse clicking of the present invention carries a strong ergonomic advantage in reducing injury due to repetitive stress injury. The present invention solves a problem not solved by the prior art by allowing a user to work separately on email messages and their attachments, without leaving the same activity folder. Therefore, it is an important advantage of the present invention that a user may receive, amend, add to, move and/or send an attachment from within the same activity interface without having to access different folder structures of various applications first.
It is an advantage of the present invention that various objects left accumulated in the general desktop folder at the end of the last working session will be automatically placed into a general archive folder and are either retrievable by subject, sender/recipient or date and movable back to either the general desktop folder or any old or new folder, or may be deleted.
A further advantage is that, for users traveling with a portable computing system who need to store and maintain various kinds of objects while on the road, the present invention facilitates synchronization of files. By maintaining all the different objects a user may need to use on the road in one folder location, known and defined by the user, the present invention makes copying between computing systems or devices less burdensome as well as creates identical folders on different computing systems or devices, thereby reducing loss of information and maximizing efforts spent on file maintenance.
These and other objects, features and advantages of the present invention may be more clearly understood and appreciated from a review of the following detailed description of the disclosed embodiments and by reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an information handling system that provides the operating environment for an exemplary embodiment of the present invention.
FIG. 2 is a block diagram of a typical personal computer system comprising processor, keyboard, mouse, and display with a computer-usable medium, such as a magnetic disk, for storing a program capable of performing the method of the present invention.
FIGS. 3A-C are block diagrams showing various ways for software program code that performs a method of the present invention may interface with the hardware of a computer system.
FIG. 4 is an image generated by computer program code performing a method of the present invention on a display showing the opening screen of the program.
FIG. 5 is an image generated by computer program code performing a method of the present invention on a display showing computer program tools and icons available to the user.
FIG. 6 is an image generated by computer program code performing a method of the present invention on a display showing an activity-oriented interface folder containing different types of user objects.
FIG. 7 is an image generated by computer program code performing a method of the present invention on a display showing interface elements, including top desktop area, folders/contacts tabs, desktop folder and its contents, subfolders of the tools folder, archive folder, user activity folders, and general computer drives and folders.
FIG. 8 is an image generated by computer program code performing a method of the present invention on a display showing an activity folder containing a received electronic communication, separated on arrival into a message and a file, and also showing an indication of a recipient for the sent communication versus a sender for received communication.
FIG. 9 is an image generated by computer program code performing a method of the present invention on a display showing an activity folder with all communications with a certain contact.
FIG. 10 is an image generated by computer program code performing a method of the present invention on a display showing indication of an encryption of an outgoing communication.
FIG. 11 is an image generated by computer program code performing a method of the present invention on a display showing an address book activity folder for contacts.
FIG. 12 is a collaboration diagram showing program modules and parts of program modules as well as the interactivity among them of a software method of the present invention.
FIG. 13 is a diagram showing the operation of a client program according to one aspect of the present invention.
FIGS. 14A-14C are diagrams showing the operation of a “display contents of current folder” routine used with the client program of FIG. 13 .
FIGS. 15A-15C are diagrams showing a “process user input operation” used with the client program of FIG. 13 .
FIG. 16 is a diagram showing the “create” routine used with the sequence of FIGS. 15A-15C .
FIG. 17 is a diagram showing the “folder” routine used with the sequence of FIGS. 15A-15C .
FIG. 18 is a diagram showing the “contact” routine used with the sequence of FIGS. 15A-15C .
FIGS. 19A-19B are diagrams showing the “open” routine used with the sequence of FIGS. 15A-15C .
FIG. 20 is a diagram showing the “copy/move” routine used with the sequence of FIGS. 15A-15C .
FIG. 21 is a diagram showing the “move folder” routine used with the sequence of FIGS. 15A-15C .
FIG. 22 is a diagram showing the “rename” routine used with the sequence of FIGS. 15A-15C .
FIG. 23 is a diagram showing the “duplicate” routine used with the sequence of FIGS. 15A-15C .
FIG. 24 is a diagram showing the “delete” routine used with the sequence of FIGS. 15A-15C .
FIG. 25 is a diagram showing the “color” routine used with the sequence of FIGS. 15A-15C .
FIG. 26 is a diagram showing the “sticker” routine used with the sequence of FIGS. 15A-15C .
FIG. 27 is a diagram showing the “add contacts” routine used with the sequence of FIGS. 15A-15C .
FIG. 28 is a diagram showing the “send” routine used with the sequence of FIGS. 15A-15C .
FIG. 29 is a diagram showing the “send to” routine used with the sequence of FIGS. 15A-15C .
FIGS. 30A-30B are diagrams showing the “reply” routine used with the sequence of FIGS. 15A-15C .
FIG. 31 is a diagram showing the “cancel send” routine used with the sequence of FIGS. 15A-15C .
FIG. 32 is a diagram showing the “connect” routine used with the sequence of FIGS. 15A-15C .
FIG. 33 is a diagram showing a “send files from outbox” used with the “connect” operation of FIG. 32 .
FIG. 34 is a diagram showing a “process outbox changes” operation used with the “connect” operation of FIG. 32 .
FIG. 35A-35B are diagrams showing a “process inbox changes” operation used with the “connect” operation of FIG. 32 .
FIG. 36A-36B are diagrams showing a “process RFC-822 Message” operation used with the “process inbox changes” operation of FIGS. 35A-35B .
FIG. 37 is a diagrams showing a “process message part” operation used with the “process inbox changes” operation of FIGS. 36A-36B .
DETAILED DESCRIPTION
Definitions
Object. A current paradigm used for designing and implementing the present invention into a software program is object-oriented programming, which defines and packages objects. An object consists of a data structure plus the operations available for that structure. Once objects are defined, it is possible to build a program as a simple sequence of processes to be performed on specified instances of the objects. An integral part of object definition is the ability to create new, more elaborate objects as enhancements of those previously defined.
Activity. A user-defined class of related files whereby a user lumps together different categories of information stored and accessed from different files into a conceptual whole and classifies the whole as a project, task, operation, etc. An activity is a user-defined folder that contains related files which were each not created from the same application programs.
Activity-oriented interface. A user interface, which may be icon- and/or menu-based, by which a user can create, manipulate, store and access various kinds of program application files from within the same folder.
General folder structure. The most comprehensive arrangement of hierarchically nested folders so that all folders are contained and organized within. The folder is part of the directory structure, known as a tree directory structure. Therefore, for the purposes of this description, a folder is the equivalent of a directory. Each folder or directory may contain one or more files and may contain one or more folders or subdirectories.
Operating Environment Variations
The following discussion together with FIGS. 1 , 2 and 3 briefly describe an example of a suitable and typical information handling environment in which the invention may be practiced. The invention is described hereinbelow in the context of an application program that runs on an operating system in conjunction with a personal or business computer processor. Nonetheless, those skilled in the art will be aware that the invention may be practiced in combination with other program modules, such as routines, programs, components, etc. that perform particular tasks. Further, those skilled in the art will recognize that the invention may be practiced with computerized systems other than that described hereinbelow, such as hand-held devices, multi-processor systems, programmable consumer electronics, minicomputers, and mainframe computers, as well as in distributed computing environments in which remote processing devices are linked through a communication network to perform tasks.
With reference to FIG. 1 , a typical example of an information handling system 100 for implementing the present invention includes at least one processor 110 , a system memory 112 , which includes Random Access Memory (RAM) 114 and Read Only Memory (ROM) 116 , and a system bus 118 that couples the system memory 112 to the processor 110 . The system bus 118 also couples the basic input/output system 120 (BIOS) for connecting peripheral devices such as disk units 122 , tape drives 124 and printers 126 to the processor 10 . Moreover, the system bus 118 couples the processor 110 to the user interface adapter 128 , which is connected to various user interface devices, such as keyboard 130 , microphone 132 , a pointing device such as a mouse 134 having buttons 135 a and 135 b , speaker 136 , and touch screen device 138 . Further, the system bus 118 couples the processor 110 to the display adapter 140 , which is connected to a display device 142 . For connecting the information handling system to a data processing network 146 , the system bus 118 couples the processor 110 to a communications adapter 144 , which may link the system of FIG. 10 with perhaps thousands of similar systems or devices, such as remote printers, remote servers, or remote storage units.
With continuing reference to FIG. 1 and now referring to FIG. 2 , the present invention is typically implemented as an application program in an information handling system, such as a conventional personal computer system 200 , comprising processor 210 , keyboard 230 , mouse 234 having buttons 235 a and 235 b and display 242 . The hard drive 248 or storage device 250 contains computer program code that performs a method of the present invention preloaded or stored therein. As is well known, the user clicks a mouse button, or alternatively uses a touch pad, trackball or a touch sensitive screen, to supply input signals that move a cursor visible on the screen (or that lights up portions of the selected display). By moving the cursor over the icons shown on the screen, the user can perform desired tasks in the methods of the present invention.
The present invention may also be practiced by an article of manufacture using a computer-usable medium, such as a floppy disk or a CD-ROM, containing computer-readable program code configured to cause the computer to perform a method of the present invention as explained hereinbelow.
The information handling system 100 of the present invention or the method of the present invention or the article of manufacture of the present invention comprises in part a computer program code 500 that interacts with the computer hardware in one of several possible ways. FIG. 3A shows one embodiment of the present invention wherein the computer program code 500 , executable by the computer processor 110 , interfaces with an application program interface (API) 506 which interfaces with an operating system 508 which then interfaces with the hardware of the computer 502 , typically the processor, memory and hard disk drive. The operating system can comprise be virtually any of the well-known ones, such as a version of Windows (Microsoft Corporation), MacOS (Apple Computer), or UNIX or Linux, or any other operating system appropriate to the pertinent hardware and firmware, and having a known API.
Alternatively, FIG. 3B shows the computer program code 500 interfacing directly with an operating system that is able to directly interface with the computer hardware 502 , such as a version of Windows operating system, (Microsoft Corporation) or a version of the Unix operating system. Further, FIG. 3C shows the computer program code 500 incorporating the necessary operating system elements, so that it may interface directly with the hardware 502 . In yet another embodiment, the computer program code 500 could be written in a hardware-independent language, such as JAVA (Sun Microsystems) or JavaScript (Netscape Communications Corp.).
FIG. 4 shows a display 5 , which is the output of the display device 142 and which interfaces with a user. The screen real estate of the display 5 is organized into several functionality areas, including a Program Area 10 , a Folders/Contacts Tabs Area 30 , a General Folder Structure Area 36 , an Arrows Area 70 and a Workspace Area 90 .
The Program Area 10 comprises at least two kinds of icons: a plurality of first icons 12 a - l and a plurality of second icons 14 a - d . Each of the first icons 12 a - l is a graphical representation of an individual utility function. Icons 12 a - l in the Program Area represent the following functions: Create 12 a by which a user may create a new file, folder or address book group; Rename 12 b by which to rename a file, folder or address book group; Duplicate 12 c by which to create a copy of a file or address in the same folder; Print 12 d by which to print a file; Assign Color 12 e by which to attach a color code to a file or address; Attach Sticker 12 f by which to attach a sticker note to a file or address; Send & Receive 12 g by which to connect to a server and to send and receive email messages; Reply to Mail 12 h by which to send an email message to the sender of a previously received message; View With Address 12 i by which to view files sent or received from a selected address; Configure Program 12 j by which to establish setup parameters for connection to a private server and for automatic, transparent encryption and decryption of sent and received e-mails; Configure Fonts 12 k by which to set up fonts used in the interface; Delete 121 function by which to put files or folders into a “trash bin” and to delete addresses, groups or program icons.
Each of the second icons 14 a - d in the Program Area 10 is a graphical representation of a shortcut to a program application. This is illustrated hereinbelow in a Windows (Microsoft Corporation) environment. Shortcuts to applications function in a Windows environment by loading and invoking the selected application. The user may place into the Program area those application shortcut icons that he or she commonly uses. FIG. 4 shows examples of the following shortcut icons: 14 a for Microsoft Notepad; 14 b for WinZip; 14 c for Microsoft Word, and 14 d for Microsoft Excel.
Four email functions 15 a - d are provided in the Program Area 10 . These are Compose 14 a , Send 14 b , Add to Contacts 14 c and Delete 14 d.
The Folders/Contacts Tab Area 30 comprises two tabs: a Folders Tab 32 and a Contacts Tab 54 . FIG. 4 displays the Folders Tab 32 selected. When the Folders Tab 32 is selected, a My Documents Area 34 displays the General Folder Structure 36 shown in FIG. 11 , when the Contacts Tab 54 is selected, an Address Book Area 56 is displayed.
FIG. 4 shows an exemplary default organization of the General Folder Structure 36 , which contains all applications, icons and objects available to the user on the computing system 100 . As shown, the General Folder structure 36 includes the following specialized object locations or folders: ARCHIVE 42 ; My Computer 46 ; and TRASH 48 .
Also shown in FIG. 4 is the Workspace Area 90 , which displays the files and contents of a folder in the My Documents area 34 that has been highlighted and an Arrows Area 70 , which organizes the Workspace Area 90 into fields 70 a - f that identify certain properties of the files.
FIG. 4 shows output from a display device without indicating a particular hardware-software configuration or operating system environment as discussed in reference to FIG. 3 . Although FIGS. 5-11 shows output from a display device wherein a software program of the present invention is running within an exemplary operating system environment, herein Windows, the invention as disclosed in FIGS. 3A-C may be practiced within any hardware-software configuration and from within any suitable operating system.
Referring now to FIG. 5 , the output shows an opened TOOLS folder 38 , which comprises the following folders: Program tools 38 a , New Documents 38 b , Programs 38 c and Windows Desktop 38 d . The program tools 38 a are tools associated with the inventive program. FIG. 5 shows the program tools folder 38 a highlighted and the Workspace Area 90 displaying the contents of the highlighted folder 38 a . The program tools folder 38 a contains the same icons and corresponding commands 12 a - l that represent program utilities as are displayed in the Program Area 10 and as discussed with reference to FIG. 4 . Also appearing in the program tools folder 38 a are email icons 14 a - c . The email Delete icon 14 D is not in the program tools folder 38 a , but can be invoked from other menus as desired. A user may click on either a corresponding command 12 a - l in the Workspace Area 90 or an icon in the Program Area 10 to accomplish the same set of utility functions.
FIG. 6 shows an activity-oriented user-defined folder containing different types of user objects or files. Specifically, FIG. 6 shows that opened ARCHIVE folder 42 contains four user-defined folders: Activity A 42 a ; Activity A 1 42 b ; Hobby B 42 c and Project C 42 d . Each of folders 42 a - d represents exemplary activities, projects, tasks, etc. defined by a user. Activity A folder 42 a is shown highlighted and its exemplary contents are displayed in Workspace 90 as files 44 a - m . Particularly noteworthy is that Activity A folder 42 a has stored within it the following various kinds of files, which may be accessed by a user: Microsoft Notepad files — 44 a , 44 c , 44 e , 44 j through m ; Microsoft Word document — 44 b : Internet web page: 44 e ; Microsoft Excel files: 44 g & h ; e-mails — 44 f & i.
FIG. 6 also displays the various icons used within fields 70 a - g of Workspace 90 . In field 70 a icons indicate the application that the file is associated with. In field 70 b , icons indicate whether a user has attached a sticker note to the file or color-coded it. Field 70 c displays the user-assigned file name. Field 70 d displays the date and time when the field was created (e.g., files 44 f & 44 g ) or sent (e.g., file 44 i ) or received (e.g., files 44 b & 44 c ). In field 70 e , the icon indicates that the file was received into the Activity A folder 42 a ; when clicked on, the icon in field 70 e displays the e-mail address of the sender of the file (not shown). Files received into the Activity A folder 42 a include files 44 a - 44 e , whereas files sent out of Activity A folder 42 a include files 44 h , 44 i , 44 k - m . Field 70 f displays the name of the sender or recipient of the file depending on how the file has been processed. Information in fields 70 c , 70 d , and 70 f that relates to files 44 b to 44 e is shown in italics, which indicate that these files have not yet been opened. In field 70 g , the icon indicates that the file may be sent or has been sent outside the file folder, here Activity A folder 42 a . When the icon in field 70 g is activated, the e-mail address of the recipient of the file is displayed (not shown).
FIG. 7 shows an opened My Computer Folder 46 , located in the General Folder Structure 36 . As shown, the opened My Computer folder 46 displays an exemplary My Computer file structure 60 , used to identify storage locations of files saved on a storage medium, typically a disk drive or flash memory chip in a computing system. The My Computer file structure 60 as shown in FIG. 7 is for illustrative purposes only and may include any customary file structure suitable for the computing system used and adopted by those skilled in the art as well a more tailored file structure developed for a specific user.
Composing
With continuing reference to FIGS. 4-7 , when a user desires to create a new file while using the method of the present invention, unlike with interfaces in the prior art, all he or she has to do is to open a desired folder in the My Documents area 34 . The user is then presented in the Workspace Area 90 with a list of software applications that are currently available to the user from within the computing system he or she is using, either because the applications have been stored within the computing system or because the user has Internet access to them. When the user clicks on an application icon, that application is executed and a new document page for that application is displayed. The user may then create a new document for that application. All new documents are assigned a date and time when they are first created, which is always visible along with the assigned file name.
Storing Documents from a Variety of Applications
Once a new document has been created, a user may save it to a folder within the ARCHIVE folder 42 displayed in the My Documents area 34 of the software method of the present invention. The user saves a new document to an existent folder by activating or “picking” the file to be stored, which causes an icon to be displayed that indicates that the file has been selected. The user then moves the icon to the desired folder and then de-activates or “drops” the file by right-clicking onto the desired folder. This technique is called “pick-and-drop”. A software method of the present invention employs this technique for saving, routing and transporting files.
A user may save a new document into a new folder. Creating a new folder is done by opening the My Documents area folder 34 and then activating the Create New Folder icon 12 a in the Program Area 10 . Once a new folder is created, a user can save a new document into it using the pick-and-drop technique.
All folders are stored in the ARCHIVE 42 folder of the My Documents folder area 34 . Importantly, a user can save any new document created with any application accessible to the user's computing environment (either stored on a hard drive or network, or used directly from the Internet) into any folder in the ARCHIVE 42 . A user is not limited to saving files created with one application into one ARCHIVE folder (see FIGS. 5 through 10 ). In practical terms, then, a user may create a new folder, naming it for a particular activity, task, work session, project, etc., and then save into that folder all files related to that activity, etc., regardless of which application they were created with. Thus, unlike software applications or operating systems in the prior art, the present invention actually permits a user to create a user-defined activity folder and to store different kinds of files—regardless of application type—into it, especially as shown in FIGS. 5 to 7 .
Storing Electronic Communications
FIG. 8 shows a user-defined activity folder, Activity A 42 a , that contains a received electronic communication that has been separated upon arrival by a software method of the present invention into an e-mail message and an attachment. In FIG. 8 , the contents of opened Activity A folder 42 a is shown listed in the Workspace Area.
Shown in FIG. 8 are two related files, 44 q and 44 r , which both show in field 70 d that they were received at the same time. For attachments to e-mail messages (and for sticker notes placed in field 70 b of any file), a user may position the cursor over the icon in field 70 b to bring into view a message window that displays the name of the attached file (or the content of the sticker note attached to the file).
The present invention separates e-mail messages from their attached files upon arrival, while storing these two kinds of files within the same activity folder, which is not done by the prior art. A user, therefore, may process and access these two kinds of files from within the same activity folder.
Moreover, with continuing reference to FIG. 8 , field 70 f in Workspace 90 shows the name of the sender or the recipient of the file. The arrow icon in field 70 e indicates the file was received; whereas the arrow icon in field 70 g indicates the file was sent.
Sorting Electronic Communications
As shown in FIG. 9 , a user, while working within a user-defined folder
may sort the files displayed in the Workspace 90 to include only those communication files, i.e., e-mail messages and attachments, that contain a certain contact. In FIG. 9 , the sort was limited to those files within an exemplary user-defined activity folder, Activity A folder 42 a , that contain an exemplary contact, “Contact 2 ”, in field 70 f . Thus, FIG. 9 shows that subset of folders, 44 e , 441 , 44 i , and 44 n , within user-defined Activity A folder 42 a that contain “Contact 2 ” in field 70 f . Highlighted in FIG. 9 is the file “Memo on Activity A ( . . . ”, which displays in field 70 f not a specific Contact name but a LIST, which indicates that the file has been sent to more than one Contact. When a user places the cursor on the icon in Field 70 g of File 44 n , a window message 47 is shown that indicates that the file has been sent to “Contact 2 ” and to “Contact 4 ”.
Sending/Receiving Electronic Communications
With continuing reference to FIGS. 4-9 , a user may receive an electronics communication by activating the Send/Receive Mail icon 12 g in Program Area 10 , which will cause a software method of the present invention to connect to a private communications server (so long as the user has configured a software method of the present invention beforehand to connect to a private server by activating the Configure Program icon 12 j ). Communication messages that the user has received from any of its registered PPP servers will appear in the Workspace Area 90 when the user activates the My Documents area 34 (so long as the user has configured a software method of the present invention beforehand by activating the Configure Program icon 12 j ). The user may then store any of the communications messages into a user-defined activity folder in the ARCHIVE 42 by picking (selecting) a message in the My Documents area 34 , positioning the cursor over the ARCHIVE 42 folder of choice and then dropping (right-clicking) the message there. To reiterate, e-mail messages and their attached documents are received by a user as two separate files, so that a user may store, process and access them as separate files within the same user-defined activity folder.
A user may send a communication message in a similar manner as described above. A user first creates a text message in the My Documents area 34 and then picks and drops a contact name onto the message to indicate the address to which the message is being sent. (See the description of FIG. 11 hereinbelow). To attach a file, a user may pick-and-drop a file onto the message in My Documents area 34 . A user then activates the Send/Receive Mail icon 12 g to connect to a private server, which will send the communication message (so long as the user has configured a software method of the present invention beforehand by activating the Configure Program icon 12 j ).
Encrypting
With continuing reference to FIGS. 8 & 9 , FIG. 10 shows an output display for an encryption of a communication file stored in the same user-defined ARCHIVE 42 folder as shown in FIG. 8 , titled Activity A 42 a . An Encrypting Window 80 (also used for display of transfer) is displayed when a user sends an e-mail message via the private server, so long as the user has first activated the Configure Program icon 12 j in the Program Area 10 . A user configures a software program of the present invention by supplying the required information requested.
An Encrypting Window 80 conveys to the user that the file(s) being sent are being encrypted but the processes of encryption and decryption are actually transparent to the user, once configuration of a software program of the present invention has been completed. The user therefore does not need to learn the encryption software or maintain encryption keys.
In one embodiment, messages between the client and server are transmitted in a format in which message encryption is accomplished with file compression software. Therefore when a message is encrypted it's also compressed because the encryption algorithm compresses data. Examples of encryption software includes PkZip 2.04G sold by PkWare, and other PKZip compatible software. If a message is from one user of the program to another, then nothing else is done as far as encryption is concerned and the encrypted file is transferred, in encrypted form by the server from the sending client to the receiving client. If a message is from a program user to an internet address, then the server converts it to the standard RFC-822 format. MIME/Base64 encoding is used for non-textual data in one embodiment of the invention. Messages received from the Internet for program users are routed to the users without change, except for the transport envelope between the server host and the client. In this embodiment, the program uses two protocols for communication between server and client software; Secure HTTP (https) and a customized protocol.
Accessing Stored Files
The present invention also allows a user to access all the different kinds of application files stored into a user-defined, activity-oriented folder in the ARCHIVE folder 42 . With continuing reference to FIGS. 6 to 10 , a user may access documents and files created from different applications but stored within a single, user-defined activity-oriented folder with ease. For example, to access the stored files in Activity A folder 42 a , a user would open the ARCHIVE folder 42 and activate the Activity A folder 42 a , which appears as highlighted in the My Documents area 34 . Shown in the Workspace Area 90 are the individual files 44 a to 44 p ( FIG. 6 ) that are stored in Activity A folder 42 a . As discussed above, these files are different kind of objects created from different applications.
Address Book Functionality
FIG. 11 shows the functioning of a software method of the present invention when the Contacts Tab 54 is selected. When the Contacts Tab 54 is selected, an ADDRESS BOOK area 56 is displayed. The ADDRESS BOOK Area 56 corresponds to the My Documents area 34 when the Folders Tab 32 is selected. (Refer to the description of FIG. 4 ). When the ADDRESS BOOK 56 is selected, the Workspace 90 displays a list of contacts that have been stored in ADDRESS BOOK 56 . A user enters the particulars of a contact by keying in the requested information in Fields 62 , 64 , and 66 . A user may also create folders in the ADDRESS BOOK Area 56 in which related contacts may be stored. Shown in FIG. 11 is Activity A folder 58 , which contains three contacts, 58 a - c.
With continuing cross reference between FIG. 11 and FIGS. 6 , 8 - 10 , Contact 1 , identified as 58 a in FIG. 11 , is the same Contact 1 as listed in Field 70 f of file 44 a . Contact 1 sent the Memo on Activity A file, 44 a , as shown in FIGS. 6-10 . To send a document to a particular contact, a user, working with the Contacts Tab 54 activated, uses the pick-and-drop technique. The user picks a contact from those shown within the Workspace Area 90 (typically by clicking on it). For example, in FIG. 11 , Contact 4 , 58 c , may be selected. A user then activates the Folders tab 32 , opens the Activity A folder 58 , activates an activity-oriented folder, for example, Activity A 42 a , as shown in FIGS. 6-10 . The user then “drops” the contact onto a file in Activity A 42 a by deactivating the contact. The contact is now associated with the file and the file may now be sent to the contact.
Relationships Among Program Modules
FIG. 12 shows a state diagram that illustrates the collaboration and interactivity among modules and part modules especially as these relate to information input by a user of a software program of the present invention. The modules comprise Main Display 300 , File System Extension, 310 , Point-and-Click Interface 330 , Communication with Server 350 , Pick-and-Drop Interface 360 and Custom Dialogues 370 . The program modules allow user interaction with contacts, documents, web links, mail and other objects that are stored within and accessible from a user-defined activity folder.
Main Display 300 and File System Extension 310
The Main Display 300 represents the choices available to the user when the inventive program first opens: namely, the Folder Tree 302 , the Document, Contact or Tool List 304 or the Toolbar 306 . File System Extension 310 provides data to files shown in the Main Display 300 , which a user may access through the Folder Tree 302 of the Main Display 300 . Two-way communication exists between the Main Display 300 and File System Extension 304 , which means that the File System Extension 304 allows a user to add various kinds of information to different kinds of file types and the information will be shown in the Main Display 300 . There are several pieces of information the File System Extension 310 allows a user to add to a file, including Address Information 312 , Extended Document Title 314 , Extended Date/Time Information 316 , Color Coding 318 , Document Sticker 320 , Contacts 322 and Contact Groups 324 .
The File System Extension 310 receives information input from the Main Display 300 , the Point-and-Click Interface 330 , Communication with Server 350 , the Pick-and-Drop Interface 360 and sends the information to the files and objects displayed in Main Display 300 .
Point-and-Click Interface 330
From the Main Display 300 , a user may activate a Point and Click Interface 330 to accomplish various operations. Activating a Point and Click Interface 330 may be done by using any device having a pointing function, such as a mouse, trackball, touchpad, etc. The operations that may be accomplished through a Point and Click Interface 330 include Folder Tree Navigation 332 , Document Browsing/Editing 334 , Document/Contact Color Coding 336 , Sticker Editing 338 , Address Filtering 340 , Toolbar Contacts 342 , External Programs 344 , New Document Creation 346 and program Tools 348 .
Through the Point-and-Click Interface 330 the user may interact with Custom Dialogues 370 , a Pick-and-Drop Interface 360 or Communication with Server 350 . The Point-and-Click Interface 330 receives information from the Main Display 300 and sends information to the Pick-and-Drop Interface 360 , Communication with Server 350 and the File System Extension 310 .
Communication with Server 350
A Communication with Server 350 module allows the user to perform various functions, including Sending and Receiving Mail 352 , Encryption and Decryption 354 , Security Protocol 356 and Confirmation Receipts 358 . Communication with Server 350 receives information from Point-and-Click Interface 330 or Pick-and-Drop Interface 360 and sends information to the File System Extension 310 .
Pick-and-Drop Interface 360
The Pick-and-Drop Interface 360 receives information from the Point-and-Click Interface 330 and sends information to Custom Dialogues 370 , Communication with Server 350 and File System Extension 310 .
Custom Dialogues 370
Various customized dialogues may be displayed to a user in response to information that is received from the Point-and-Click Interface 230 or Pick-and-Drop Interface 260 and then sent to the File System Extension 210 module. These dialogues include Contact Information 372 , Message 374 , Question 376 , Color Selection 378 , Document Title Input 380 , Sticker Input 382 , program Setup 384 , External Mail Configuration 386 , Encryption Setup 388 , New User Registration 390 and Password Input 392 .
Although the invention has been described with a certain degree of particularity, it should be recognized that elements thereof may be altered by persons skilled in the art without departing from the spirit and scope of the invention. One of the embodiments of the invention can be implemented as sets of instructions resident in the random access memory of one or more computer systems configured generally as described in FIG. 1 . Until required by the computer system, the set of instructions may be stored in another computer-readable memory, for example, in a hard disk drive, or in a removable memory such as an optical disk for use in a CD-ROM drive or a floppy disk for eventual use in a floppy disk drive. Further, the set of instructions can be stored in the memory of another computer and transmitted over a local area network or a wide area network, such as the Internet, when desired by the user. One skilled in the art would appreciate that the physical storage of the sets of instructions physically changes the medium upon which it is stored electrically, magnetically, or chemically so that the medium carries computer-readable information.
Operation
FIG. 13 is a flow chart diagram showing the operation of a client program according to one aspect of the present invention. After program start 410 an initialize program sequence 411 is performed an a toolbar display 412 is presented. In addition, a “display folder tree” subroutine 413 is performed. A “display contents of current folder” subroutine 414 is performed and user input is monitored 415 . User input is processed by a “process user input” subroutine 416 and a determination 417 is made if the folder tree is changed. If the folder tree has changed the display folder tree subroutine 413 is again performed; if not a determination 418 is made of whether the folder contents have changed. If the folder contents have changed, the “display contents” subroutine 414 is again performed; if not, a determination 419 is made whether to exit program. If the program is not to be exited, the program continues to monitor user input 415 ; otherwise, a de-initialize program subroutine 420 is performed. After deinitialization 420 , the program terminates 421 .
FIGS. 14A-14C are flow chart diagrams showing the operation of a “display contents of current folder” routine 414 used with the client program of FIG. 13 . Upon start 431 , an extended file information set is read 432 . This provides file information stored in the folder. A temporary list of extended file information records is made 433 , and the first file in the folder is located 434 . A determination 435 is made if the first file in the folder is located 434 . If the first file in the folder is located 434 , then a display 436 of standard file information is made. Extended file information for this file is found 437 , a determination 438 is made of whether the extended file information is found and a determination 439 is made of whether an extended title is found. If these determinations 438 , 439 result in “yes” answers, then a display 450 is made of an extended title. If these determinations 438 , 439 result in a “no” answer, then no display 450 of the title is made. The non-determination is usually indicative of a hidden file or another file type which would typically not be used by someone working with the file system at a user level. In either case, a determination 451 is made as to whether a sticker note is found. If a sticker note is found, a display 452 of the sticker note is made regardless of whether the sticker note is found 451 , a decision 453 is made as to whether color coding is found. The color coding is a function of the software coded according to one embodiment of the invention and indicates a user preference for the file. If color coding is found ( 453 ), the color coding is displayed 454 . Regardless of whether the color coding is found ( 453 ), a determination 455 is made as to whether a communication record is found. If a communication record is found, a display 456 is made of the communication time, display 457 of the communication direction is made, a display of 458 of the communication address is made, and a deletion 459 is made of the extended file information from a temporary list.
Regardless of whether a communication record is found ( 455 ), a find 460 of the next file in the folder executed. At this point, the sequence beginning with the determination 435 is made of whether the file is found, and the sequence is continued. If the determination 435 of whether the file is found is negative, then a find 461 procedure is instituted to locate the first record in the temporary list. A determination 462 is made as to whether the record is found. If the record is not found, then the routine terminates 463 . If the record is found, a determination 464 is made as to whether the record is a communication record. If the record is a communication record, then a display 465 of communication time, a display 466 of communication direction and a display 467 of communication address made. If the determination ( 464 ) is that the record is not a communication record, then a determination 468 of whether the record is a contact record is made. If the record is a contact record, then the contact information is retrieved 469 from a contact list, and a display 470 is made of the contact information. If the record is determined ( 464 ) not to be a communication record, or a determination ( 468 ) is made that the record is not a contact record, or the display of communication or contact ( 465 , 466 , 467 or 470 ) is made, then the next record in the temporary list is found for 471 . The record found determination 462 is repeated until the last record in the temporary list is found. The records may be displayed as a communication address 467 or as a contact information display 470 . At that time, the result of the record found decision 462 is negative and the process terminates 463 .
FIGS. 15A-15C are a flow chart depicting the processor user input step 416 of FIG. 13 . The “process user input” subroutine accepts one of a number of different user inputs. In the example, user inputs 501 - 520 are processed. These include, create new document 501 , create new folder 502 , create new contact 503 , open document 504 , open contact 505 , rename 506 , copy document 507 , move document 508 , move folder 509 , duplicate document 510 , delete 511 , print document 512 , color code document 513 , sticker attach 514 , add to contacts 515 , send document 516 , send to 517 , reply 518 , cancel sending 519 , and connect to server 520 . Each of these user inputs 501 - 520 invokes a corresponding decision. Upon each decision, a corresponding procedure 531 - 550 is invoked.
Procedure 542 is used to invoke a print program which is supplied with the operating system, such as Microsoft Windows 9x or later editions. The “print document” procedure 542 is treated in a different manner than the other procedures 531 - 541 and 543 - 550 in that the “print document” procedure 542 executes through an external printing routine provided with the operating system or otherwise separately installed. The “print document” procedure 542 is executed by a separate program which is associated with the operating system, such as the Microsoft Windows Operating System. In order to provide an acknowledgment to the “process user input” subroutine 416 , the “process user input” subroutine 416 is not terminated 562 until the conclusion of the “print document” process 542 . Print routines such as the Microsoft Windows “print” function, Postscript, Ghostscript and others are well-known to those skilled in the art of consumer level computers. The use of these print routines avoids a requirement to configure printers for each installed program. In the case of the present invention, the use of standard print routines provides convenient printing capabilities which can be executed according to the configuration of the printer and a file registration list.
In addition, it is possible to provide for processing other requests 561 . After all decisions 509 - 520 and other process requests 561 are executed, the “process user input” subroutine 416 terminates 562 .
Each of FIGS. 16-32 depict respective ones of the processes or procedures invoked by the “process user input subroutine 416 .
FIG. 16 is a flow chart depicting the “create” procedure 531 . Upon invoking the create procedure 531 , an empty document is created 601 , and the document is opened in a window 602 . The user is able to execute instructions, typically text input, and the process waits for the user to close 603 the document window. A determination 604 is made as to whether the document is modified, and if it has not been modified, the new occurrence of the document is deleted 605 . If the document has been modified, the user is prompted 606 for a document title. The document title is used to set 607 the document name. The user input is then ended 562 .
FIG. 17 is a flow chart depicting the “create new folder” routine 532 . Upon invoking the “create new folder” routine 532 , the user is prompted for a folder title 611 and a folder is created 612 . At that point, the waiting for user input routine ends 562 .
FIG. 18 is a flow chart depicting the “open contact” routine 535 . Upon invoking the open contact routine 535 , information is read 626 from a contact file. The contact information is displayed 621 in an information window. After displaying the contact information 621 , the process waits 622 for user input, and a determination 623 is made as to whether the contact information is modified. If the contact information is modified, the information is saved 624 to the contact file. In either case, the process terminates 562 . If the “new contact” routine 533 is invoked, the display 621 of the contact information is performed followed by waiting for user input 622 and determining if contact information is modified 623 . The modified information is then saved 624 .
FIGS. 19A and 19B are a flow chart depicting the “open document” routine 534 . Upon invoking the “open document” routine 534 , a determination 631 is made as to whether the document is already open. If the document is already open, the process switches 632 to an “open document” window. If the document is not already opened, a determination 633 is made as to whether the document is unread. If the document is unread, the document is then marked 634 as read. Whether or not the document is marked as read or unread, a determination 635 is made as to whether the document is a contact file. If the document is a contact file, a determination 637 is made as to whether the document is already in the contact list. If the document is in the contact list, the process terminates 562 . If not, the document is added 638 to the contact list and the process terminates 562 . If the document is not a contact file, a determination 639 is made as to whether the document is an executable file. If the document is an executable file, the executable file is executed 640 and the process terminated. If the document is not an executable file, a determination 641 is made as to whether the document is a web link, and if so, the web link is opened 642 . If the document is not a web link, a determination 643 is made whether the document is protected from modification. If the document is protected from modification, a backup copy 644 is made and the document is nevertheless opened 645 in a window. The backup copy is used as the protection from modification. If the document is not protected from modification, the document is nevertheless opened 645 in the window, but the backup copy (block 644 ) is not made. After the document is opened 645 , the process waits 646 for the user to close the document window. A determination 647 is made as to whether the document is modified. If the document is modified, a determination 648 is made as to whether the document is protected. If the document is protected from modification, the modified document is renamed 649 and the original document 650 is restored from the backup copy. The process terminates when a determination that the document is not protected is made in block 648 or the original document is restored from the backup copy 650 . At this time, the process is terminated 562 . If the document has not been modified (block 647 ), a determination 651 is made as to whether the backup copy has been created 644 is made. If the backup copy is made, the backup copy is deleted 652 and the process terminated. If the backup copy has not been created, the process terminates 562 regardless.
FIG. 20 is a flow chart depicting the copy and move process 537 , shown in FIG. 15 . After the copy/move process 537 is invoked from either the copy document determination or the move document determination 508 , a determination 661 is made as to whether the folder is considered to be deletable. If the folder is considered deletable, the delete process 541 is invoked. If the folder is not considered to be deletable, a determination 663 is made as to whether the document is already in a destination folder. If the document is not in the destination folder, a copy of the document is created 664 in the destination folder. If the document is already present in the destination folder, a determination 665 is made as to whether to move the folder. If the folder is to be moved, the document is deleted 666 from the current folder and the process terminated 562 . If the document is not to be moved, the process is terminated.
FIG. 21 is a flow chart depicting the “move folder” process 539 invoked by the “process user input” subroutine 416 of FIGS. 13 and 15 . Upon initiation of the move folder routine 539 , a determination 671 is made as to whether the destination folder is a subfolder of the source. If the destination is a subfolder of the source, the process terminates. If the destination is not a subfolder of the source, the folder is moved 672 to the destination and the process terminates 562 .
FIG. 22 is a flow chart depicting the response to the “rename” process of FIG. 15 . Upon invocation of the rename process 536 , the user is prompted 677 for a new name. The new name is then set 678 and the process terminated 562 .
FIG. 23 is a flow chart depicting the “duplicate” routine 540 . Upon invocation of the “duplicate” routine 540 , the user is prompted 681 for a new document title and a copy of the document with the new title is created 682 , and the process is terminated 562 .
FIG. 24 is a flow chart depicting the response to a delete call 541 . Upon invocation of the delete call 541 , a determination 691 is made as to whether the trash is the current folder. If the trash is the current folder, the folder is deleted 692 from the disk. If the trash is not the current folder, the trash is set 693 as the destination and a request move operation 694 is initiated. This invokes the copy/move call 537 . If the folder is deleted from the disk 692 , the process terminates 562 .
FIG. 25 is a flow chart depicting a response to a color call 543 . Upon invoking the color call 543 , a color picker window is displayed 701 and user input 702 is received. Upon receipt of user input 702 , the new color is assigned 703 to the document and the process terminated 562 .
FIG. 26 is a flow chart depicting the response to a sticker call 544 . Upon receipt of the sticker call 544 , the process displays 710 a sticker editor window. User input 711 is awaited and a determination 712 is made as to whether the sticker is empty. If the sticker is empty, the sticker note 713 is removed and the process terminated 562 . If the sticker is not empty, the sticker note is attached 714 to the file and the process terminated 562 .
FIG. 27 is a flow chart depicting the response to the add contacts call 545 . Upon invocation of the add contacts call 545 , a determination 721 is made as to whether the document has been sent. If the document is sent, the recipients on the document are added 722 to the contact list and the process terminated 562 . If the document has not been sent, a determination 723 is made as to whether the document has been received. If the document has been received, the sender is added 724 to the contact list and the process terminated. If the document has been neither sent nor received, the process is terminated 562 .
FIG. 28 is a flow chart depicting the response to the send call of 546 . Upon receipt of the send call 546 , a copy of the document is sent 731 to an outbox. A control record is also created 732 in the outbox and a communication record is created 733 in the current folder. The communication record is marked 734 as “unsent” and the process terminated 562 .
FIG. 29 is a flow chart depicting a system response to a send to call 547 . Upon invocation of the send to call 547 , a contact information window is displayed 741 and the process awaits user input 742 . A determination 743 is then made as to whether the contact information has been modified. If the contact information has not been modified, the process terminates 562 . If the contact information has been modified, a determination 744 is made whether to add the contact information to the contacts. If the information is to be added to the contacts, the information is saved 745 to the contact file and the recipient address is set 746 , followed by invoking a send operation 546 . If the contact information is not added to the contacts, the send operation 546 is also invoked.
FIG. 30 is a flow chart depicting the system response to a reply call 548 . Upon receipt of the reply call 548 , a determination 751 is made as to whether the document has been received. If not, then the process is terminated 562 . If the document has been received, a determination 752 is made as to whether the document is marked as “unread”. If the document is marked as “unread”, the document is marked 753 as “read” and an empty reply 754 is created. If the document is not marked as “unread”, the empty reply 754 is created. If creating the empty reply 754 , a header is inserted 755 into the reply and a determination 756 is made as to whether the document has a sticker. If the document has a sticker, the sticker is inserted 757 into the reply. After inserting the quoted sticker text into the reply 757 or a negative determination is made that the document has a sticker, a determination 758 is made as to whether the document is text. If the document is text, the quoted document text is inserted 759 into the reply and the reply is opened 771 in a window. If the document is not text (block 758 ), the reply is opened 771 in the window without the inserted quoted document text. After the window is opened 771 , user response is awaited 772 in order to close the reply window. A determination 773 is made as to whether a reply is modified. If the reply is modified, the subject line is set 774 and the recipient address is set 775 . This results in an invocation of the send call 546 . If the reply has not been modified (block 773 ), the reply is deleted 776 , and the process terminated 562 .
FIG. 31 is a flow chart depicting a response to a cancel send call 549 . Upon invocation of the cancel send call 549 , the document to be canceled is deleted 781 from the outbox, the control record is deleted 782 from the outbox and the communication record is deleted 783 from the current folder. The process is then terminated 562 .
FIG. 32 is a flow chart depicting a response to a connect call 550 . Upon invocation of the connect call, a determination 791 is made as to whether a connection is already in progress. If a connection is not in progress, a connection is initialized 792 and a connection 793 to the server is effected. Upon connection to the server, a determination 794 is made as to whether the connection has failed. If the connection has failed, the connection is de-initialized and process outbox changes and process inbox changes are made 796 , 797 . The process is then terminated 562 . If the connection has not failed, files from the outbox server are sent 798 and files from the server are received 799 and placed in the inbox. The connection is then de-initialized 795 , outbox changes are processed and inbox changes are processed 796 , 797 , followed by process termination 562 .
FIG. 33 is a flow chart showing the process of sending files from the outbox to the server 798 of FIG. 32 . Upon starting 831 the send operation, a first control record is found 832 in the outbox. A determination 833 is made as to whether the record is found. If a record has not been found, the send operation 798 is ended 834 . If a record has been found, a request is made for the recipient's public key 835 and a determination 836 is made as to whether the public key is obtained. If the public key is obtained, the file is encrypted 837 with the public key, and the control record is sent 838 to the server. If the public key is not obtained, a determination 839 is made as to whether the recipient is marked “enforced encryption”. If the recipient is not marked with “enforced encryption”, the control record is sent 838 to the server. After sending the control record to the server in either case, the file is sent 840 to the server, the file is deleted 841 from the outbox, the control record is deleted 842 from the outbox and a find 843 operation is performed for the next control record. If the recipient is marked with “enforced encryption”, the find operation 843 is invoked but the file is not encrypted nor sent. After invoking the find operation 843 , the process then again determines 833 if the control record is found and the process continues until a control record is not found, thereby ending 834 the process.
FIG. 34 is a flow chart showing the operation of the “send files from outbox to server” routine 798 depicted in FIG. 32 . Upon process start 851 , a find operation 852 is initiated to find a first communication record marked as “unsent”. A determination 853 is made as to whether the communication record is found. If the communication record is found, a determination 854 is made as to whether a corresponding file exists in the outbox. If a corresponding file is in the outbox, the communication is marked 855 as “sent”. Then a find next communication record marked as “unsent” is initiated. The next marked as “unsent” is also found if the corresponding file does not exist in the outbox (block 854 ) with marking the (nonexistent) corresponding file as sent. This initiates the determination 853 as to whether the communication record is found. If the communication record is not found, the process ends 857 and the “process inbox changes” 797 routine is initiated ( FIG. 32 ).
FIGS. 35A and 35B are a flow chart showing the process for the processing of outbox changes 796 shown in FIG. 32 . Upon start 861 , the process first attempts to find 862 a first control record in the inbox. A determination 863 is made as to whether the control record is found. If the control record is found, a determination 864 is made as to whether the message is an RFC-822 record. An RFC-822 record is typically received from outside sources on the Internet and is handled accordingly by processing 865 as an RFC-822 record. If a control record is not found (determination 863 ), the process 797 is ended 866 . If the message is found but is not an RFC-822 message (determination 864 ), a determination 867 is made as to whether the message is encrypted. If the message is encrypted, the message is decrypted 868 with the user's private key. In either case, extended information is read 869 from the control record. A determination 870 is then made as to whether the message is a delivery confirmation receipt. If the message is a delivery confirmation receipt, the original message is found 871 , and a determination 873 is made as to whether the original message is found. If the original message is found, the delivery time is added 874 to the document's extended information. If the message is not a confirmation receipt, then the new message contents are saved 877 as a new document, extended information is saved 878 with the new document and the document is marked 879 as “unread”. In the case of both receipted documents and new documents, the incoming message is deleted 875 from the inbox and the next control record is searched for 876 . This returns the process to the control record found determination 863 until no control record is found, resulting in process termination 866 .
FIGS. 36A and 36B are a flow chart showing the processing of an RFC-822 message depicted in box 865 of FIG. 35A . After start 881 , the message header is read 882 and a determination 883 is made as to whether the message is a multipart message. In the case of multipart messages, the message may be a “multipart-alternative” message or a “multipart-related” message. A determination 885 is made as to whether the message is a “multipart-alternative” message. If the message is a “multipart-alternative” message, all message parts except for the last part are deleted in 886 . If the message is not a “multipart-alternative”, a determination 887 is made as to whether the message is a “multipart-related” message. If the message is a “multipart-related” message, all message parts but the first are deleted 888 . In any of the above cases (decision 883 , decision 885 and decision 887 ), one message part is read 889 and presented to the user. In any case involving a non-multipart message (decision 883 ), or a “multipart-alternative” or “multipart-related” message, the remaining message parts are deleted (blocks 886 , 888 ) and the remaining message part has been read 889 . At this point, a decision 890 is made as to whether a message part is found. If a message part is found, the message part is processed 891 and a next message part is found 892 . The determination 890 is again made as to whether the message part is found until all message parts have been processed. When the message part is not found (determination 890 ), a determination 893 is made as to whether 2 or more messages are in the inbox. If there are 2 or more messages in the inbox, a determination 894 is made as to whether the first resulting message is text. If the first resulting message is text, the contents of the first resulting message 895 are added as a sticker to all the other resulting messages and the first resulting message is deleted 896 from the inbox. This is a change in the RFC-822 packet in that the contents of the first resulting message has a text message or added as a sticker in step 895 .
FIG. 37 is a flow chart depicting the processing of the message part shown in block 891 of FIG. 36A . Upon start 901 , a determination 902 is made as to whether the part is an encapsulated RFC-822 message. If the part is encapsulated RFC-822 message, the message is processed as an RFC-822 message, as depicted in block 865 and described in connection with FIGS. 36A and 36B . This is often the case, wherein an entirely encapsulated RFC-822 message is forwarded by another email client.
If the part is not an encapsulated RFC-822 message, as determined at determination 902 , then the series of determinations 905 , 906 , 907 are made as to whether the message is “Base64”, “UUencoded” or “quoted-printable” encoded. The parts are then decoded 908 , 909 , 910 accordingly.
While the above provides a full and complete disclosure of the exemplary embodiments of this invention, equivalents may be employed without departing from the true spirit and scope of the invention. Therefore, the above description and illustrations should not be construed as limiting the scope of the invention which is defined by the appended claims.
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An email client and file manager provides combined file management and communications management in a single interface. An interface allows documents, email messages, contact information, web links or pages, and user-attached notes to be stored in the same folders. This facilitates communication by email and fax. The interface permits the user to combine this data in folders which the user categorizes according to a folder tree created by the user. In one embodiment of the invention, the client, in its email function, communicates with a dedicated host which in turn communicates with external servers according to standard internet protocol.
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BACKGROUND OF THE INVENTION
This invention relates to a cathode ray tube (CRT) for color television and allied display applications, employing a shadow mask for color separation, and more particularly relates to such a CRT having an improved shadow mask mounting system.
CRTs for color television, computer monitors and other display applications rely on a cathodoluminescent phosphor screen to provide a visible display. Such a screen is composed of a repetitive pattern of a large number of small red, blue and green-emitting phosphor elements, which are excited to luminescence by electron beams emanating from an electron gun behind the screen. There are three beams, one for each of the red, blue and green components of a color display signal. In operation, the screen is repetitively scanned by the three beams simultaneously, while the intensities of the beams are modulated by the respective individual primary color components of the display signal. The large number of phosphor elements, together with the scanning frequency, results in the perception of a steady, full color display by a viewer.
Such CRTs typically employ a shadow mask to achieve color separation. A shadow mask is a thin sheet having a large number of apertures and mounted between the phosphor screen and the electron gun, a short distance behind the screen. The apertures are aligned with the phosphor elements on the screen and the electron beams are directed from the electron gun to converge at the mask. When the beams pass through the individual apertures, they diverge from one another to land on the phosphor element of the corresponding color.
The mask, which is typically 0.15 to 0.25 mm thick, is supported on a frame to maintain its shape. This frame is then securely mounted in the glass envelope in order to maintain the mask in proper registration with the screen. Such registration must not only be maintained in the X and Y directions, but also in the Z direction, i.e., along the tube axis in order to insure that the beams do not land on adjacent phosphor elements, which would degrade the color purity of the display image.
Particularly during the warm-up period, the mask heats up and expands in all directions. Once the frame also warms up, then the thermal compensation effect of the suspension system takes place, moving the whole mask closer to the screen, maintaining overall color purity by bringing all of the mask apertures back into the electron beam path. When the temperature differential between the mask and frame is large during initial warm-up, the time required for thermal compensation is longer. This differential is minimized by using a frame of as low a mass as possible.
A common technique to maintain the proper Q space (distance between mask and screen) during tube warm-up has been to employ bimetal mounting springs attached to three sides of the frame, which springs are attached to mounting studs embedded in the wall of the glass envelope.
As the mask heats and expands in the X, Y, and Z directions, the mounting springs also heat, and the different expansion rates of the component metals in the springs produce a compensating motion of the entire mask toward the screen.
A more recent design employs a so-called "corner lock" suspension system, in which corner lock mechanisms, each of which include thermal compensation means, are attached to the four corners of the frame. This results in a more stable arrangement than that achievable using the side mounting arrangement, thereby enabling use of a lighter and less costly mask and/or frame.
U.S. Pat. Nos. 3,986,072 and 3,999,098, assigned to Zenith Radio Corporation, disclose corner lock systems wherein the frame is formed integrally with the mask, which is welded to four corner brackets. Cantilevered leaf springs welded to the corner brackets engage legs fixed to the face plate of the vacuum tube adjacent four corners of the display screen. Three of the springs are provided with holes which engage studs on the legs, while a fourth spring is provided with a slot which engages a stud on the fourth leg. This slot permits movement of the mask in the X and Y directions (parallel to the screen) and fix it in the Z direction.
The "frameless mask" of Zenith is formed in a complex shape in order to provide the structural integrity to withstand compressive stresses for mounting without welding. However it is not sufficiently strong to support direct mounting of an internal magnetic shield to the corner brackets.
The current Philips mask suspension system is described in an article by Robert Donofrio entitled "Corner Lock Suspension" in the November 1995 issue of Information Display. This system employs corner brackets welded to lightweight diaphragm strips to form a rectangular frame; each diaphragm strip has an angular cross section formed by a base section and an upright section to which the shadow mask is welded. A resilient plate, also referred to as a temperature compensating plate or as a hinge plate, is fixed to each corner plate by a spring which loads it toward a pin embedded in a corner of the skirt adjacent to the face plate. The pin is engaged by a floating washer mounted to the hinge plate. During assembly, the floating washers are welded to the hinge plates after the mask/frame assembly is engaged to the pins. The phosphor elements are then applied in a photo-lithographic screening process which involves removing and replacing the assembly several times. After a conductive coating is applied to the phosphor elements, the assembly is fixed in place by welding the floating washers to the studs. The internal magnetic shield is fixed in the vacuum envelope independently by separate links which are welded to the studs over the frame assembly.
U.S. Pat. No. 4,652,792 of Toshiba discloses a rectangular frame which is suspended at its corners by spring members which provide geometric temperature compensation during warmup. The frame is 1.6 mm thick and therefore relatively heavy, and generates considerable scrap during manufacture insofar as it is stamped from a single piece and formed without seams.
A corner suspension system of Thompson Consumer Electronics is described in an article by R. C. Bauder and F. R. Ragland entitled "An Improved Shadow-Mask Support System for Large-Size CRTs" in SID Intl. Technical Papers (1990). This system employs bimetal clips welded to the corners of a one-piece frame, and backward extending springs welded to the distal ends of the clips.
Drawbacks of the known systems include difficulty in salvaging masks and frames, where they are welded to the studs; high scrap rates during manufacture; complex parts including bimetallic clips; inability to mount the IMS directly to the frame; or systems with heavy frames, which result in poor color purity from the long warm up times, and instability of the assembly when dropped.
SUMMARY OF THE INVENTION
According to the invention, the frame is a light weight frame with four diaphragm elements 0.2 to 0.4 mm thick welded to the corner brackets and resilient plates extending away from the display screen cantilever-fashion to engage the mounting pins embedded in the skirt. These plates provide the sole spring force for loading the plates against the pins, and this spring force provides the sole retention between the frame and the skirt. The internal magnetic shield is attached directly to the corner brackets of the frame.
Since the plates are not welded to the pins, the material of the plates as well as its thickness and shape must be chosen to provide a spring force exceeding two pounds in order to withstand the shock incurred by dropping the CRT as well as long term thermal cycling. In this regard a precipitation hardened stainless steel having a thickness of 0.20 mm to 0.30 mm and a trapezoidal shape has been found to be especially suitable.
The CRT according to the invention reduces the amount of scrap during manufacture, because the diaphragm strips are formed from strip stock, rather than stamping a rectangular shape and forming it.
If either the mask and frame or the face plate and skirt are found to be defective subsequent to assembly, the components can be readily dismantled for salvage, which also reduces scrap. Likewise, the internal magnetic shield can be readily detached from the frame.
Since separate springs are not required to achieve adequate retention force, the number of parts and therefore the number of manufacturing steps are reduced. Likewise, the elimination of welding steps for retaining the mask/frame and the magnetic shield simplifies manufacture. The chief advantage of eliminating welding, however, is improved salvageability of the components.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section view of a cathode ray tube according to the invention,
FIG. 2 is a plan view of the supporting frame and mask, seen from the rear,
FIG. 3 is a partial perspective view of the corner bracket, frame, and mask exploded the face plate;
FIG. 4 is a plan view of a corner bracket and temperature compensating plate, seen from the front;
FIG. 5 is a section view taken along line 5--5 of FIG. 4;
FIG. 6 is a plan view of a corner bracket and alternative embodiment of temperature compensating plate,
FIG. 7 is a section view taken along line 7--7 of FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a color display tube includes a glass vacuum envelope 10 having a neck 11, a funnel 12, a substantially rectangular face plate 15, and a skirt 13 extending between the face plate and the funnel. Mounting pins 14 embedded in the skirt adjacent the four corners of the face plate serve to position the color selection electrode or shadow mask 22 with respect to the display screen 18 on the inside surface of the face plate 15. The display screen 18 is composed of a large number of red, green and blue luminescing phosphor elements which are covered with an aluminum coating 20. The elements luminesce when bombarded by electrons in the beams 21 emitted from an electron gun 20 mounted in the neck. The beams 21 are deflected by deflection coils 24 which are coaxially arranged about a longitudinal axis of the tube, and pass through apertures 23 in the mask 22 to illuminate the phosphor elements.
The mask 22 is welded to a supporting frame 25 which in turn is mounted on the pins 14. The frame 25 includes four corner brackets 26 connected by diaphragms 33 and 36, each bracket 26 having a resilient plate 40 welded thereto, the plates 40 being loaded against the pins 14 to position the mask 22 and frame 25 with respect to the vacuum envelope 10. According to the invention, an internal magnetic shield 52 is mounted directly to the corner brackets, in this example by dart clips 54. The shield 52 is connected to a metallic layer 57 on the inside of funnel 12 by spring loaded contact 56. This shields the electron beams from the earth's magnetic field and other interference.
FIG. 2 is a plan view of the mask 22 and frame 25 seen from the rear, i.e. the side opposite the display screen. Two long diaphragms 33 and two short diaphragms 36, all having angled cross sections, are welded to the corner brackets 26 to form a rectangle. Each of the diaphragms 33, 36 has a thickness of 0.2 mm to 0.4 mm, which closely matches the 0.2 mm thickness of the mask and assures a uniform expansion of the assembly during warm-up. The mask and diaphragms are preferably low carbon steel; the corner brackets, which are 0.5 to 0.8 mm thick, are either low carbon steel, nickel plated low carbon steel, or stainless steel. The corner brackets 26 each have a rectangular hole 28 which receives a dart clip for retaining the internal magnetic shield 52 (FIG. 1).
The resilient plates 40, which accommodate thermal expansion and are also referred to as temperature compensation plates, are welded to respective corner brackets 26 and extend toward the viewer as cantilevers. Three of the resilient plates 40 have round holes 42 which fix their corresponding corners in the Z direction, and also fix the entire mask diaphragm assembly in the X and Y directions. The fourth resilient plate has a slot 43 which fixes its corner in the Z direction, the position in the X and Y directions being fixed by the other three plates.
FIG. 3 shows the assembly of mask and frame in greater detail. Each long diaphragm 33 is formed by a base portion 34 and an upright flange 35 which meet at a right angle. Each short diaphragm 36 is formed by a base portion 37 and an upright flange 38 which meet at a right angle. The base portions 34, 37 are welded to the base 27 of the corner bracket 26. The upright flanges 35, 38 serve as mounting means for the mask 22, which is welded thereto. Only some of apertures 23 for directing the electron beams are shown. The resilient plate 40 is welded to the bracket 26 as shown in FIG. 4, and is provided with a round aperture 42 which is aligned for mounting against the round head of pin 14 on the skirt 13. The handling ears 14 are designed for automated handling of the frame during manufacture and are not germane to the present invention.
During manufacture, the corner brackets 26 and plates 40 are placed on an assembly block which serves as a positioning jig (not shown), and the plates are welded to the respective corner brackets. The diaphragms are then welded to the corner brackets 26, and the completed frame is removed from the assembly block. The shadow mask 22 is then welded to the flanges 35, 38, and the assembly is placed in the skirt 13 with the plates 40 resiled so that the holes 42 and slot 43 engage respective pins 14. The assembly is now ready for screening.
Screening is a well known process in which a photosensitive coating for each of the colors is exposed through the mask and developed. First a coating for one color of luminescing phosphors is exposed, then the mask/frame is removed and the coating is developed to leave the luminescing elements. Then a photosensitive coating for another color is coated over the elements, the mask/frame is replaced, and the coating is exposed through the mask. The mask/frame is removed and the coating developed. The process is repeated for the third color, then all of the phosphor elements are coated with a 200-500 mm thick layer of aluminum and the mask/frame is again replaced on the pins 14. The internal magnetic shield 52 (FIG. 1) is then fixed to the frame by means of dart clips received through apertures 28, and the vacuum envelope 10 (FIG. 1) is sealed to the skirt and evacuated.
FIG. 4 is a plan view of the corner bracket 26 and resilient plate 40 which is welded thereto; FIG. 5 is a section view. The two views will be discussed together.
Each bracket 26 comprises a flat base portion 27 from which lateral flanges 32 are formed at substantially right angles, and mounting flange 31 is formed at about forty-five degrees. The flange 31 is provided with a mounting tab 32 to which the plate 40 is welded at welds 41. The plate 40 extends rearward as a cantilever and provides the spring force for loading the holes 42 (and slot 43, FIG. 2) against the pins.
FIG. 6 is a plan view of an alternative embodiment of resilient plate 46 which carries a slide plate 48 having a formed boss 49 which engages the respective pin. The slide plate 48 can move in the X-Y plane by virtue of tabs 50 received through slots 47 in the TC plate. During manufacture, the slide plates 48 are welded to the plate 46, after the diaphragms are welded to the brackets, when the frame is initially placed on pins. This assures precise alignment with the face plate, but entails additional parts.
Essential to the present invention are the choice of material, thickness, and shape of the resilient plates 40. These design considerations should be effective to load each plate against the respective pin with a force of at least two pounds, without being subject to fatigue over the life of the CRT. This is necessary to maintain alignment of the mask and frame with an internal magnetic shield fixed thereto, without welding the assembly to the skirt on the face plate.
The material of the resilient plates is preferably a precipitation hardened stainless steel such as Cartech Custom 450, Custom 455, 466, 17-7PH, etc. These steels consist mainly of Fe, Ni, Cr, and other additives as necessary to provide a yield strength between 50 and 300 ksi, preferably exceeding 200 ksi. The thickness is preferably 0.20 to 0.40 mm, and the shape is tapered to form a trapezoid substantially as shown. In the preferred embodiment a 17-7PH steel is used, and the trapezoid has parallel edges with lengths of 9 mm and 28 mm, and connecting edges with lengths of 24 mm.
For the alternative embodiment of TC plate 46 shown in FIGS. 5 and 6, the slide plate 48 is of like material as the plate 46, which is as for plate 40. In an alternative embodiment of the slide plate 48, it may be of regular stainless steel such as 304 or 305 which are composed of 18% Cr and 8% and 12% N; respectively, the remainder being substantially Fe.
The foregoing is exemplary and not intended to limit the scope of the claims which follow.
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An apertured shadow mask directs electron beams toward phosphor elements on the inside surface of the face plate of a CRT. The mask is fixed to a rectangular frame having corner brackets connected by light-weight diaphragm strips and resilient plates molded to the brackets. The resilient plates have holes toward the distal ends thereof which engage pins embedded in a skirt surrounding the face plate. The plates are precipitation hardened stainless steel having a thickness of 0.20 mm to 0.30 mm and provide sufficient spring force to retain the mask and frame as well as the internal magnetic shield which is fixed to the corner brackets by clips.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a portable storage medium with a magnetic stripe such as a multifunctional IC card with a magnetic stripe.
2. Description of the Prior Art
A multifunctional IC card houses an IC chip comprising a CPU and a memory, a liquid crystal display (hereafter LCD) and a thin battery packaged on a wiring board in a portable-sized card body. The display unit of the LCD can be seen from outside through a suitably opened window, and a keyboard is provided on the surface of the card body. Also, contacts are formed on the surface of the card body for sending/receiving required data to and from external systems, such as a reader/writer.
According to ISO (International Organisation for Standardisation) standard, the thickness of a multifunctional IC card is defined as 0.76 mm, and the length and width are also respectively defined as prescribed dimensions.
A multifunctional IC card has not only a recording function for required information, but also various functions such as key input, calculation, and character display. Therefore, in order to strengthen rigidity and to protect the housed electronic components against external impact and load, the multifunctional IC card requires high rigidity. As shown in FIGS. 1 and 2, a card body 10 of the multifunctional IC card was constructed as a metal case in which a pair of stainless steel outer plates 12 and 14 were bonded by welding to a stainless steel outer frame 16. A contact section 18 composed of a plurality of contacts is formed on stainless steel outer plate 12 and a wiring board 20 is located between the pair of stainless steel outer plates 12 and 14.
From the viewpoint of combined use with the magnetic cards as, for example, cash cards for banks, the present multifunctional IC cards are constructed as hybrid multifunctional IC cards. On the hybrid multifunctional IC card, a magnetic stripe 22 is bonded onto the surface of the card body 10 for magnetically recording information in a similar way to magnetic cards.
On the other hand, a magnetic stripe reader in the automatic cash dispenser systems provided by banks are constructed for use with a magnetic stripe bonded on to a card body which has flexibility because it is made of resin.
In a conventional multifunctional IC card with a magnetic stripe, a magnetic stripe 22 was bonded onto the surface of the stainless steel outer plate 12, which has high rigidity. Therefore, magnetic stripe 22 did not adapt itself readily to the magnetic heads MH in the magnetic stripe readers which are in general use, as shown in FIG. 3. Therefore, there were cases of incorrect reading and writing of information.
Also, since card body 10 was composed of a metal case in which a pair of stainless steel outer plates 12 and 14 were bonded to outer frame 16 by welding, there were cases of distortion occurring in outer plates 12 and 14 during welding. This resulted in wave-like deformation of the surfaces, and also caused wave-like deformation of the surface of the magnetic stripe bonded to such outer plate. Since a magnetic stripe with such a wave-like deformation often does not make correct contact with magnetic head MH, there is a problem in that randomness occurs in the magnetic output, and further difficulty is caused in the correct reading and writing of magnetic information.
Further, in a conventional multifunctional IC card with a magnetic stripe, metal with a permeability greater than 1.005 is used to form the stainless steel outer plates 12 and 14. However, since stainless steel outer plates 12 and 14 have a permeability of more than 1.005, information data often cannot be written accurately on magnetic stripe 12. That is, as shown in FIG. 4, magnetic head MH makes contact with magnetic stripe 22 the information data is being written on magnetic stripe 22 formed on outer plate 12. Magnetic flux generated by magnetic head MH, as shown by dotted lines, not only passes through the layer of magnetic stripe 22, but also passes through the layer of outer plate 12 due to a leak magnetic flux from magnetic stripe 22. Therefore, since the magnetic flux cannot pass sufficiently through magnetic stripe 22, it is difficult to obtain good magnetic recording on magnetic stripe 22. As a result, an accurate reading of the information data from magnetic stripe 22 is very difficult due to small level of output of the magnetic flux from the stripe 22 in comparison to the plate 12.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a portable storage medium which can suitably protect the housed electronic components from external impact and load, and can improve the capability for reading/writing of information data on the magnetic stripe.
According to the present invention, a portable storage medium including an electronic component therein, comprises card-shape housing means for housing the electronic component, including metallic means substantially surrounding the component for withstanding substantial external forces, and means having a greater flexibility than the metallic means attached to the metallic means for cushioning a portion of the housing means against external forces; and magnetic stripe means flexibly supported on the housing means for deforming a limited amount under the application of external forces to the stripe in response to the flexibility of the cushioning means.
Further, according to the present invention, a portable storage medium including an electronic component therein, comprises metal means having an outer surface, and a muximum permeability of about 1.005 for housing the electronic component and limiting influence on the applied external magnetic flux; and a magnetic recording region on the outer surface of the metal means for magnetically storing the data thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view showing a portable storage medium of the prior art;
FIG. 2 is a sectional view of the portable storage medium of FIG. 1 taken along the line II--II of FIG. 1;
FIG. 3 is a partial sectional view of the portable storage medium of FIG. 1 showing a magnetic read/write operation with a magnetic head;
FIG. 4 is a partial sectional view of the portable storage medium of FIG. 1 along the longitudinal direction of a magnetic stripe showing the magnetic read/write operation with the magnetic head;
FIG. 5 is a plan view showing a first embodiment of a portable storage medium according to the present invention with an outer plate removed;
FIG. 6 is a partial sectional view of the portable storage medium of FIG. 5 taken along the line VI--VI of FIG. 5;
FIG. 7 is a plan view showing a second embodiment of a portable storage medium according to the present invention;
FIG. 8 is a plan view showing a third embodiment of a portable storage medium according to the present invention with an outer plate removed;
FIG. 9 is a partial sectional view of the portable storage medium of FIG. 8 taken along the line IX--IX of FIG. 8;
FIG. 10 is a plan view showing a fourth embodiment of a portable storage medium according to the present invention;
FIG. 11 is a sectional view of the portable storage medium of FIG. 10 taken along the line XI--VI of FIG. 10;
FIG. 12 is a sectional view showing a fifth embodiment of a portable storage medium according to the present invention;
FIG. 13 is a sectional view showing a sixth embodiment of a portable storage medium according to the present invention;
FIG. 14 is a partial sectional view of the portable storage medium of FIG. 13 showing a magnetic read/write operation with a magnetic head;
FIG. 15 is a partial sectional view showing a seventh embodiment of a portable storage medium according to the present invention;
FIG. 16 is a partial sectional view of the portable storage medium of FIG. 15 along the longitudinal direction of a magnetic stripe showing the magnetic read/write operation with a magnetic head;
FIG. 17 is a graph showing the relationship between the permeability of the magnetic stripe used in the portable storage medium of FIG. 15 and the output voltage; and
FIG. 18 is a graph showing the relationship between the hardness of the metal used as an outer plate and the permeability.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 5 and 6 show a multifunctional IC card with a magnetic stripe as a portable storage medium of a first embodiment according to the present invention. Reference numeral 30 denotes a card body. Card body 30 comprises a metal case 32 and a supporting plate 34. An outer frame 36, of which the top portion is cut away, is formed in U-shape. A pair of outer plates 38 and 40 made of stainless steel are bonded by welding to both faces of outer frame 36 to form metal case 32 having a rigid construction. An opening 32a is formed at the top portion of metal case 32 corresponding to the top portion of outer frame 36. A wiring board 42 is housed in metal case 32. On wiring board 42, electronic components such as an LSI chip 44 which composes a CPU and a memory, a liquid crystal display (hereafter LCD) 46, chip condensers 48a and 48b and a thin battery 50 are mounted in a packaged state. Each electronic component is housed in this packaged state inside metal case 32. Among these electronic components, LCD 46 is housed so that it is visible from the outside through a window 38a opened in outer plate 38. Also, a contactor including a plural number of contacts (not shown) for the transmission/reception of required data to/from an external device such as a reader/writer, and keys (not shown) for a keyboard construction are provided on wiring board 42. The contacts are also visible from the outside through suitable windows opened in outer plate 38.
The parts where wiring board 42 and each electronic component are in contact with the inner faces of outer plates 38 and 40 are suitably secured by bonding with adhesives.
At opening 32a of metal case 32, supporting plate 34, made of shock-absorbent material of the same thickness as the thickness of metal case 32, is integrally bonded, thus making card body 30 of the required configuration and dimensions. Magnetic stripes 52 are attached on both surfaces of supporting plate 34.
The shock-absorbent cushioning material for supporting plate 34 may be, for example, as follows:
______________________________________Shock-absorbent material Modulus of longitudinal(Synthetic resin) elasticity (kg/cm.sup.2)______________________________________Vinyl chloride 24,605-42,180Acrylic resin 31,635Polycarbonate 22,496Polyacetal 28,828Polyamide 18,278-28,120______________________________________
Thus, a modulus of longitudinal elasticity of 10,000-50,000 kg/cm 2 is desirable as the shock-absorbent material for supporting plate 34.
As the material for magnetic stripe 52, for example,
γ--Fe.sub.2 O.sub.3 +binder
and as the magnetic properties,
Residual magnetic flux φr: 1.25±0.5 maxwell/cm
Magnetic resistance Hc: 650±50 Oe
Angular ratio: 0.7 or more
are used.
Since the multifunctional IC card is constructed as above, the electronic components housed are suitably protected by rigid metal case 32.
When the IC card is inserted into an IC card reader/writer, terminals of the reader/writer butt against and make contact with the contacts, and the reading and writing of the required information data is carried out, and also the required judgments and calculations are performed inside the card.
Also, when the CPU of LSI chip 44 is operated by manual operation of the keyboard, stored contents in the memory of LSI chip is confirmed through LCD 46.
When the IC card is inserted into the magnetic stripe reader of an automatic cash dispenser system, magnetic stripe 52 attached to supporting plate 34, is placed correctly in contact with a magnetic head of the magnetic stripe reader. As a result, the above-listed magnetic properties are fully exhibited, and thus the information data recorded on magnetic stripe 52 is correctly read out, and the IC card functions correctly as a magnetic card.
A second embodiment of the present invention is shown in FIG. 7. Incidentally, in FIG. 7 and in the following FIGS. 8 through 14 which show each embodiment, components and positions which are the same or equivalent to those in FIGS. 5 and 6 are shown with the same reference numerals to avoid repetitional descriptions.
In the second embodiment, an extended portion 34a of supporting plate 34 is bonded throughout the whole of metal case 32, and thus the bond strength between metal case 32 and supporting plate 34 in the card body 54 is increased. Reference numeral 56 denotes a contactor including a plural number of contacts, and 58 denotes a keyboard.
The functions of the multifunctional IC card of the second embodiment are similar to those in the first embodiment. However, longer life is achived by increasing the bond strength between supporting plate 34 and metal case 32 in card body 54.
FIGS. 8 and 9 show a third embodiment of the present invention. The construction of the card body 60 is similar to that in the first embodiment shown in FIGS. 5 and 6. However, an extended portion 42a is extended from wiring board 42 to supporting plate 34 and is bonded to supporting plate 34. Wiring board 42 is securely bonded to both outer plates 38 and 40 directly or via the packaged electrical components in the side of metal case 32, and extended portion 42a of wiring board 42 is bonded to supporting plate 34. Thus, the bond strength between metal case 32 and supporting plate 34 in card body 60 is increased in the same way as in the second embodiment. LCD 46a may be mounted on extended portion 42a of wiring board 42 in supporting plate 34.
A fourth embodiment of the present invention is shown in FIGS. 10 and 11. A groove 64 which is slightly wider than magnetic stripe 52 is formed in outer plate 38 of a card body 62. A cushion member 66 made of silicone resin is provided in this groove 64. As cushion member 66, for example, silicone resin TSE3663, TSI3101 or TSE25 (trade names; manufactured by Toshiba Silicone Co.) may be used. The silicone resin is filled into groove 64 so that the surface of cushion member 66 is level. Magnetic stripe 52 is attached to cushion member 66.
According to the fourth embodiment, compared with the first embodiment, the construction of the structural unit having shock-absorbency can be simplified. In this type of simplified construction, the surface of cushion member 66 can be made level even if wave-like deformation occurs on the surface of outer plate 38 due to distortion when welding it to outer frame 36. Therefore, it is possible to put the magnetic head accurately into contact with magnetic stripe 52 without any effect of wave-like deformation of the surface of outer plate 38. Thus, randomness of magnetic output can be prevented and reading operation of information data can be correctly carried out.
A fifth embodiment of the present invention is shown in FIG. 12. A cushion member 70 made of silicone resin is provided beneath the surface of outer plate 38 to which magnetic stripe 52 is bonded, that is, inside a card body 68. In the fifth embodiment, in order to increase the shock-absorbent effect of cushion member 70, the area occupied by wiring board 42 is made as small as possible and cushion member 70 is provided over approximately one third of the width of the inside of card body 68.
With the simplified construction of the fifth embodiment, the readability of the magnetic information data can be increased by making magnetic stripe 52 correctly contact with the magnetic head.
A sixth embodiment of the present invention is shown in FIG. 13. In a card body 72, part of outer plate 38 and wiring board 42 are cut away to form openings 74 and 76 at the bonding position of magnetic stripe 52 and a cushion member 78 made of silicone resin is provided in openings 74 and 76.
With the construction of the sixth embodiment, the shock-absorbent effect by cushion member 78 can be further increased when compared with the fourth embodiment (FIG. 11) and the fifth embodiment (FIG. 12).
FIG. 14 is an illustration of magnetic stripe 52 being correctly in contact with magnetic head MH due to the shock-absorbent action of cushion member 78 in the sixth embodiment.
A seventh embodiment of the present invention will be described with reference to FIGS. 15 to 18. As shown in in FIG. 15, a card body comprises an outer frame 82 and a pair of outer plates 84 and 86 made of metal which are bonded by welding to both faces of outer frame 82. In card body 80, a wiring board 88 on which electronic components 90 are mounted is housed. An under layer 92 is laminated on to outer plate 84 and a printed layer 94 is coated on under layer 92. A magnetic stripe 96 is mounted on printed layer 94. This magnetic stripe 96 comprises a magnetic layer 98, which forms the magnetic recording medium, and an overcoat layer 100 on magnetic layer 98.
Outer plate 84 is designed to protect electronic components 90 mechanically, and is formed of metal with a permeability of 1.005 or less. By this means, the unfavorable effect on the magnetic stripe, as shown in FIG. 4 in prior art, is reduced. That is, as shown in FIG. 16, magnetic head MH makes contact with magnetic stripe 96 when the information data is being written on magnetic stripe 96. Magnetic flux generated by magnetic head MH, as shown by the dotted lines, almost passes through the layer of magnetic stripe 96. Therefore, since the magnetic flux passes sufficiently through magnetic stripe 96, a good magnetic recording and reading out operation can be performed.
FIG. 17 is a graph showing the output read out from magnetic stripe 96 when the permeability of the metal used as outer plate 84 is varied. A curve shown by the solid line shows the mean voltage when the output read out from magnetic stripe 96 is logic "0", and the dotted line is logic "1". The output voltages from magnetic stripe 96 fall as the permeability increases. Also, it can be seen that the voltage difference between the output voltages for logic "0" and logic "1" is comparatively small and hardly varies.
FIG. 18 is a graph showing the permeability against the hardness of the metal when four types of metals with different properties were used as the metal for outer plate 84. A curve A shows the properties when "SUS304" (Steel Special Use Stainless is abbreviated "SUS" in Japanese Industrial Standard) was used as the metal, curve B shows the properties when "SUS316" was used, curve C shows the properties when "SUS316L" was used, and curve D shows the properties when "NAR-304G" made by Nippon Stainless Steel Co. was used.
As show in FIG. 18, it can be seen that when the hardness increased, the permeability rapidly increased after it has exceeded a certain point. The point at which the hardness starts to increase in this way is in the region of a permeability of about 1.005. Therefore, from the curves shown in FIGS. 17 and 18, it is desirable to form outer plate 84 of a metal with a permeability of 1.005 or less.
By setting the permeability at 1.005 or less in this way, as shown in FIG. 18, the type of metal, that is to say the material, can be determined according to the required hardness. For instance, it can be seen from FIG. 18 that when a metal with a hardness of 300-350 Hv is required, "NAR-304G" is a suitable example.
Although an IC card is exemplified in the above description of the first to seventh embodiments as the portable storage medium, the present invention is not limited to IC cards.
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A portable storage medium having an electronic component therein, includes a card-shape case for housing the electronic component. The card-shape case includes a metallic plate substantially surrounding the electronic component for withstanding substantial external forces. The card-shape case includes a cushioning member which has a greater flexibility than that of the metallic plate. The cushioning member is attached to the metallic plate for cushioning a portion of the card-shape case against external forces. A magnetic stripe is flexibly supported on the card-shape case for deforming a limited amount under the application of external forces to the magnetic stripe in response to the flexibility of the cushioning member.
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[0001] This application is a continuation of U.S. patent application Ser. No. 10/315,897, filed Dec. 9, 2002, now pending, which is a continuation-in-part of U.S. patent application Ser. No. 10/013,191, filed Dec. 7, 2001, now issued U.S. Pat. No. 6,671,204 which claims priority from U.S. Provisional Application No. 60/307,572 filed on Jul. 23, 2001, all of which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is related to the field of semiconductor memory devices and, more specifically, to a flash memory device with a page buffer circuit having dual registers.
[0004] 2. Description of the Related Art
[0005] The recent trends in semiconductor memory devices are for high integration, large capacity, and to support systems operating at high speeds. These trends are for both volatile memories (e.g., DRAM and SRAM) and non-volatile memories (e.g., flash memories).
[0006] Flash memories are generally subdivided into NOR-type flash memories and NAND-type flash memories. The NOR-type flash memories are used in applications necessary for reading information of a low volume at a high speed non-sequentially, while the NAND-type flash memories are used in applications necessary for reading information sequentially.
[0007] Flash memory devices use memory cells to store data. The memory cells include cell transistors. Each cell transistor has a control electrode and a floating gate. Since the flash memory device stores information using tunneling via an insulation film, it takes some time to store information.
[0008] In order to store information of a large volume in a short time, the NAND-type flash memory uses a register, which is also known as a page buffer circuit. Large volumes of data are supplied externally, for quick storing in the storage region. They are first stored in the register, and from there in the memory cells.
[0009] In the case of a conventional NAND-type flash memory, the magnitude of a page of data does not exceed 512 bytes. If it is assumed that a program time (or information storing time) of a NAND-type flash memory is about 200 to 500 microseconds, and 1-byte of data is loaded on the page buffer circuit from the exterior in a period of 100 nanoseconds, it takes about 50 microseconds to load 512-byte information in the page buffer circuit.
[0010] FIG. 1 shows a specific example in the prior art. FIG. 1 of the instant document is from U.S. Pat. No. 5,831,900 (that document's FIG. 7 ). Additional reference numerals have been added for the present discussion.
[0011] The device of FIG. 1 teaches that data are loaded to a latch 30 from a data line 10 , after page buffers 20 - i are reset by the surrounding circuitry. The data loaded to the latch are programmed to the memory cells 2 - 1 , 2 - 2 , 2 - 3 , through a transistor Q 4 (often by receiving an appropriate program command signal). This programming procedure is normally used to program NAND flash memories.
[0012] This procedure, however, has a limitation. In this program operation, if data is to be loaded to latch 30 , it will have to wait until the data that was previously loaded finish programming in the previous program cycle. As it was described above, data loading to latch 30 progresses by byte units (e.g. 8 bit). So, it takes a long time for data to load to a page of as many as 2048 bytes. This is because latch 30 continues to store data until the information of the register is stored in the appropriate corresponding memory cells.
[0013] Another problem in the prior art is the copy back problem. Sometimes, a copy operation needs to be performed from a first page to a second page of data. If it is desired to perform the copy operation after the data of the memory cells in first page is latched to the latch circuit 30 through transistor Q 7 , then the latched data is programmed to the second page through the transistor Q 4 . In that case, programmed data copied to the second page are reversed, because of the latch circuit. In other words, 1 has become 0, and 0 has become 1. This problem is addressed in the prior art by providing flag cells to the memory cell array, and updating their value depending on whether the data has been inverted or not.
[0014] FIG. 2 shows a specific example of this problem in the prior art. FIG. 2 of the present document is from U.S. Pat. No. 5,996,041 (that document's FIG. 8 and FIG. 9 ). Additional reference numerals have been added for the present discussion.
[0015] In FIG. 2 , copy back functions are shown. Data in the first page within the memory cell array is loaded to a page buffer. After that, the data is copied to another place in the array, but in inverted form. The bit to the right is the flag cell, to indicate that this data is in inverted form.
[0016] The prior art is limited as to how large the memory devices can become. For example, if it is assumed that the page buffer circuit can temporarily store 2048-byte information, it takes about 200 microseconds to load the 2048-byte of information when 1-byte information is loaded on a page buffer circuit by a period of 100 nanoseconds. Therefore the loading time is nearly similar to the information-storing time (or the program time) of 200 to 500 microseconds. Accordingly, the information-storing characteristic of the NAND-type flash memory is seriously affected by the loading time.
[0017] As integration of NAND-type flash memory increases, data must be processed in larger and larger volumes, as compared to the conventional flash memory. And it must be processed without deterioration in the information-storing characteristic.
[0018] The parent application's disclosure is briefly summarized in FIGS. 22 and 23 of the present application. As shown in FIGS. 22 and 23 , a page buffer includes two registers including latches. The first register has a first latch LATCH 1 and the second register has a second latch LATCH 2 . The detailed description of this structure is explained in parent U.S. patent application Ser. No. 10/013,191. As shown in FIG. 22 , data to be programmed is loaded to the node N 4 in LATCH 1 via the Data Line during phase F 1 . Next the data is transferred (or dumped) from mode N 4 in LATCH 1 to the node N 3 of the LATCH 2 during phase F 2 . According to the data state of the node N 3 , the data is programmed to the first page of the memory cell array, during a program phase F 3 in FIG. 23 . If the data of the node N 3 is “0” (ground level and program state), then the memory cells are programmed. If on the other hand the data of the node N 3 is “1” (Vcc level and program inhibit state), then the memory cells are not programmed. Note that a page includes a group of memory cells that are controlled by one word line.
[0019] After programming, the memory cells of the page must be checked to determine whether the memory cells have been successfully programmed. This checking procedure is referred to herein as “program verify read”, phase F 4 of FIG. 23 . In the program verify read procedure, if the cell to be programmed is not programmed, the state of node N 3 is reset to “0” and if the cell to be programmed is programmed, the state of node N 3 is reset to “1”. The cells that are not programmed must be reprogrammed according to the above program procedure.
[0020] If all of the cells are programmed, the node N 3 is set to “1” during phase F 5 . This concludes the procedure for the first page of the memory cell array.
[0021] During the program procedure of the first page of the memory cell array, the data of the second page are simultaneously loaded to the node N 4 in the LATCH 1 . As a result, two procedures are carried out concurrently in a given page buffer.
[0022] U.S. Pat. No. 6,031,760 entitled SEMICONDUCTOR MEMORY DEVICE AND METHOD OF PROGRAMMING THE SAME describes in connection with FIG. 5 thereof a prior art single-latch memory device that is typical of conventional memory devices. The described circuit has a single sense amplifier S/A that includes only a single latch circuit LT.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a diagram of a memory device having a page buffer in the prior art.
[0024] FIG. 2 is an illustration of a copyback operation in the prior art, and of the flag bit it render necessary because it inverts the data.
[0025] FIG. 3 is a block diagram of a semiconductor memory device made according to an embodiment of the invention.
[0026] FIG. 4 is a diagram of an array scheme of the memory of FIG. 3 .
[0027] FIG. 5 is a detailed circuit diagram of a page register and a Y-gating circuit of the device of FIG. 3 .
[0028] FIG. 6 is a flowchart illustrating a programming method according to an embodiment of the present invention.
[0029] FIG. 7 is a timing diagram of signal commands for effectuating the method of FIG. 6 .
[0030] FIG. 8 is a depiction of flow of data in the circuit of FIG. 5 , while the signal commands of FIG. 7 are being applied.
[0031] FIG. 9 is a timing diagram of signal commands for effectuating a reading method in the device of FIG. 3 .
[0032] FIG. 10 is a depiction of flow of data in the circuit of FIG. 5 , while the signal commands of FIG. 9 are being applied.
[0033] FIG. 11 is a flowchart illustrating a copyback method according to an embodiment of the present invention.
[0034] FIG. 12 is a timing diagram of signal commands for effectuating a copyback method according to an embodiment of the present invention in the device of FIG. 3 .
[0035] FIG. 13 is a depiction of data having been transferred from memory cells into a page buffer by following signal commands of a first portion of FIG. 12 .
[0036] FIG. 14 is a depiction of data having been transferred from a page buffer into memory cells by following signal commands of a second portion of FIG. 12 .
[0037] FIG. 15 is a flowchart illustrating an erase method according to an embodiment of the present invention.
[0038] FIG. 16 is a timing diagram of signal commands for effectuating an erase method in the device of FIG. 3 .
[0039] FIG. 17 is a depiction of flow of data in the circuit of FIG. 5 , while the signal commands of FIG. 16 are being applied.
[0040] FIG. 18 is a depiction of how large volumes of memory are counted for two alternate memory device designs.
[0041] FIG. 19 is a table illustrating various design choices for memory devices, including the two of FIG. 18 .
[0042] FIG. 20 is a block diagram illustrating the arrangement of 1 block.
[0043] FIG. 21 is a diagram illustrating a time sequence of how data would be loaded according to the present invention to achieve higher capacity.
[0044] FIG. 22 is a schematic circuit diagram representing a simplified summary of the dual-register memory device described in detail in the parent application of which the present invention is a continuation in part.
[0045] FIG. 23 is a flowchart representing a simplified summary of the method for dual-register memory device programming described in detail in the parent application.
[0046] FIG. 24 is a schematic circuit diagram of a typical memory device illustrating the problem addressed by the present invention.
[0047] FIG. 25 is a graph of the distribution of voltages over a plurality of memory cells, and illustrates a problem addressed by the present invention.
[0048] FIG. 26 is a schematic circuit diagram of the invented dual-register memory device in accordance with one embodiment of the invention.
[0049] FIG. 27 is a flowchart illustrating one embodiment of the invented dual-register memory device programming method.
[0050] FIG. 28 is a timing diagram illustrating various signals and their relative timing in accordance with the invented programming method.
[0051] FIG. 29 is a graph of the distribution of voltages over a plurality of memory cells, and illustrates the solution proposed by the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0052] As has been mentioned, the present invention provides semiconductor memory devices, and methods of using the same. The invention is now described in more detail.
[0053] Referring now to FIG. 3 , a memory device 100 made according to the invention is described. Memory device 100 may be a NAND flash memory. Memory device 100 has an array 110 of memory cells to store data, a Page Register and Sense Amplifier (S/A) block 120 , and a Y-gating circuit 130 to gate data stored in a group of the memory cells. Page Register and S/A block 120 is coupled between memory cell array 110 and Y-gating circuit 130 .
[0054] Page Register and S/A block 120 includes a page buffer 122 . Page buffer 122 includes dual registers according to the invention, as will be described in more detail below.
[0055] Device 100 also includes additional components, such as X-buffers latches and decoders, Y-buffers latches and decoders, a command register, a Control Logic and High Voltage Generator, and global buffers. They exchange data, address, and command signals as shown, and as will be understood from the description below.
[0056] Referring now to FIG. 4 , a sample arrangement is shown for the array 110 of the memory cells. Many bit lines are shown, alternatingly designated BLe, BLo, with “e” representing even and “o” representing odd. Many memory cells (M 1 , M 2 , . . . , Mm) are connected to each bit line.
[0057] A group of memory cells (e.g. M 1 ) are controlled by a single word line (e.g. WL 1 ). The cells in that group are called a page unit for purposes of this application.
[0058] Referring now to FIG. 5 , Page Register and S/A block 120 and Y-gating circuit 130 are described in more detail.
[0059] Y-gating circuit 130 is between Page Register and S/A block 120 and a data line 131 . Data line 131 may be for bits D 0 -D 7 .
[0060] Y-gating circuit 130 is made from two NMOS transistors 132 and 133 . Transistors 132 and 133 are controlled by signals YA, YB. Signals YA, YB may be derived from information from a column address.
[0061] Page Register and S/A block 120 includes a single page buffer 122 , which has a sense line 125 that includes a sense node E. One or more bit lines may be connected to page buffer 122 at node E. In the example of FIG. 5 , two bit lines BLe, BLo are connected to node E.
[0062] A transistor 141 has a source connected to a corresponding bit line BLe, a drain which is connected to a node providing signal VIRPWR and a gate connected to receive the gate control signal VBLe.
[0063] A transistor 142 has a source connected to bit line BLo, a drain which is connected to the node providing signal VIRPWR, and a gate connected to receive the gate control signal VBLo.
[0064] The node providing signal VIRPWR is charged at either one of a first or a second supply voltage. Accordingly, transistors 141 and 142 apply the first or second supply voltage to bit lines BLe and BLo, in response to gate control signals VBLe and VBLo.
[0065] In addition, an NMOS transistor 143 connects the bit line BLe to node E in response to a BLSHFe signal. An NMOS transistor 144 connects the bit line BLo to node E line in response to a BLSHFo signal.
[0066] Page buffer 122 is thus coupled to bit lines BLe, BLo through node E of sense line 125 . A PMOS transistor 148 supplies current to the bit lines BLe, BLo via sense line 125 during a read operation. The PMOS transistor 148 is connected between a power supply voltage and the sense line and turns on/off according to a control signal PLOAD.
[0067] Importantly, page buffer 122 has two registers 150 , 170 . The prior art provides only one such register. Both are connected to sense line 125 .
[0068] Second register 150 is also known as main register 150 . Main register 150 includes two NMOS transistors 151 , 152 , two inverters 153 , 154 , and a PMOS transistor 155 . The data is stored in main latch 156 , formed by inverters 153 , 154 . PMOS transistor 155 forms a precharge circuit for main latch 156 .
[0069] First register 170 is also called an auxiliary register 170 . Auxiliary register 170 includes two NMOS transistors 171 , 172 , two inverters 173 , 174 , and a PMOS transistor 175 . The data is stored in auxiliary latch 176 , formed by inverters 173 , 174 . PMOS transistor 175 forms a precharge circuit for auxiliary latch 176 .
[0070] The dual register (made from the two registers 150 , 170 ) of the page buffer 122 of the present invention provides many advantages. Functions are performed better than in the prior art, which are found to justify increasing the magnitude of the page buffer circuit.
[0071] Additional structure is provided to facilitate and control exchanging data between the two page buffer registers 150 , 170 , memory cell array 110 , and Y-gating circuit 130 .
[0072] An NMOS transistor 181 controlled by a control signal PDUMP is turned on to transfer data between auxiliary register 170 and main register 150 . Alternately, it is turned off to electrically isolate auxiliary register 170 from main register 150 . This transfer is advantageously performed over sense line 125 . NMOS transistor 181 is also known as an isolation switch.
[0073] NMOS transistors 182 , 183 provide for storing information in auxiliary register 170 . This is performed responsive to the externally input signals DI and nDI, respectively.
[0074] A NMOS transistor 184 connects or disconnects main register 150 to or from a selected one of bit lines BLe, BLo. This is performed when information to be programmed is transferred to the selected one of the bit lines from main register 150 .
[0075] A NMOS transistor 185 is controlled by a control signal PBDO. Transistor 185 outputs information read out via the selected bit line to the exterior of page buffer 122 during a selected interval of time.
[0076] A transistor 186 is prepared for checking the program state, and provides program pass/fail information at a node B of main register 150 .
[0077] Methods of the invention are now described.
[0078] Referring now to FIG. 6 , FIG. 7 , FIG. 8 and also FIG. 4 , programming methods according to the invention are described. Programming is where data is input in the memory cells of a device from outside the device.
[0079] In FIG. 6 , a flowchart 600 is used to illustrate a programming method according to an embodiment of the invention. The method of flowchart 600 may also be practiced by circuit 100 of FIG. 3 .
[0080] According to a box 610 , first external data is passed through a Y-gating circuit, such as circuit 130 . The first external data is passed towards a page buffer, such as page buffer 122 . It can be a single datum or many data. It may even be a whole page of data.
[0081] According to a next box 620 , the first data passed at box 610 is stored at a first register of a page buffer. The first register may be auxiliary register 170 .
[0082] According to an optional next box 630 , a switch may be activated to connect the first register with a second register. The second register may be main register 150 . The switch may be NMOS transistor 181 , controlled by control signal PDUMP.
[0083] According to a next box 640 , the first data that is stored in the first register is stored at the second register.
[0084] According to an optional next box 650 , the switch may be activated to isolate the first register from the second register.
[0085] According to a next box 660 , the first data that is stored in the second register is stored at a cell of a memory cell array, which is also called programming. Concurrently, second external data is received at the first register, and stored therein. Therefore, an information-storing operation can be carried out without increasing the information-loading time.
[0086] In the embodiment of FIG. 3 , the concurrent operation of box 660 is made possible because of the isolation of the first register and the second register. Other methods are also possible.
[0087] Referring to FIG. 7 and FIG. 8 , a programming method of the invention is described in more detail. FIG. 7 shows command signals that may be applied to the circuit of FIG. 5 . The horizontal axis is divided into nine time segments, respectively labeled 1, 2, . . . , 9.
[0088] FIG. 8 shows how data is transferred in the circuit of FIG. 5 , resulting from applying the command signals of FIG. 7 . FIG. 8 should be referred to along with FIG. 7 , using the same cross-referenced time segments as FIG. 7 .
[0089] At a first step (time segment 1), a data line 131 is taken to a ground voltage, and transistor 175 is turned on by PBSET signal. This is also known as page buffer setting for the first page.
[0090] Afterwards (time segment 2) a node D of auxiliary latch 176 is at a high state, and NMOS transistors 132 and 133 are turned on. Data “0” or “1” in data line is thus stored to auxiliary latch 176 by applying phases of DI and nDI signals. This is also known as data loading of the first page, and loosely corresponds to box 610 described above.
[0091] Then (time segment 3), the stored data is transferred to sense line 125 from the auxiliary register 170 . This is accomplished by transitioning control signal PDUMP to a logic high state. Prior to transferring the data to main register 150 , sense line 125 and node A of latch 156 are precharged by the transistor 148 and 155 respectively.
[0092] Afterwards (time segment 4) the signals are zeroed. The process is also called HV enable.
[0093] Then (time segment 5), the appropriate one of the bit lines BLe, BLo is set up, by being precharged.
[0094] Then (time segments 6 and 7), two actions happen concurrently, corresponding to box 660 above. The data to be programmed is transferred from main register 150 to selected bit line BLe by activating the BLSLT signal, and from there to the memory cell. In addition, the next data to be programmed is stored (loaded) in auxiliary register 170 from the exterior of the memory device.
[0095] Generally, the data loading operation is done by byte unit, while programming operation is done by page unit. Data loading means that data is transferred from the data line to the auxiliary register 170 , while programming operation means that data transfers from main register 150 to the memory cells in the memory cell array 110 . As described above, page unit means that a plurality of memory cells are connected and controlled by a single word line.
[0096] Since the two actions take place concurrently, the data-storing characteristic is maintained, even at high volumes of data. Thus implementing the page buffer circuit with auxiliary register 170 is well worth increasing the magnitude of the page buffer circuit.
[0097] Then (time segment 8), the read operation is verified, and (time segment 9), the bit lines are precharged again for the next load/program operation.
[0098] Referring now to FIG. 9 and FIG. 10 , a read operation of the device of FIG. 3 is described in more detail. Data is assumed to be read out from one of the memory cells of array 110 , and that gate control signals of memory cells to be read apply appropriate voltages to word lines.
[0099] FIG. 9 shows command signals that may be applied to the circuit of FIG. 5 . The horizontal axis is divided into six time segments, respectively labeled 1, 2, . . . , 6.
[0100] FIG. 10 shows how data is transferred in the circuit of FIG. 5 , resulting from the command signals of FIG. 9 . FIG. 10 should be referred to along with FIG. 9 , using the same cross referenced time segments as FIG. 9 .
[0101] Briefly, reading out is performed directly through main register 150 , bypassing auxiliary register 170 . This way, auxiliary register 170 does not obstruct reading data, while it facilitates data loading and data programming as described above.
[0102] In order to perform a stable read operation, the bit lines BLe and BLo are first discharged through NMOS transistors 141 and 142 by zeroing the VIRPWR signal, and activating the control signals VBLe and VBLo high. (Time segment 1.)
[0103] At the same time, a PBRST signal transitions from a logic high state to a logic low state, so that a state of the main register 150 (or an input of inverter 153 ) is set to a predetermined state (i.e., a logic high state).
[0104] Afterwards, the PLOAD signal goes low, and thus PMOS load transistor 148 is turned on. The control signal BLSHFe of the NMOS transistor 143 is made to have a voltage of summing a bit line precharge voltage and a threshold voltage of the NMOS transistor 143 . After precharging the bit line BLe with an appropriate voltage, the BLSHFe signal goes to a logic low state of the ground voltage. (Time segment 2.)
[0105] A precharged voltage of the bit line is varied according to a state of a selected memory cell. For example, in the case where the selected memory cell is an off cell, the precharged voltage of the bit line continues to be maintained. In the case where the selected memory cell is an on cell, the precharged voltage of the bit line is lowered. (Time segment 3.)
[0106] If a voltage of the BLSHFe signal is changed into an intermediate voltage between the precharge voltage and the previous BLSHFe signal level, a voltage on sense line 125 is maintained at the power supply voltage by shutting off the NMOS transistor 143 when the selected memory cell is an off cell. If not, however, a voltage on sense line 125 is lowered along a bit line BLe voltage (or is synchronized with a bit line BLe). At a midway point where the BLSHFe signal goes to a logic low state of the ground voltage, the PLOAD signal turns to the power supply voltage.
[0107] After this, a gate control signal PBLCHM of NMOS transistor 152 goes to a logic high state of the power supply voltage, and NMOS transistor 151 is turned on or off according to a state of the sense line. As a result, the state of sense line 125 is stored in main register 150 . (Time segment 4.)
[0108] Then the data stored in main register 150 is transferred to the data line via NMOS transistor 185 , which is controlled by control signals PBDO and next via Y-gating circuit 130 . (Time segment 6.)
[0109] Copy-back methods according to the invention are now described. During the performance of reading operation, it may become necessary to perform a page copy operation by copying data read from a first page of memory cells at a first address to a second page of memory cells at a second address.
[0110] Referring now to FIG. 11 , a flowchart 1100 is used to illustrate a copy-back method according to an embodiment of the invention. The method of flowchart 1100 may also be practiced by device 100 of FIG. 3 .
[0111] According to a box 1110 , data of a first cell is stored at a first register of a page buffer. This may be performed by reading out data into the auxiliary register 170 . Reading out may be performed as described above.
[0112] According to a next box 1120 , the data stored in the first register is stored at the second register of a page buffer. This may be performed by transferring the read out data between the auxiliary register 170 and the main register 150 . The transfer may optionally involve activating a switch to connect the first register with the second register.
[0113] According to a next box 1130 , the data of the second register is stored at a second cell of the memory cell array. This may be performed as a programming operation, as described above.
[0114] Referring now to FIG. 12 , FIG. 13 , FIG. 14 , a copy-back operation of the device of FIG. 3 is described in more detail. Data is assumed to be read out from original memory cells of array 110 into page buffer 122 , and copied back there, into different cells.
[0115] FIG. 12 shows command signals that may be applied to the circuit of FIG. 5 . The horizontal axis is divided into eleven time segments, respectively labeled 1, 2, . . . , 11.
[0116] The data is first read out from the cells to the page buffer. It will be recognized that the signal commands in the first four time segments 1, 2, 3, 4 are substantially the same as in those of FIG. 10 , except that data is read into auxiliary register 170 , instead of main register 150 .
[0117] Referring to FIG. 13 , the data read out into the page buffer is shown. A blank space is also shown, where the prior art of FIG. 2 required an additional indicator bit to indicate the polarity (inverted or not) of the stored data.
[0118] Returning to FIG. 12 , the data is then transferred from auxiliary register 170 into main register 150 of the page buffer. This takes place during time segments 5, 6.
[0119] Then the data is programmed from main register 150 into other cells of the memory, during time segments 7, 8, 9, 10, 11. It will be recognized that the signal commands during time segments 5-11 are substantially the same as in those of FIG. 8 .
[0120] Referring to FIG. 14 , the reprogrammed data is shown. It will be appreciated that the data is stored in the different cells according to the invention without being inverted from how they were stored in the original cells. Accordingly, there is no need to include the indicator bit of FIG. 2 , which further saves space.
[0121] Erase methods according to the invention are now discussed. Erasing generally dumps data. In a flash memory, the threshold voltage goes to a value between −1V and −3V by applying a high voltage to the memory cells. Data in registers is dumped.
[0122] Referring now to FIG. 15 , a flowchart 1500 is used to illustrate a verify read operation after erasing according to another embodiment of the invention. The method of flowchart 1500 may also be practiced by device 100 of FIG. 3 .
[0123] According to a box 1510 , data of first memory cell is dumped through a first register of a page buffer.
[0124] According to another box 1520 , data stored in the first register of the page buffer circuit is dumped through a second register.
[0125] According to an optional box 1530 , data stored in the first register is checked pass or fail of the memory cell state by transistor 186 .
[0126] Referring now to FIG. 16 and FIG. 17 , an erase method is described for the device of FIG. 3 . FIG. 16 shows command signals that may be applied to the circuit of FIG. 5 . The horizontal axis is divided into seven time segments, respectively labeled 1, 2, . . . , 7.
[0127] FIG. 17 shows how data is erased in the circuit of FIG. 5 , resulting from applying the command signals of FIG. 16 . FIG. 17 should be referred to along with FIG. 16 , using the same cross-referenced time segments as FIG. 16 .
[0128] In time segments 1 and 2, an erase execution command is received. In time segment 3, bit lines BLe, BLo are grounded for discharge. In time segment 4, a Verify Read operation takes place for a first cell. In time segment 5, a Verify Read operation takes place for a second cell.
[0129] In time segment 6, data is dumped through the first register. The data includes data of a memory cell, and also data from main register 150 and supplemental register 170 of the page buffer. In time segment 7, a wired OR operation takes place, and data is dumped from node B of main register 150 .
[0130] The invention offers the advantage that, even if the size of the page is increased, the program time (or the information-storing time) of the memory is increased slightly or not at all. In addition, a time for loading information on the page buffer circuit is increased in proportion to the increased magnitude of the page.
[0131] Referring to FIG. 18 , FIG. 19 , FIG. 20 , FIG. 21 , examples are discussed of handling large volumes of data in memories. Efficiencies of the invention are thus illustrated.
[0132] FIG. 18 is a depiction of how large volumes of memory are counted for the capacity of a memory device, for two cases, namely A and B.
[0133] A three dimensional box depicts the total memory capacity of a device. It can be thought of as a stack of blocks, and each block is a stack of pages. Each page (and also each block) is one byte (1B) wide. A byte equals eight bits, namely I/O 0 -I/O 7 .
[0134] In case A, one page is (512+16) 528 B long. Assuming blocks of 32 pages, a capacity of 2048 blocks will yield a device of 264 Mbit.
[0135] In case B, enabled by the present invention, one page is (2048+64) 2112 B long. Assuming blocks of sixty-four pages, a capacity of 1024 blocks will yield a device of 1 Gbit.
[0136] FIG. 19 displays various design choices for memory devices, including devices A and B of FIG. 18 .
[0137] FIG. 20 illustrates how a block can be reconfigured to sixty-four pages (such as for device B of FIG. 18 ) from thirty-two pages (such as for device A of FIG. 18 ) by designating successive pages of data as “even” and “odd”.
[0138] The invention attains faster loading times than the prior art. This is illustrated by examples. Assuming:
T 1 =1B loading time=0.1 μs F 2 =1 page (for two cases of 528 B and 2112 B) T 3 =program time=200 μs F 4 =1 block (here thirty-two pages)
[0143] Then the time required by the device of the prior art for the sequence of data loading, program, data loading, program, etc. requires
Total time (prior art)=[(T 1 ×F 2 )+T 3 ]×F 4 Equation (1)
[0144] This yields 8,089.6 μs for a device of 528 B and 13158.4 μs for a device of 2112 B. Accordingly, it is not possible to store information of large volume into the page buffer in a short time (the information-storing characteristic deterioriates).
[0145] Referring to FIG. 21 , data would be loaded and programmed according to the present invention more efficiently. The total time required would be
Total time (present invention)=(T 1 ×F 2 )+(T 3 ×F 4 ) Equation (2)
[0146] This, for a device of 2112 B, yields 6611.2 μs, which is about half of the comparable time of Equation 1. This means that a page buffer circuit of a large volume (e.g., over 2048 B) may now be used.
[0147] FIGS. 24 through 29 relate to another embodiment of the invention, to be described in detail below.
[0148] FIG. 24 shows a memory cell array 100 in a NAND flash memory device. The memory cell array has a plurality of strings that comprise a plurality of memory cells. Each of the string is connected to one bit line. The strings are connected to a common source line CSL in parallel. The common source line CSL is connected to ground.
[0149] In the NAND flash memory device, all of the memory cells that are connected to one word line are simultaneously programmed. In other words, if the word line WL 1 is enabled, all of the memory cells MC 1 are programmed according to the state of the bit line. If the bit line state is “0”, then the memory cells are programmed. If the state of the bit line is “1”, then the memory cells are not programmed.
[0150] Afterwards, during the program verify procedure, the state of the memory cells is latched in the data node (N 3 of LATCH 2 in FIG. 26 ).
[0151] When the bit line state is “0”, all of the memory cells are not programmed in the first program step.
[0152] Normally, the cells are successfully programmed after several steps of the program procedure. Because the coupling ratios of the memory cells are different from one another according to the vagaries of the semiconductor manufacturing process, even though the state of the bit line is a program state “0”, all of the memory cells to be programmed are not necessarily programmed during a single cycle or step of the program procedure. In general, before starting the program procedure, all of the memory cells in a NAND flash memory are erased. Accordingly, all of the memory cells have a negative threshold voltage. After several program steps in the first page, all of the memory cells go to a positive threshold voltage above the verify voltage. In a given page containing plural memory cells, if the first page has finished the first program step then during the program verify procedure all of the memory cells are checked whether the threshold voltage of the memory cells is below the verify voltage or not. The verify voltage is shown in FIG. 25 . At that time, even though a portion of the memory cells have been successfully programmed (to “0”), nevertheless most of the memory cells typically are below the range of the verify voltage for the above-described reason.
[0153] Referring still to FIG. 24 , during the program verify procedure, the voltage level of a common source line CSL rises because of resistors R 0 , R 1 , R 2 , . . . . Rm and currents Ic 0 , Ic 1 Ic 2 , . . . Icm. This of course is derived from Ohm's law (V=IR). Those of skill in the art will appreciate that the resistors R 0 , R 1 , R 2 , . . . Rm represent parasitic resistances of the common source line and the currents Ic 0 , Ic 1 , Ic 2 , . . . . Icm represent the currents that flow from each bit line to the common source line. Such currents flow through the cells that remain in erased state or that are not sufficiently programmed.
[0154] As a result, the voltage level of the common source line CSL rises because of the current flowing through the strings. The fluctuation of the voltage level of the common source is referred to as CSL noise.
[0155] This phenomenon occurs more readily after the first program step because of the memory device's condition. But after several program steps, the phenomenon is minimized because the current that flows to the memory cells is minimal.
[0156] Referring now to FIG. 25 , because of the CSL noise, during the program verify procedure, the LATCH 2 sets the node 3 to a programmed state “1”, even though the threshold voltage of the memory cell is actually below the level of the verify voltage. As a result, the memory cell that is not sufficiently programmed is falsely and misleadingly indicated as a sufficiently (successfully) programmed cell.
[0157] For example, if the memory cell MC 0 has a threshold voltage of 0.3V after the first program, and the level of the CSL is 0.7V because of the CSL noise, the threshold voltage of the memory cell MC 0 becomes 0.7V during the program verify procedure.
[0158] If the verify voltage is 0.7V, the memory cell is indicated as a programmed memory cell in the page buffer. Accordingly, the node N 3 of the LATCH 2 goes to “1”.
[0159] In other words, even though the memory cell (MC 0 in FIG. 24 ) is not sufficiently programmed, the node N 3 of the LATCH 2 is in the high state “1”. If the memory cell is programmed in the second step, because the node N 3 of the LATCH 2 remains in the state “1”, the threshold voltage of the memory cell MC 0 having a 0.3V threshold voltage is not changed.
[0160] One object of this invention is to solve this problem.
[0161] Another object of this invention is that the memory cell not to be programmed sustains a program inhibit state and the memory cell to be programmed cell is reprogrammed even though the memory cell is falsely indicated as having achieved a programmed state during the program verify procedure.
[0162] FIG. 26 depicts the present invention in schematic circuit form. From FIG. 26 it may be seen that the present invention comprises a storing circuit and a restoring circuit not shown in the embodiments of the invention described in parent U.S. application Ser. No. 10/013,191.
[0163] By reference to FIGS. 26 and 27 , the present invention will be explained.
[0164] In FIG. 26 , a page buffer comprises a first sense amplifier 1 , a second sense amplifier 2 , a pass/fail check circuit, a storing circuit and a restoring circuit. Those of skill in the art will appreciate that the sense amplifier ( 1 or 2 ) is referred to as a register in the parent patent application.
[0165] In step F 1 , the data to be programmed and the data to be program inhibited are loaded to the node N 4 in one data register LATCH 1 . The data to be programmed is “0” (GND) and the data to be program inhibited is “1” (VDD).
[0166] In step F 2 (in FIG. 27 ), the data “0” and “1” are dumped to the node N_DATA. Before step F 2 , the node N_DATA is pre-charged to VDD level according to a PRE signal.
[0167] In step F 3 , the data in the node N 4 is dumped to the node N 3 of another data register LATCH 2 through the transistor TR 12 . The phase of the data in the node N 3 is the same as the phase of the data in the node N 4 and is the inverse phase of the data in the node N_DATA in the storing circuit.
[0168] In step F 4 , the memory cells are programmed according to the state of the node N 3 of the other register LATCH 2 . If the state of the node N 3 is “0”, then the memory cell is programmed. If the state of the node N 3 is “1”, then the memory cell is not programmed. The program state means that the threshold voltage of the memory goes to a level above the verify voltage, wherein the verify voltage has an intermediate level between the threshold voltage of a programmed memory cell and that of an erased memory cell.
[0169] In step F 5 , the node N 3 is restored according to the state of the storing circuit. If the state of the node N_DATA is “1”, then the node N 3 is reset to “0”. If the state of the node N_DATA is “0”, then the node N 3 retains the previous data.
[0170] In step F 6 , the program verify read procedure is executed. In the first program verify read step, the memory cell that is not sufficiently programmed is indicated as being in a programmed state in the LATCH 2 . But the memory cell is indicated as a cell that is not programmed because the CSL noise is reduced after several program steps. Because the node N 3 is reset to “0” according to the state of the storing circuit, the memory cell that is insufficiently programmed is programmed during the next program step.
[0171] In step F 7 , the state of the node N 3 of LATCH 2 is checked in the pass/fail check circuit. If the state of the node N 3 is “1”, then the program procedure is finished. If not, then the procedure returns to step F 4 .
[0172] FIG. 28 is a timing diagram of the invented programming and verifying method. The steps F 1 through F 7 are represented along the horizontal axis, while the various control and data signals are represented along the vertical axis. The control signals include X-Decoder Signals SSL; W/L (Sel.) (selected word line); W/L (Unsel.) (unselected wordline); GSL; CSL (common source line). They also include Page Buffer signals VIRPWR (power supply voltage); VBLe (even bit line voltage); VBLo (odd bit line voltage); BLSHFe (even bit line shift voltage); BLSHFo (odd bit line shift voltage); PBLCHM (gate control); PBLCHC; PLOAD; PBset; PDUMP 1 ; BLSLT (selected bit line); DI (data input); nDI (inverse data input); PRE (precharge); RESET; PDUMP 2 and DATA LINE. These signals will be understood in large part to be conventional or understood from the disclosure of the parent application.
[0173] As may be seen from FIG. 28 , in accordance with the invention, PDUMP 2 (during phase F 2 ) precedes PDUMP 1 (during phase F 3 ) so that the previous state of node N 3 of LATCH 2 is temporarily stored for restoration of node N 3 in the case the bit must be programmed again by returning when needed to step F 4 , as described above.
[0174] Table 1 below illustrates typical voltages for the program and verify modes of programming a memory device of the type described herein.
TABLE 1 WL WL BL BL (selected) (unselected) (program) (inhibit) PROGRAM 18 V 12 V 0 V Vcc VERIFY 1 V 4.5 V 0.8 V 0.8 V
[0175] The word line voltage step-up, with the programming voltages and steps, proceeds as follows:
15.5V−>VERIFY−>16V−>VERIFY−>16.5V−> . . . (and so on)
[0177] In accordance with one embodiment of the invention, the maximum step-up count (number of cycles) is twelve and the step-up voltage increment is 0.5V/step. Those of skill in the art will appreciate that alternative maximum step-up counts and/or alternative step-up voltage increments are contemplated, and are within the spirit and scope of the invention. Typically, programming is completed within in five or six steps so that the maximum count is not reached.
[0178] Finally, FIG. 29 is a graph showing the distribution of voltages across a plurality of memory cells after programming in accordance with the invention. It may be seen by contrast to FIG. 25 that, in accordance with the invention, the number of bits successfully programmed rises significantly by effectively pushing the programming of all or substantially all data “0”-programmed cells to a higher threshold voltage that is above their verify voltages. This is illustrated by the lack of any overlap in FIG. 29 of the data “0” programming of all bits (represented by the bell curve on the right side of the graph) and the verify voltage level (represented by a vertical dashed line).
[0179] A person skilled in the art will be able to practice the present invention in view of the description present in this document, which is to be taken as a whole. Numerous details have been set forth in order to provide a more thorough understanding of the invention. In other instances, well-known features have not been described in detail in order not to obscure unnecessarily the invention.
[0180] While the invention has been disclosed in its preferred embodiments, the specific embodiments as disclosed and illustrated herein are not to be considered in a limiting sense. Indeed, it should be readily apparent to those skilled in the art in view of the present description that the invention may be modified in numerous ways. The inventor regards the subject matter of the invention to include all combinations and sub-combinations of the various elements, features, functions and/or properties disclosed herein.
[0181] The following claims define certain combinations and sub-combinations, which are regarded as novel and non-obvious. Additional claims for other combinations and sub-combinations of features, functions, elements and/or properties may be presented in this or a related document.
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A nonvolatile memory device and programming method and apparatus therefore are described that include operatively coupled first and second sense amplifiers having first and second data registers or latches, a storage circuit for storing a data of the second amplifier, a pass/fail check circuit for checking the content of the second data register whether a cell of the memory device has been sufficiently programmed and a restore circuit for resetting the second data register for reprogramming the device until sufficiently programmed.
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TECHNICAL FIELD OF THE INVENTION
An aspect of the present invention relates to a condom as a sanitary contraceptive, the use of which making possible the inhibition of or protection against AIDS and various venereal diseases. Another aspect of the invention relates to a condom which has an ejaculation-restraining effect on the male during sexual intercourse or stimulation in order to promote the health of the male. These features may also be found together in the present invention, as well.
BACKGROUND OF THE INVENTION
Condom is the general name for a sanitary contraceptive, and the condoms known hitherto were devised in various patterns; however, these condoms do not exhibit the ejaculation-restraining effect on the male during sexual intercourse and some of them as shown in the accompanying drawings (FIGS. 14 and 15 as in Japanese Utility Model Laying-open Publication No. 86-4335) have special contours only for the sake of curiosity. Therefore, such condoms are not suitable for home or normal use.
Furthermore, the basic type of condoms as illustrated in FIG. 12 and 13, which are widely distributed among consumers, have not actively been used because they were made only for the contraceptive effect neglecting the curiosity. Especially, these kinds of condoms cannot give substantial help to the male in preventing a premature ejaculation. As a result, continued premature ejaculation causes sexual dissatisfaction in the female partner as well as undesirable sexual dreams.
Furthermore, with conventional condoms, a female partner cannot receive the masculine hormone discharged from the male partner so that the communication of feeling between male and female as taught by Chinese medicine cannot be achieved, thereby discouraging the habitual use of condoms.
SUMMARY OF THE INVENTION
The condom according to the present invention is provided with a protruded thick round portion at the tip of the main portion of the condom. The glans of the male sexual organ is contacted on the bottom of the thick protruded portion, and so is protected from sensitive frictions. This prevents the premature ejaculation of the male, and enables the male partner to successfully inhibit ejaculation in order to keep a healthy life. Further, in the case where the sexual organ of the male partner is too short, the condom according to the present invention provides the effect of lengthening the organ to provide added pleasure to the female partner, thereby removing the sexual dissatisfaction of the female partner.
Therefore, the device according to the present invention is useful for the balanced sexual life of married couples, and enables family planning to proceed smoothly through the communication of feeling provided by the features of the invention, at the same time enjoying sexual life, and preventing the female partner's dissatisfaction and thus undesirable sexual dreams.
It is an object of the present invention to provide a condom of improved structure with which a female may receive only masculine hormones from her male partner, thus permitting the communication of feeling between male and female as taught by Chinese medicine, while protecting the male sexual organ from being subjected to sensitizations which would result in premature ejaculation, as well as greatly reducing the possibility of contracting or transmitting venereal diseases, including AIDS.
Accordingly, the condom according to the present invention has the advantages of preventing undesirable sexual dreams, maintaining the health and well being of the male partner due to prevention of premature ejaculation, maintaining a healthy and happy marital life, and making it possible to practice family planning through the active use of the condom.
In order to attain to the above object and advantages, the present invention provides a relatively large arcuate top portion at the end of the main portion of the condom.
Inside the arcuate top portion, a cap is inserted, the cap being fitted to the inside of the arcuate top portion and the cap having a deep recess in it.
This cap is integrally attached to the inside of the arcuate top portion, and the inner wall of the cap can cover almost the whole area of the glans of the male sexual organ.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially cut-out perspective view of the device according to the pesent invention illustrating the process of the manufacturing;
FIG. 2 is a longitudinal cross sectional view of the finished product of the present invention;
FIG. 3 is a partially cut-out perspective view of another embodiment of the present invention illustrating the process of the manufacturing;
FIG. 4 is a longitudinal cross sectional view of the finished product of the device of FIG. 3;
FIG. 5 illustrates the process of applying the device of the present invention to a conventional condom;
FIG. 6 is a longitudinal cross sectional view of the product in which a conventional condom is combined with the device of the present invention;
FIG. 7 through 11 show the various other embodiments of the present invention;
FIG. 12 through 15 show various types of conventional condoms; and
FIG. 16A is a longitudinal cross sectional view showing the flow path formed in the center of the cap of absorbent and FIG. 16B and 16C show embodiment wherein the arcuate top portion and the cap are both penetrated.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The object and the advantages of the present invention will become more evident by describing the preferred embodiments of the present invention in more detail with reference to the attached drawings.
FIG. 1 illustrates an embodiment of the present invention, FIG. 2 is a cross sectional view of FIG. 1, FIG. 3 through 11 and FIG. 16 show other embodiments of the present invention, and FIG. 12 through 15 are selected examples of conventional condoms.
The device of FIG. 1 is the general type showing the embodiments of the present invention, in which an arcuate top portion 3 is formed on a cylindrical main portion 1, the diameter of the former being a little smaller than that of the latter. A cap is inserted into and integrally attached to the inside of the arcuate top portion 3, the outside diameter of the former being the same as the inside diameter of the latter. The cap 2 has a considerably thick wall with a deep recess on its center and is gently rounded at its bottom in order to cover almost the whole glans of the male sexual organ. The main portion 1 is made of a material containing latex, while the cap 2 is made of a soft material selected from those which do not give a harmful effect to the human body. The height of the cap 2 comes within the range of 10 mm to 30 mm, and there are various types of caps having different heights within the range.
Also, the cap 2 of the present invention may be applied to conventional condoms by forcefully inserting the cap into the tip portion of a conventional condom 5 as illustrated in FIG. 5 and 6.
The methods of making the condom utilize conventional techniques. These include dipping a phallic shaped mandrel of predetermined size, usually made of ceramic or steel, (which may be stationary or rapidly rotating about the longitudinal axis) into a warm bath containing a natural rubber latex.
A circumferential groove is located at the upper end of the mandrel. The mandrel is generally immersed in the latex bath to the top of the groove (i.e., so that the surface of the latex liquid is coincident with the top of the groove).
After a predetermined length of time the latex-coated mandrel is withdrawn from the latex bath. The latex coating in the mandrel is allowed to dry and, usually, a lubricant material is applied to the latex sheath.
A thickened ring of latex is formed at the upper (open) end of the condom. Starting from the upper portion the latex sheath is then rolled off the mandrel surface around the thickened latex ring to form a cup-shaped elastic ring of predetermined size and circumference.
In addition, in the present invention the mandrel is covered with the cap 2 before the mandrel dipping step, as shown in FIG. 1. After the mandrel and cap assembly is withdrawn, a latex coating conforming to the shape of the assembly is created and, after drying results in a latex sheath with an integral cap. Various types of caps may be applied to the mandrel to provide various embodiments of the capped condoms.
It should be noted that cap 2 which is a soft absorbent material, e.g., sponge, has an additional function, that of absorbing the ejaculated sperm. The cap 2 entraps the sperm and thus prevents or inhibits the transmission of venereal disease and AIDS to a greater extent than conventional condoms which, due to their thin walls may allow infected sperm to be transferred from the AIDS carrier.
Referring to FIG. 16A, cap 2 has a slot 2a which is closed at one end thus providing an absorption tube but still allowing sperm entrapment. In the embodiments of FIGS. 16B and 16C, a slot is formed through the cap portion of the condom with the inner wall of the slot being coated with a spermicidal agent and/or venereal disease medication so that infertile seminal fluid is allowed to pass through. However, the transmission of AIDS is not completely prevented in this embodiment until an effective medication for treating AIDS is developed.
For males who have the tendency of especially premature ejaculation, an extension 4 may be provided at the bottom of the cap 2, so that it can completely cover the head portion of the male sexual organ to keep the sensitive portion of the male organ from being stimulated. Further, as shown by the embodiment of FIG. 7, the cap 2 can be provided with a cavity 6 and a partition 7 in order to double the soft elastic feeling and to give help to inhibiting or delaying ejaculation.
According to other embodiments of the present invention as shown in FIG. 8 through 11, various types of the cap 2' can be provided correspondingly to the various shapes of the tip of the main portion 1, as for as the cap can cover the whole area of the head portion of the male sexual organ.
A slot 2a may be formed in the cap 2 having a strong absorption force to provide an absorption tube for the ejaculation sperm passing through the slot, as shown in FIG. 16A.
Furthermore, the slot 2a may be extended through an opening 3a of the top portion 3 with a sterile agent layer 2b or 2b' being coated on the inner wall of the slot 2a as shown in FIGS. 16B and 16C. The sterile agent layer 2b or 2b' is comprised of a fertilization-restraining agent (for example nonylphenoxypolyethoxyethanol and dodecaethyleneglycol monolaurate) or a composition of said fertilization restraining agent and a sterilizing agent for treating bacilli in the vagina (for example VEGINAN, SUPPOSITORY, POBIDON JOD, and other various ingredients, such as antibiotics, antibacterials, trichomonacides and moniliacides). When the sperm is ejaculated into the slot 2a of the cap 2, the sperm is killed by the sterile agent layer 2b or 2b' while passing through the layer and then the killed sperm are permitted to enter the vagina naturally.
For example, and effective amount of nonylphenoxypolyethoxyethanol as a sperm-neutralizing agent is approximately 3.6-7.2 mg. In the embodiment of FIG. 16B, the sterilizing material is coated on the inner wall of cap slot 20, whereas the sterilizing and venereal medications preferably in the form of a mixture, coat the inner wall of cap slot 2a of FIG. 16C.
Therefore, the sterilization and treatment for the bacilli is also effected by the thus-constructed device. The slot 2a or the opening 3a is not limited to one but a plurality of them may be provided.
It should be noted that the type of anti-venereal medication is not critical and any suitable available drug for prevention of venereal disease may be used. An MIC dosage or prophylactic dosage may be used.
All the above described embodiments fall within the scope of the present invention, because they are intended to cover and protect with soft cushions the head portion of the male sexual organ. They are just variations of the standard device of the present invention.
The device of the present invention constituted as described above keeps the head portion of the male organ from being subjected to sensitizations and stimulation owing to the cap 2 of the present invention. This can bring the result of inhibiting the discharge of sperm and, consequently, such prevention of premature ejaculation can bring the effect of maintaining the good health of the male sexual partner in spite of frequent sexual intercourse, as taught by Oriental medical theory. Therefore, the device of the present invention provides a complete solution to the persons who are in difficulty because of premature ejaculation. Persons who especially suffer from premature ejaculation can use the type of condom which is shown in FIGS. 3 and 4, and in which the extension 4 of the cap 2 is formed. A protruded thick, round portion 2 at the tip of the condom may cover the sensitive glans of the male organ, thus dulling stimulation during coitus and effectively inhibiting or prolonging the time when ejaculation of the male takes place.
In the embodiment of the invention as shown in FIG. 7, the cavity 6 and partition 7 in the cap 2 will provide the space for the discharged sperm as well as a doubled soft feeling. The partition 7 is adapted to fit closely over the glans of the male sexual organ to dull the sensitivity and prohibit premature ejaculation.
Therefore, the device according to the present invention will provide for satisfied sexual life as well as preventing undesirable sexual dreams and, consequently, the device of the present invention will provide for a sustained happy home life in addition to an assured and reliable family planning aid.
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A new kind of condom provided with a cap is disclosed. The cap is integrally attached into an arcuate top portion of the main portion of the condom. This cap is protruded considerably long, and the bottom of the cap covers almost the whole area of the head portion of male sexual organ in order to protect the head portion from being subjected to sensitizations and stimulation. With the thus constructed condom the female sexual partner receives added pleasure because of the extended portion, and the male partner can prolong the sexual pleasure due to the ejaculation restraining effect of the cap. Therefore, the device according to the present invention brings sexual satisfaction to home life, and assures the successful execution of family planning, as well as preventing veneral diseases including AIDS.
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RELATED APPLICATIONS
[0001] The present invention claim provisional priority to and the benefit of U.S. Provisional Patent Application Ser. No. 12/784,479 filed 20 May 2010 (05/20/2010) (20.05.2010).
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the present invention relate to methods and systems for zonal isolation, where a zone isolation composition is pumped into an annulus between a borehole and a tubular member allowed to set to form an isolation seal, where the seal has a compressibility sufficient for expandable tubing to be expanded without loss in seal integrity. The cured compositions are ideally suited for use with expansion tubing, where the zonal isolation composition must be compressible, while continuing to isolate the zones.
[0004] More particularly, embodiments of the present invention relate to methods and systems for zonal isolation, where the zone isolation composition is pumped into an annulus between a borehole and a tubular member allowed to test to form an isolation seal, where the seal has a compressibility sufficient for expandable tubing to be expanded without loss in seal integrity. The composition includes epoxy resins and hardening agents in the presence or absence of a solvent or solubilizing agent. The invention contemplates different combination of the resins, hardening agents and solubilizing agents for different temperature application: a low temperature zonal isolation composition, a moderate temperature isolation composition and a high temperature isolation composition, where the low temperature composition sets at a low temperature range, the moderate temperature composition set at a moderate temperature range and the high temperature composition sets at a high temperature range. All of the compositions cure to form a compressible zonal isolation epoxy seal capable of use with expansion tubing.
[0005] 2. Description of the Related Art
[0006] Conventional sealants for zonal isolation are cements, foam fluids or resins. In expandable tubing applications, the zonal isolation sealant must be able to compress and to continue to seal after the sealant is pumped behind the pipe and set. Conventional zone isolation systems do not offer the compressibility and/or resilience necessary to permit expandable pipe to expand without fracturing the system due to their hardness obviating zonal isolation. Expandable pipe must, therefore, be expanded prior to the sealant setting. This requires retarding the setting of the sealant for a time sufficient to permit the expandable pipe to be expanded prior to sealant setting. Once the tubing is expanded, the sealant sets. Problems arise when expansion of expandable tubing cannot occur within the retarding window for once the sealant sets, the expandable tubing cannot be expanded due the incompressibility of the cured sealant.
[0007] Thus, there is a need in the art for a sealant that is compressible and/or resilient permitting expandable tubing to be expanded before, during and/or after sealant curing. The solution to these problems is a sealant that is compressible or resilient enough to allow expansion of the expandable pipe before, during or after the material has harden.
SUMMARY OF THE INVENTION
[0008] Embodiments of the present invention provide an epoxy zonal isolation composition including one epoxy resin or a plurality of epoxy resins and one hardening agent or a plurality of hardening agents in the present or absence of a diluent or solvent, where the composition cures to form a cured epoxy zonal isolation composition having sufficient compressibility and/or resilience properties to permit compression of the composition without substantial loss in seal integrity or zonal isolation. In certain embodiments, the compressibility is sufficient to allow expansion of expansion tubing pipe during or especially after hardening or curing of the composition. The sealant compositions are designed to have sufficient strength and bonding characteristics so that the liner, expandable tubing or other tubing inserted into the borehole is held in place in the borehole and the borehole is sealed so that there is no migration of fluids from one zone to another zone. The term substantial loss of seal integrity means that the seal integrity after compression with is at least 75% of the seal integrity before compression. In other embodiments, the term means that the seal integrity after compression with is at least 85% of the seal integrity before compression. In other embodiments, the term means that the seal integrity after compression with is at least 90% of the seal integrity before compression. In other embodiments, the term means that the seal integrity after compression with is at least 95% of the seal integrity before compression.
[0009] Embodiments of the present invention provide an epoxy resin system having desired mechanical properties that allow the epoxy resin system to have improved compressibility and/or resiliency properties.
[0010] Embodiments of the present invention provide a resilient sealant composition for use as a squeeze material to shut off annular gas migration and/or zonal isolation during primary casing or liner top isolation. The sealant composition is unique because the mechanical properties are set to allow the composition to be ductile and offer long term isolation.
[0011] Embodiments of the present invention provide methods for zonal isolation including inserting a tubing into a borehole. After tubing placement, pumping a composition of this invention into an annulus between the wall of the borehole and an outer wall of the tubing. Allowing sufficient time for the composition to cure sealing the annulus. The composition can be pumped in two parts, the resins and the hardening agents are pumped separately downhole and mixed in a static mixing chamber downhole prior to being pumped into the annulus. In the case of expansion tubing, the methods may also include expanding the tubing, where the expansion of the tubing results in a compression of the composition, where the composition maintain isolation after expansion.
[0012] Embodiments of the present invention provide methods for squeeze operations including pumping the composition into annulus or a region, where fluid (gas, liquid, or mixture thereof) migration is occurring to form a seal to reduce or eliminate such migration. The methods may also include isolating the region so that the composition locally reduces or prevents fluid (gas, liquid, or mixture thereof) migration. The methods may also include maintaining isolation until the composition is fully cured.
[0013] Embodiments of the present invention provide a method for zone isolation including pumping an epoxy-based composition in an annulus between a borehole and a tubing string. The composition is then allowed to cure to form a zonal isolation structure comprising the cured composition. The cured composition is compressible and cures at a temperature range between about 50° and about 300° F. The method may also include prior to pumping, isolating a section of an annulus between the borehole and the tubing string so that the zonal isolation structure is located along a length of the tubing string. The method may also include during or after curing, expanding a section of the tubing string, where the compressibility of the cured is sufficient to allow expansion of tubing without substantial loss in seal integrity or zonal isolation. The zonal isolation structure is locate at a distal end of the borehole. The composition comprises one epoxy resin or a plurality of epoxy resins and one hardening agent or a plurality of hardening agents in the present or absence of a diluent or solvent, where the composition cures to form a cured epoxy composition having sufficient compressibility and/or resilience properties to permit compression of the composition without substantial loss in seal integrity or zonal isolation. The diluents comprise aromatic solvents and heterocyclic aromatic solvents or mixtures and combinations thereof. The epoxy resins may comprise a) glycidyl ethers epoxy resin prepared by the reaction of epichlorohydrin with a compound containing a hydroxyl group carried out under alkaline reaction conditions; (b) epoxy resins prepared by the reaction of epichlorohydrin with mononuclear di- and tri-hydroxy phenolic compounds; (c) epoxidized derivatives of natural oils with mixed long-chain saturated and unsaturated acids having between about 14 and 20 carbon atoms; (d) polyepoxides derived from esters of polycarboxylic acids with unsaturated alcohols; (e) polyepoxides derived from esters prepared from unsaturated alcohols and unsaturated carboxylic acids; (f) epoxidized butadiene based polymers; (g) epoxidized derivatives of dimers of dienes, and (h) mixtures or combinations thereof. The epoxy resins may have a molecular weight between about 50 and about 10,000. The curing agents may comprise polyamine curing agents, alkoxylated polyamine curing agents, heterocylic amine curing agents, or similar compounds including a plurality of amino groups, or mixtures and combinations thereof. The curing agents may comprise alkoxylated aliphatic polyamines, alkoxylated cycloaliphatic polyamines, alkoxylated aromatic polyamines, alkoxylated heterocyclic polyamines or mixtures and combinations thereof. The curing agents may comprise alkoxylated N-alkyl- and N-alkylenyl-substituted 1,3-diaminopropanes or mixtures and combinations thereof. The aromatic heterocyclic amine curing agents may comprise pyrrolidine, alkyl pyrrolidines, oxazoline, alkyl oxazolines, triazoles, alkyl triazoles, pyrazolidine, alkyl pyrazolidine, piperidine, alkyl piperidines, piperazine, alkyl piperazines, imidazoline, imidazolidine, alkyl imidazolidines, azepane, alkyl azepane, azepine, alkyl azepines, morpholine, alkyl morpholines, diazapines, alkyl diazapines, or mixtures and combinations thereof. The curing agents comprise alkyl pyridines and DURA COAT 2B™ available from JACAM Chemicals, LLC, of Sterling, KS.
[0014] In certain embodiments, the temperature range is between about 150° F. to about 300° F. and the composition comprises from about 60 wt. % to about 85 wt. % of an epoxy resin or mixture of epoxy resins, from about 1 wt. % to about 15 wt. % of a curing agents, and from about 39 wt. % to about 0 wt. % of a diluent or solvent, where the diluent or solvent is used to reduce the viscosity of the composition. The epoxy resins are glycidyl ethers epoxy resins or mixture of glycidyl ethers epoxy resins, the curing agent is an alkoxylated polyamine or mixture of alkoxylated polyamines and the diluent is an aromatic heterocyclic solvent or mixture of aromatic heterocyclic solvents. The epoxy resin is DURA COAT 1A™ available from JACAM Chemicals, LLC, of Sterling, KS, the curing agent is DURA COAT 2B™ available from JACAM Chemicals, LLC, of Sterling, KS and the diluent is AKOLIDINE™ 11 available from Lonza Group Ltd, Joseph Colleluori, Muenchensteinerstrasse 38, CH-4002 Basel, Switzerland.
[0015] In certain embodiments the temperature range is between about 90° F. and about 150° F. and the composition comprises from about 70 wt. % to about 50 wt. % of an epoxy resin or mixture of epoxy resins and from about 30 wt. % to about 50 wt. % of a curing agents. The epoxy resins may be glycidyl ethers epoxy resin or mixture of glycidyl ethers epoxy resins and the curing agent may be a heterocyclic amine. The epoxy resin may be DURA COAT 1A™ available from JACAM Chemicals, LLC, of Sterling, KS and the curing agent may be a imidazoline or mixture or imidazolines.
[0016] In certain embodiments the temperature range is between about 50° F. and about 90° F. and the composition comprises from about 75 wt. % to about 99 wt. % of an epoxy resin or mixture of epoxy resins and from about 25 wt. % to about 1 wt. % of a curing agents. The epoxy resins may be glycidyl ethers epoxy resin or mixture of glycidyl ethers epoxy resins and the curing agent is a imidazoline, pyrrolidine, pyrrole, pyridine, piperidine or mixtures thereof. The epoxy resin may be DURA COAT 1A™ available from JACAM Chemicals, LLC, of Sterling, KS and the curing agent may be a imidazoline, pyrrolidine, pyrrole, pyridine, piperidine or mixtures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention can be better understood with reference to the following detailed description together with the appended illustrative drawings in which like elements are numbered the same:
[0018] FIG. 1A depicts an annulus between a borehole and a tubing inserted into the borehole.
[0019] FIG. 1B depicts the annulus of FIG. 1A having an sealant supply conduit inserted into the borehole with a packer to prevent the sealant from filling the casing showing the annulus being filled with an epoxy zonal isolation or sealant composition of this invention.
[0020] FIG. 1C depicts the annulus of FIG. 1A after a zone of the borehole has been filled with the epoxy zonal isolation composition.
[0021] FIG. 1D depicts the zone of the annulus of FIG. 1A filled with a compressible, cured epoxy zonal isolation composition after curing.
[0022] FIG. 2A depicts an annulus between a borehole and a tubing inserted into the borehole.
[0023] FIG. 2B depicts the annulus of FIG. 2A having an sealant supply conduit inserted into the borehole with packers and an isolation member to isolate a section of the annulus showing the section being filled with an epoxy zonal isolation or sealant composition of this invention.
[0024] FIG. 2C depicts the annulus of FIG. 2A after the section has been filled with the epoxy zonal isolation composition.
[0025] FIG. 2D depicts the zone of the annulus of FIG. 2A filled with a compressible, cured epoxy zonal isolation composition after curing.
[0026] FIG. 3A depicts an annulus between a borehole and an expandable tubing, where the annulus is being filled with an epoxy zonal isolation composition of this invention.
[0027] FIG. 3B depicts the annulus of FIG. 3A being filled with the epoxy zonal isolation composition.
[0028] FIG. 3C depicts the annulus of FIG. 3A after curing of the epoxy zonal isolation composition in the annulus and inserting of an expansion member at the end of the casing.
[0029] FIG. 3D depicts the zone of the annulus of FIG. 3A after expansion of the casing.
[0030] FIG. 4A depicts a borehole including a region through which fluid flow into and out of the casing.
[0031] FIG. 4B depicts the annulus of FIG. 4A after isolating the region and filling the annulus around the region with the epoxy zone isolation composition.
[0032] FIG. 4C depicts the annulus of FIG. 4A after the annulus region has been filled with the epoxy zonal isolation composition.
[0033] FIG. 4D depicts the zone of the annulus of FIG. 4A filled with a compressible, cured epoxy zonal isolation composition after curing.
[0034] FIG. 5 depicts a viscosity versus temperature plot of an embodiment of a high-temperature zonal isolation composition of this invention compared to its components.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The inventors have found that a thermal setting epoxy based resin system can be used as a zone isolation sealant in downhole zone isolation operations. The epoxy based resin system cures to form a zonal isolation composition having a compressibility sufficient for use in expansion tubing applications, where the composition compresses during tubing expansion without substantial loss in seal integrity, where the term substantial means that the seal integrity after expansion is at least 80% of the seal integrity prior to expansion and after setting. In other embodiments, the seal integrity after expansion is at least 85% of the seal integrity prior to expansion and after setting. In other embodiments, the seal integrity after expansion is at least 90% of the seal integrity prior to expansion and after setting. In other embodiments, the seal integrity after expansion is at least 95% of the seal integrity prior to expansion and after setting. The inventors have also found that the composition may be pumped into an annulus between the wellbore and the expansion tubing, and the tubing expanded while the composition is curing. The compositions of this invention are designed to cure after the composition has been pumped into a zone, where isolation is required or desired. In certain embodiments, the hardening agents have delayed cure on-set. In other embodiments, the hardening agent are added to the resins downhole, just prior to the composition being pumped into the zone. In these latter embodiments, the resin and hardening agents may pass through a static mixer, mechanical mixer, electromechanical mixer or other type of mixer to insure adequate dispersal of the hardening agent in the resin.
[0036] Embodiments of the present invention broadly relate to an epoxy-based zonal isolation composition including one epoxy resin or a plurality of epoxy resins and one hardening agent or a plurality of hardening agents in the present or absence of a diluent or solvent. The composition cures to form a cured epoxy-based zonal isolation composition having sufficient compressibility and/or resilience properties to permit compression of the composition without substantial loss in seal integrity or zonal isolation. In certain embodiments, the compressibility is sufficient to allow expansion of expansion tubing pipe during or especially after hardening or curing of the composition. The sealant compositions are designed to have sufficient strength and bonding characteristics so that the liner, expandable tubing or other tubing inserted into the borehole is held in place in the borehole and the borehole is sealed so that there is no migration of fluids from one zone to another zone.
[0037] Embodiments of the present invention specifically relate to high-temperature epoxy-based zonal isolation compositions including one epoxy resin or a plurality of epoxy resins and one hardening agent or a plurality of hardening agents in the present or absence of a diluent or solvent. The composition is designed to thermally set at temperature between about 150° F. to about 300° F. In certain embodiments, the high-temperature zonal isolation composition includes from about 60 wt. % to about 85 wt. % of an epoxy resin or mixture of epoxy resins, from about 1 wt. % to about 15 wt. % of a curing agents, and from about 39 wt. % to about 0 wt. % of a diluent or solvent. The diluent or solvent is used to reduce the viscosity of the composition. In other embodiments, the high-temperature zonal isolation composition includes from about 65 wt. % to about 85 wt. % of an epoxy resin or mixture of epoxy resins, from about 5 wt. % to about 10 wt. % of a curing agents, and from about 30 wt. % to about 5 wt. % of a diluent or solvent. In other embodiments, the high-temperature zonal isolation composition includes from about 75 wt. % to about 85 wt. % of an epoxy resin or mixture of epoxy resins, from about 5 wt. % to about 10 wt. % of a curing agents, and from about 20 wt. % to about 5 wt. % of a diluent or solvent. In other embodiments, the high-temperature zonal isolation composition includes from about 80 wt. % to about 85 wt. % of an epoxy resin or mixture of epoxy resins, from about 5 wt. % to about 10 wt. % of a curing agents, and from about 15 wt. % to about 5 wt. % of a diluent or solvent. In certain embodiments, the epoxy resin is a glycidyl ethers epoxy resin or mixture of glycidyl ethers epoxy resins, the curing agent is an alkoxylated polyamine or mixture of alkoxylated polyamines and the diluent is an aromatic heterocyclic solvent or mixture of aromatic heterocyclic solvents. In other embodiments, the epoxy resin is DURA COAT 1A™ available from JACAM Chemicals, LLC, of Sterling, KS, the curing agent is DURA COAT 2B™ available from JACAM Chemicals, LLC, of Sterling, KS and the diluent is AKOLIDINE™ 11 available from Lonza Group Ltd, Joseph Colleluori, Muenchensteinerstrasse 38, CH-4002 Basel, Switzerland.
[0038] Embodiments of the present invention specifically relate to mid-temperature epoxy-based zonal isolation compositions including one epoxy resin or a plurality of epoxy resins and one hardening agent or a plurality of hardening agents in the present or absence of a diluent or solvent. The composition is designed to thermally set at temperature between about 90° F. and about 150° F. In certain embodiments, the mid-temperature zonal isolation composition includes from about 70 wt. % to about 50 wt. % of an epoxy resin or mixture of epoxy resins and from about 30 wt. % to about 50 wt. % of a curing agents. In other embodiments, the mid-temperature zonal isolation composition includes from about 60 wt. % to about 50 wt. % of an epoxy resin or mixture of epoxy resins and from about 40 wt. % to about 50 wt. % of a curing agents. In other embodiments, the mid-temperature zonal isolation composition includes from about 55 wt. % to about 50 wt. % of an epoxy resin or mixture of epoxy resins and from about 45 wt. % to about 50 wt. % of a curing agents. The mid-temperature zonal isolation compositions may be diluted with up to about 20 wt. % of a diluent or solvent, where the diluent or solvent is used to reduce the viscosity of the composition. In other embodiments, the epoxy resin is glycidyl ethers epoxy resin or mixture of glycidyl ethers epoxy resins and the curing agent is a heterocyclic amine. In certain embodiments, the epoxy resin is DURA COAT 1A™ available from JACAM Chemicals, LLC, of Sterling, KS, and the curing agent is a imidazoline or mixture or imidazolines.
[0039] Embodiments of the present invention specifically relate to low-temperature epoxy-based zonal isolation compositions including one epoxy resin or a plurality of epoxy resins and one hardening agent or a plurality of hardening agents in the present or absence of a diluent or solvent. The composition is designed to thermally set at temperature between about 50° F. and about 90° F. In certain embodiments, the low-temperature zonal isolation composition includes from about 75 wt. % to about 99 wt. % of an epoxy resin or mixture of epoxy resins and from about 25 wt. % to about 1 wt. % of a curing agents. In other embodiments, the low-temperature zonal isolation composition includes from about 85 wt. % to about 97.5 wt. % of an epoxy resin or mixture of epoxy resins and from about 15 wt. % to about 2.5 wt. % of a curing agents. In other embodiments, the low-temperature zonal isolation composition includes from about 90 wt. % to about 95 wt. % of an epoxy resin or mixture of epoxy resins and from about 10 wt. % to about 5 wt. % of a curing agents. The low-temperature zonal isolation compositions may be diluted with up to about 20 wt. % of a diluent or solvent, where the diluent or solvent is used to reduce the viscosity of the composition. In other embodiments, the epoxy resin is glycidyl ethers epoxy resin or mixture of glycidyl ethers epoxy resins and the curing agent is a heterocyclic amine. In certain embodiments, the epoxy resin is DURA COAT 1A™ available from JACAM Chemicals, LLC, of Sterling, KS, and the curing agent is a imidazoline, pyrrolidine, pyrrole, pyridine, piperidine or mixtures thereof.
[0040] Embodiments of the present invention also broadly relates to methods for zonal isolation including inserting a tubing into a borehole. After tubing placement, pumping a composition of this invention into an annulus between the wall of the borehole and an outer wall of the tubing. The method also includes allowing sufficient time for the composition to cure sealing the annulus. The composition can be pumped in two parts, the resins and the hardening agents are pumped separately downhole and mixed in a static mixing chamber downhole prior to being pumped into the annulus.
[0041] Embodiments of the present invention also provide methods for squeeze operations including pumping the composition into annular spaces, regions or locations in a complete well, where gas or oil migration is occurring to form a seal to reduce or eliminate such migration.
Suitable Materials for Use in the Invention
[0042] Suitable epoxy resin include, without limitation, (a) glycidyl ethers epoxy resin prepared by the reaction of epichlorohydrin with a compound containing a hydroxyl group (e.g., bisphenol A) carried out under alkaline reaction conditions; (b) epoxy resins prepared by the reaction of epichlorohydrin with mononuclear di- and tri-hydroxy phenolic compounds such as resorcinol and phloroglucinol, selected polynuclear polyhydroxy phenolic compounds such as bis(p-hydroxyphenyl)methane and 4,4′-dihydroxy biphenyl, or aliphatic polyols such as 1,4-butanediol and glycerol; (c) epoxidized derivatives of natural oils such as the triesters of glycerol with mixed long-chain saturated and unsaturated acids having between about 14 and 20 carbon atoms (e.g., 16, 18 and 20 carbon atoms) (soybean oil is a typical triglyceride which can be converted to a polyepoxide); (d) polyepoxides derived from esters of polycarboxylic acids such as maleic acid, terephthalic acid, oxalic acid, succinic acid, azelaic acid, malonic acid, tartaric acid, adipic acid or similar acids, with unsaturated alcohols; (e) polyepoxides derived from esters prepared from unsaturated alcohols and unsaturated carboxylic acids; (f) epoxidized butadiene based polymers such as butadiene-styrene copolymers, polyesters available as derivatives of polyols such as ethylene glycol with unsaturated acid anhydrides such as maleic anhydride and esters of unsaturated polycarboxylic acids; (g) epoxidized derivatives of dimers of dienes such as 4-vinyl cyclohexene-1 from butadiene and dicyclopentadiene from cyclopentadiene, and (h) mixtures or combinations thereof. Epoxy resins suitable for use in the invention have molecular weights generally within the range between about 50 and about 10,000. In other embodiments, the range is between about 2000 and about 1500. In other embodiments, the epoxy resin is commercially available Epon 828 epoxy resin, a reaction product of epichlorohydrin and 2,2-bis(4-hydroxyphenyl)propane (bisphenol A) and having a molecular weight of about 400, an epoxide equivalent (ASTM D-1652) of about 185-192. Exemplary examples of some epoxy resins include, without limitation: epoxidized esters of 2,3-epoxypentyl-3,4-epoxybutyrate; 2,3-epoxybutyl-3,4-epoxyhexanoate; 3,4-epoxyoctyl-2,3-epoxycyclohexane carboxylate; 2,3-epoxydodecyl-4,5-epoxyoctanoate; 2,3-epoxyisobutyl-4,5-epoxydodecanoate; 2,3-epoxycyclododedcyl-3,4-epoxypentanoate; 3,4-epoxyoctyl-2,3-epoxycyclododecane carboxylate or similar compounds; and polyepoxides derived from the latter include the following: dimethyl 3,4,7,8-diepoxydecanedioate; dibutyl 3,4,5,6-diepoxycyclohexane-1,2-carboxylate; dioctyl 3,4,7,8-diepoxyhexadecanedioate; diethyl 5,6,9,10-diepoxytetradecanedioate or similar anhydrides. In other embodiments the epoxy resin is DURA COAT 1A™ available from JACAM Chemicals, LLC, of Sterling, KS. Other epoxy resins are available from JACAM Chemicals, LLC, of Sterling, KS or maybe found in U.S. Pat. Nos. 5,936,059; 7,557,169; 7,547,373; 7,267,782; 6,943,219; and 6,277,903.
[0043] Suitable curing agents for the epoxy resins include, without limitation, polyamine curing agents, alkoxylated polyamine curing agents, heterocylic amine curing agents, or similar compounds including a plurality of amino groups, or mixtures and combinations thereof. Exemplary alkoxylated polyamine curing agents include, without limitation, alkoxylated aliphatic polyamines, alkoxylated cycloaliphatic polyamines, alkoxylated aromatic polyamines, alkoxylated heterocyclic polyamines or mixtures and combinations thereof. In certain embodiments, the alkoxylated polyamines are alkoxylated N-alkyl- and N-alkylenyl-substituted 1,3-diaminopropanes or mixtures and combinations thereof. In other embodiments, the alkoxylated polyamines include alkoxylated N-hexadecyl-1,3-diaminopropane, N-tetradecyl-1,3-diaminopropane, N-octadecyl-1,3-diaminopropane, N-pentadecyl-1,3-diaminopropane, N-heptadecyl-1,3-diaminopropane, N-nonadecyl-1,3-diaminopropane, N-octadecnyl-1,3-diaminopropane or mixtures and combinations thereof. In other embodiments, the alkoxylated polyamines include commercially available mixtures of ethoxylated N-alkylated and N-alkenylated diamines. In other embodiments, the polyamine is a commercial product, ethoxylated N-tallow-1,3-diaminopropane, where the degree of ethoxylation is approximately 10 moles ethoxylate per mole of tallow diamine. In other embodiments the epoxy curing agent is DURA COAT 2B™ available from JACAM Chemicals, LLC, of Sterling, KS. Other epoxy curing agents are available from JACAM Chemicals, LLC, of Sterling, KS or may be found in U.S. Pat. Nos. 5,936,059; 7,557,169; 7,547,373; 7,267,782; 6,943,219; and 6,277,903. Exemplary aromatic heterocyclic amine curing agents include, without limitation, pyrrolidine, alkyl pyrrolidines, oxazoline, alkyl oxazolines, triazoles, alkyl triazoles, pyrazolidine, alkyl pyrazolidine, piperidine, alkyl piperidines, piperazine, alkyl piperazines, imidazoline, imidazolidine, alkyl imidazolidines, azepane, alkyl azepane, azepine, alkyl azepines, morpholine, alkyl morpholines, diazapines, alkyl diazapines, or mixtures and combinations thereof. In certain embodiments, the curing agents are a mixture of alkyl pyridines such as AKOLIDINE™ 11, available from Lonza Group Ltd, Joseph Colleluori, Muenchensteinerstrasse 38, CH-4002 Basel, Switzerland and DURA COAT 2B™ available from JACAM Chemicals, LLC, of Sterling, KS. In other embodiments, the diluent is pyrrolidine. In other embodiments, the diluent is imodazoline.
[0044] Suitable diluents or solvents for use in the present invention include, without limitation, aromatic solvents and heterocyclic aromatic solvents or mixtures and combinations thereof. Exemplary examples include, without limitation, benzene, toluene, xylene, aromatic oils, aromatic naphtha, pyrrole, alkyl pyrrols, imidazole, alkyl imidazole, pyridine, alkyl pyridines, pyrazole, alkyl pyrazoles, oxazole, alkyl oxazoles, or mixtures and combinations thereof.
DETAILED DESCRIPTION OF THE DRAWINGS
[0045] Referring now to FIGS. 1A-D , an embodiment of a zonal isolation procedure of this invention, generally 100 , is shown to include well borehole 102 having a wall 104 . Inserted into the borehole 102 is a casing string 106 , which has a distal end 108 disposed near a bottom 110 of the well 102 . Looking at FIG. 1B , a supply conduit 112 including a packer 114 is inserted into the borehole 102 and an epoxy-based zonal isolation composition 116 of this invention is pumped into the borehole 102 through the conduit 112 and into an annular space 118 between the wall 104 of the borehole 102 and an outer wall 120 of the casing 106 . Looking at FIG. 1C , pumping is continued until the composition 116 fills the annular space 118 to a desired level 122 in the borehole 102 and the conduit 112 and packer 114 are removed (shown after equipment removal). Looking at FIG. 1D , the composition 116 cures to form a cured, epoxy-based zone isolation structure 124 .
[0046] Referring now to FIGS. 2A-D , another embodiment of a zonal isolation procedure of this invention, generally 200 , is shown to include well borehole section 202 having a wall 204 and including a casing string 206 extending through the section 202 . Looking at FIG. 2B , the section 202 is shown equipped with a bottom zone isolation sealing member 208 , outlets 210 , and a supply conduit 212 including packers 214 . An epoxy-based zonal isolation composition 216 of this invention is then pumped through the conduit 212 into an annular space 218 between the wall 204 of the section 202 above the member 208 . Looking at FIG. 2C , pumping is continued until the composition 216 fills the annular space 218 to a desired level 220 in the section 202 . The conduit 212 and packers 214 are then removed (shown after equipment removal). Looking at FIG. 2D , the composition 216 cures to form a cured, epoxy-based zone isolation structure 222 within the section 202 .
[0047] Referring now to FIGS. 3A-D , an embodiment of an expansion tubing procedure of this invention, generally 300 , is shown to include well borehole 302 having a wall 304 and including a casing string 306 extending through the borehole 302 , where the casing 306 has a distal end 308 disposed near a bottom 310 of the borehole 302 . The casing 306 also includes an expandable section 312 . Looking at FIG. 3B , the borehole 302 is shown equipped with a supply conduit 314 including a packer 316 . An epoxy-based zonal isolation composition 318 of this invention is then pumped through the conduit 314 into an annular space 320 between the wall 304 of the borehole 302 . Pumping is continued until the composition 318 fills the annular space 320 to a desired level 322 in the borehole 302 . The conduit 314 and packer 316 are then removed (not shown) and the composition 318 allowed to cure to form a cured, epoxy-based zone isolation structure 324 within the borehole 302 . An expansion member 326 is then inserted into the casing 306 and the tubing is expanded by pulling the expansion member 326 through the expansion section 312 of the casing 306 to expand the expansion section 312 as shown in FIG. 3C . The expansion operation results in a compression of the cured, epoxy-based zone isolation structure 324 to form a compressed, cured, epoxy-based zone isolation structure 328 as shown in FIG. 3D . Additional details on expansion tubing, how it is expanded and used in downhole applications may be found in, published Apr. 1, 2010 and U.S. Pat. Nos. 3,049,752, 3,678,560, 3,905,227, 4,204,426, 4,616,987, 5,271,469, 5,271,472, 5,947,213, 6,112,809, 6,296,057, 6,843,317, 6,880,632, 7,182,141, 7,215,125, 7,500,389, 7,634,942, and United States Published Application No. 20030111234, 20040099424, 20040154797, 20040163819, 20040216925, 20050173109, 20050173130, 20050279514, 20050279515, 20060027376, 20070151360, 20080083533 and 20100078166.
[0048] Referring now to FIGS. 4A-D , an embodiment of a squeeze out procedure of this invention, generally 400 , is shown to include well borehole section 402 having a wall 404 and including a casing string 406 extending through the section 402 . The section 402 includes a region 408 through which fluid flow into and out of the casing 406 . This region 408 may result in contamination of production fluids, treating fluids, or other fluids typically used in downhole operations. To reduce or eliminate the flow of fluid through the region 408 , a sealant of this invention can be pumped into the region 408 , and after curing, the sealant will form a seal reducing or eliminating fluid flow into and out of the casing 406 . Looking at FIG. 4B , the section 402 is shown equipped with a supply conduit 410 including packers 412 . An epoxy-based zonal isolation composition 414 of this invention is then pumped through the conduit 410 into an annular space 416 between the wall 404 of the section 402 and an outer wall 418 of the casing 406 . Looking at FIG. 4C , pumping is continued until the composition fills the annular space 416 to a desired level 420 in the section 402 . The conduit 410 and packers 412 are then removed (shown after equipment removal). Looking at FIG. 4D , the composition 414 cures to form a cured, epoxy-based zone isolation structure 422 within the section 402 reducing or eliminating flow through the case 406 at the region 408 .
EXPERIMENTS OF THE INVENTION
Example 1
[0049] This example illustrates the formulation of an epoxy zonal isolation composition for high temperature applications, where the composition has a set temperature in a high-temperature range between about 150° F. to about 300° F.
[0050] 22.6 grams of DURA COAT 1A™ available from JACAM Chemicals, LLC, of Sterling, KS was added to 2.6 grams of Akolidine 11 with mixing. To this solution was added 2.0 grams of DURA COAT 2B™ available from JACAM Chemicals, LLC, of Sterling, KS to form a high-temperature zonal isolation composition (HTZIC) of this invention. Table I tabulates the components, the amount and weight percentages of the HTZI composition of this invention, while Table II tabulates properties of the components.
[0000]
TABLE I
High-Temperature Zone Isolation Composition
Component
Weight (g)
Percent (w/w)
DURA COAT 1A ™
22.6
83.1
DURA COAT 2B ™
2.0
7.3
AKOLIDINE ™ 11
2.6
9.6
Total
27.2
100
[0000]
TABLE II
Properties of the Components and HTZIC
r @ 25° C. (g/
SG @
Component
Color
pH
cm 3 )
25° C.
DURA COAT 1A ™
Colorless
9.02
1.16094
1.16473
DURA COAT 2B ™
Brown
10.92
0.93827
0.94105
AKOLIDINE ™ 11
Dark Brown
3.14
0.93394
0.93685
HTZI
Dark Brown
8.40
1.11433
1.11763
[0051] Referring now to FIG. 5 , a plot of viscosity versus temperature is shown for the components used in making the HTZI composition and the composition.
Example 2
[0052] This example illustrates the formulation of an epoxy zonal isolation composition for mid-temperature applications, where the composition has a set temperature in a mid-temperature range between about 90° F. and about 150° F.
[0053] 50 grams of DURA COAT 1A™ available from JACAM Chemicals, LLC, of Sterling, KS was added to 50 grams of imodaziline to form a mid-temperature zonal isolation (MTZI) composition of this invention. Table III tabulates the components, the amount and weight percentages of the MTZI composition of this invention.
[0000]
TABLE III
Mid-Temperature Zone Isolation Composition
Component
Percent (w/w)
r (g/cm 3 )
DURA COAT 1A ™
50
1.16
Imidazoline
50
Total
100
Example 3
[0054] This example illustrates the formulation of an epoxy zonal isolation composition for low-temperature applications, where the composition has a set temperature in a low-temperature range between about 50° F. and about 90° F.
[0055] 92.5 grams of DURA COAT 1A™ available from JACAM Chemicals, LLC, of Sterling, KS was added to 7.5 grams of pyrrolidine to form a low-temperature zonal isolation (LTZI) composition of this invention. Table IV tabulates the components, the amount and weight percentages of the LTZI composition of this invention.
[0000]
TABLE IV
Low Temperature Zone Isolation Composition
Component
Percent (w/w)
r (g/cm 3 )
DURA COAT 1A ™
92.5
1.16
Pyrrolidine
7.5
0.86
Total
100
[0056] All references cited herein are incorporated by reference for every purpose permitted by controlling United States Laws. Although the invention has been disclosed with reference to its preferred embodiments, from reading this description those of skill in the art may appreciate changes and modification that may be made which do not depart from the scope and spirit of the invention as described above and claimed hereafter.
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Epoxy-based zonal isolation compositions are capable of being adjusted by varying the epoxy-based compositions for isolating zones in borehole of oil and gas wells under high-temperature, mid-temperature and low-temperature conditions.
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BACKGROUND OF THE INVENTION
The invention relates to a method and apparatus for the production of yarn.
Synthetic fibers are commonly produced by extruding molten polymer through a spinneret. In order to produce yarns which have properties approximating those of wool or other natural materials, it is common practice to subject the extrudate from the spinneret to a texturing process. This can be accomplished by a variety of procedures known in the art, such as stuffer-box crimping, false twisting, and fluid jet texturing. One particularly effective procedure involves passing the yarn to be textured and a high velocity fluid to a first passage. Subsequently, the yarn and the fluid are passed to an enlarged passage and then to a zone where the yarn is restrained and cooled. In the restraining zone individual stacked members, such as balls are used to exert a force on the yarn to restrain the yarn, which is in the form of a yarn wad. The fluid escapes from the yarn through the voids between the stacked members and a textured yarn is removed from the restraining zone. Although this procedure produces a high quality textured yarn, a particularly troublesome problem involves loss of the stacked members from the restraining zone. Frequently, stacked members become entrained in the yarn wad and are carried away from the restraining zone. Also sudden disruptions in the texturing process cause the stacked members to be thrown from the restraining zone. In addition, operators occasionally knock stacked members from the restraining zone during string up and maintenance of the equipment. Further, recovering the stacked members from the floor and/or replacing them with new ones involves considerable expense, particularly where a number of such processing lines are used.
Although it would appear such a problem could be easily solved, this has not been the case. In order for the stacked members to function properly, they must be free to act upon the yarn wad, and in addition, the restraining zone containing the stacked members must be designed to allow the operator to easily string up and maintain the equipment. It has been very difficult to satisfy both of these conditions simultaneously. However, the present invention achieves such a result.
It is an object of the invention to restrain yarn.
Another object of the invention is to restrain and cool yarn textured using a fluid jet texturing process.
Another object of the invention is to eliminate the loss of stacked members from a restraining zone.
Still another object of the invention is to provide an apparatus useful for restraining yarn.
Yet another object of the invention is to provide an apparatus useful to cool and restrain yarn textured with a fluid jet wherein the apparatus contains individual stacked members which are not removed from the apparatus by the operation thereof.
Other aspects, objects, and advantages of the invention will be apparent to those skilled in the art upon studying the drawings, specification, and the appended claims.
SUMMARY OF THE INVENTION
In accordance with the invention, a textured yarn is passed to a restraining zone containing a flexible sleeve through which the yarn is passed and a plurality of individual stacked members, said flexible sleeve being positioned so as to prevent said stacked members from being removed from said restraining zone as the stacked members exert a force upon the flexible sleeve which in turn exerts a restraining force upon the yarn.
Further according to the invention, an apparatus for restraining yarn comprises a chamber having an inlet and an outlet and an inner and outer surface; a flexible sleeve having an inlet and an outlet through which the yarn is directed and an inner and an outer surface, the inlet of the flexible sleeve being attached to the inlet of the chamber and the sleeve being positioned in and extending through the chamber; and a plurality of individual stacked members positioned in the chamber between the inner surface thereof and the outer surface of the flexible sleeve.
DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an embodiment of the apparatus of this invention and a fluid jet which is employed to texture the yarn.
FIG. 2 is a plan view of the embodiment of FIG. 1.
FIG. 3 illustrates another embodiment of the invention used with a fluid jet.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings and to FIG. 1 in particular, there is shown a crimping or texturing apparatus generally designated by reference numeral 10. This apparatus comprises an elongated sleeve 11 which has a hollow needle 12 positioned in the inlet section thereof. An elongated plug 14 is disposed in the outlet section of sleeve 11. Plug 14 has a central opening 14b therethrough. The inlet of opening 14b is tapered to provide a seal 14a adjacent the tip of the needle 12. The outlet of central opening 14b constitutes a section 14c of increased diameter. A conduit 17 communicates with sleeve 11 adjacent needle 12 to introduce a fluid, such as steam or air, at an elevated temperature. The above described apparatus is generally known as a fluid jet for texturing yarn.
Further according to the invention, a hollow chamber 18 having an inlet 18a is mounted immediately above sleeve 11 to receive yarn which is crimped in the fluid jet. A large number of relatively small individual stacked members, such as balls, 19a and 19b, are disposed within chamber 18. Chamber 18 can be provided with an outlet conduit 21 which is connected to a drain or to a source of reduced pressure, not shown. A screen 21a is positioned across conduit 21 to retain balls 19a and 19b within chamber 18. A plurality of rigid members 24, generally defining a rigid cylindrical sleeve, are used to guide the yarn wad 20c. A flexible sleeve 26 is attached to the inlet 18a of chamber 18 using a clamp 27 and is positioned between the stacked members 19a, 19b and the yarn wad 20c. The upper end of sleeve 26 can be loose or, as shown in FIG. 3, the flexible sleeve 26 can be extended to enclose the stacked members 19a, 19b by clamping an extended portion of the flexible sleeve 26a to the hollow chamber 18 with clamp 28.
In the operation of the apparatus of FIG. 1, one or more filaments 20a are inserted through needle 12 into the central passage of plug 14. These filaments can be delivered to the apparatus by any suitable feed means, not shown. In the normal start-up operation, the filaments are threaded completely through the apparatus. Fluid is introduced through conduit 17 and flows upwardly through plug 14 into chamber 18. In the present embodiment which employs a fluid jet to texture the yarn, chamber 18 functions both as a restraining zone and a cooling zone. The fluid so introduced surrounds needle 12 to elevate the temperature of the incoming filaments. The velocity of the introduced fluid is sufficiently high to produce a zone of substantial turbulence in the outlet region 14c of plug 14. The yarn 20b in the turbulent zone passes upwardly to form an elongated generally cylindrical wad 20c in the center of chamber 18 which is guided by a plurality of rigid members, such as rods 24. This wad 20c passes through the flexible sleeve 26 which is surrounded by a plurality of stacked members, such as balls 19a and 19b. The balls confine and restrain the yarn wad, but they are prevented from becoming entrained in the yarn wad by the flexible sleeve. The fluid passes through pores in the flexible sleeve and into the voids between the individual stacked members. The yarn is cooled in passing through chamber 18 so that permanent crimps are imparted. The resulting textured yarn 20d is removed through a take-up device 30 and passed to a storage zone, not shown.
The velocity and temperature of the fluid introduced through conduit 17 are such as to impart the desired degree of crimp in the yarn. If desired, an external heater can be employed to assist in elevating the temperature of the crimping apparatus 10. The texturing fluid passes upwardly through the central opening 14b of plug 14, into chamber 18, and out through flexible sleeve 26 and voids between the stacked members, such as balls 19a, and 19b.
The stacked members can be formed of metal, glass or any other material which is inert to the yarn at the temperatures encountered. Stacked members in the shape of spheroids or balls have produced good results; however, the invention is not limited to the use of balls as the stacked members, since other configurations of stacked members are also suitable, such as for example ellipsoids. As illustrated, stacked members 19a are larger than stacked members 19b to provide better packing; however, the stacked members can be all the same size. The height of the stacked members in chamber 18 should be sufficient to produce the desired degree of restraint.
It is important to point out that when the restraining zone of the present invention is in communication with a fluid jet texturing zone, and thus is used therewith, the restraining zone also functions as a cooling zone, particularly where the flexible sleeve contains pores through which the fluid can pass. However, it is equally important to point out that although the present invention finds particular applicability when used in conjunction with a fluid jet texturing zone, that the invention should not be limited thereby in its broadest aspect. In general, the present invention can be used with most any process or apparatus in which it is desirable to use a container of stacked members through which a product passes and in which it is desirable to prevent the stacked members from being removed from the container.
As for the construction of flexible sleeve 26, a variety of materials are suitable. For example, flexible materials such as nylon, polyester, polyolefins, glass, metal wire and polytetrafluoroethylene can be used to advantage. Suitable materials are usually woven or formed into the flexible sleeve. Generally, flexible sleeve 26 is constructed with a cross-sectional area larger than that of section 14c; however, the cross-sectional area of the flexible sleeve can be smaller than that of section 14c if the flexible sleeve is capable of expanding sufficiently to permit the stacked members to exert the primary restraining force on the yarn wad rather than the flexible sleeve. It is emphasized that the purpose of the flexible sleeve is to isolate the stacked members from the yarn, that is, to prevent the stacked members from becoming entrained in the yarn; but at the same time the flexible sleeve permits the stacked members to restrain the yarn. When used with a fluid jet, the flexible sleeve 26 should contain pores which are of sufficient size to permit passage of the fluid but not the stacked members or balls 19a, 19b as shown in FIG. 1. In FIG. 2, the rigid sleeve as indicated by rods 24, is positioned on the yarn side of the flexible sleeve 26; however, the flexible sleeve can be positioned on the yarn side of the rigid sleeve if desired.
In one specific example of this invention utilized in conjunction with a fluid jet as illustrated in FIG. 1, balls 19a had a diameter of about one-fourth inch; and balls 19b had a diameter of about one-eighth inch. Approximately 70 percent of the total number of balls in chamber 18 were balls of 1/4-inch diameter. Chamber 18 had an internal diameter of about 3 inches, with the depth of balls being about 4 inches. The diameter of the yarn wad produced in the fluid jet was approximately three-fourth inch. The flexible sleeve was constructed from nylon 6, 6 double knit, which had 44 courses per inch and 32 wales per inch. The nylon double knit was made from 100 denier, 34 filament yarn. The flexible sleeve was 13/4 inches inside diameter and 53/4 inches long.
In one specific mode of operation, a bundle of 126 polypropylene filaments having a denier of about 1800-2000 was introduced into the above described fluid jet at a velocity of about 1000-1100 meters per minute. Superheated steam at 90 psig and 365°F was introduced at a rate of about 20 pounds per hour. The textured yarn was removed at a velocity of about 800 meters per minute.
Approximately 30 pounds of textured yarn were produced employing the above apparatus. No balls were carried away from the hollow chamber of entrainment in the yarn wad or thrown from the hollow chamber due to disruptions in the texturing process. Also string up by the operator was readily accomplished.
While this invention has been described in conjunction with presently preferred embodiments, it obviously is not limited thereto.
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Yarn is passed to a texturing zone wherein a yarn wad is formed, and the yarn wad is then passed through a flexible sleeve in a restraining zone wherein the yarn wad is restrained by a plurality of individual stacked members. In addition an apparatus is provided useful in the method of the invention.
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BACKGROUND OF THE INVENTION
[0001] 1) Field of the Invention
[0002] The present invention relates to technology for reading tag data included in a compressed data file.
[0003] 2) Description of the Related Art
[0004] Advancement in data compression technology in recent years has made it possible to compress audio data such as songs, music, etc. and video data such as movies and be used as digital data. The compressed digital data is recorded on an optical recording medium such as a compact disk (CD), a digital versatile disk or digital video disk (DVD), or a magneto optical recording medium such as a mini disk (MD), or a magnetic recording medium such as a hard disk. The digital data is decoded and played in a predetermined format by a suitable player.
[0005] For instance, MP3 (MPEG1 Audio Layer 3) is a widespread audio data compression technology that allows compression of audio data such as songs, music, etc. without degrading the sound quality. The music data compressed by means of the MP3 method is stored on a CD in the form of an MP3 file and is played by an MP3 file player. However, when the number of MP3 files on a CD becomes considerable, it is difficult to recognize the contents of the MP3 files merely by their titles. Therefore, an area called ID3Tag is secured in the MP3 file for storing text data pertaining to the MP3 file such as the title of the music data, artist name, etc. The format of the ID3Tag that is compatible with most of the MP3 file players is called ID3Tag Ver1. A fixed length data area of 128 bytes, containing data such as the title, artist name, etc. of the MP3 file, is appended to the end of the MP3 file. FIG. 1 is a schematic diagram of an MP3 file structure in which the ID3Tag Ver1 is appended to the music data. As shown in FIG. 1 , an MP3 file 1 includes music data 2 in the form of compressed song or music data and an ID3Tag Ver1 (hereinafter, “ID3Tag”) 3 appendedappended to the end of the music data 2 and that stores information pertaining to the music data 2 . A recording medium usually stores a series of MP3 files 1 a, 1 b, 1 c, and so on, of the aforementioned format.
[0006] A process of how an MP3 file player reads the ID3Tag is explained next. FIG. 2 is a flowchart of a conventional method by which the MP3 file player reads the ID3Tag. FIG. 3 is a schematic for explaining the conventional method. When a user selects an MP3 file, the MP3 file player searches for the address of the specified MP3 file on the recording medium (step S 11 ). That is, the MP3 file player retrieves from header data of the MP3 file, the data required for playing the music data, such as bit rate, sampling, etc. Based on the data volume of the specified MP3 file, the MP3 file player calculates the address of the ID3Tag, and searches for the calculated address of the ID3Tag (step S 12 ). The MP3 file player then reads the ID3Tag (step S 13 ), retrieves the text data recorded in the data area, and displays it on a display unit of the MP3 file player (step S 14 ). The MP3 file player then searches again for the starting position address of the MP3 file specified by the user (step S 15 ), and starts playing the music data (step S 16 ), thus ending the reading process of the ID3Tag.
[0007] Thus, the conventional MP3 file player automatically reads the ID3Tag before playing the MP3 file specified by the user. Even if the ID3Tag is blank, the conventional MP3 player without fail performs reading of the ID3Tag and only then plays the music data, resulting in unnecessary delay. The audio player disclosed in Japanese Patent Laid-Open Publication No. 2002-245720 is provided with a read specifying unit which allows the user to specify beforehand whether to read the ID3Tag prior to playing the MP3 file. If the user specifies that the ID3Tag is not be read, the audio player directly plays the MP3 file without reading the ID3Tag, and if the user specifies that the ID3Tag is to be read, the audio player plays the MP3 file after reading the ID3Tag. Thus, when the user specifies that the ID3Tag is not be read, the loading of the MP3 file can be started early; however, the ID3Tag data will not be displayed on the audio player. If the user specifies that the ID3Tag is to be read, the process until the time the MP3 file is played gets very complex, as shown in FIG. 2 and FIG. 3 . For instance, as shown in FIG. 3 , if the user selects the MP3 file 1 b while the MP3 file 1 a is playing or after the MP3 file has finished playing, the audio player will need to perform a total of three searches, namely, for the starting position of the MP3 file 1 b (music data 2 b ), the starting position of the ID3Tag 3 b, and the starting position of the MP3 file 1 b. Therefore, there is a delay between the time the MP3 file is specified and the time when the MP3 starts playing.
[0008] According to the technology disclosed in Japanese Patent Laid-Open Publication No. 2002-245720, specification can be made in the audio player not to read the ID3Tag to shorten the duration until the next file is played. However, even though the duration is reduced, the disadvantage is that the user will not be able to see the data of the ID3Tag.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to at least solve the problems in the conventional technology.
[0010] According to an aspect of the present invention, a method for reading tag data of a compressed data file that includes compressed data and a data tag appended to the compressed data at a predetermined position, and performing a predetermined process based on a type of compressed data, includes searching a starting position of the tag data in the compressed data file, retrieving the tag data, and then searching a starting position of the compressed data.
[0011] According to another aspect of the present invention, a device that reads tag data of a compressed data file that includes compressed data and a data tag appended to the compressed data at a predetermined position and performs a predetermined process based on a type of compressed data, includes a searching/retrieving unit that first searches a starting position of the tag data in the compressed data file, retrieves the tag data, and then searches a starting position of the compressed data.
[0012] According to still another aspect of the present invention, a computer-readable recording medium stores therein a computer program that causes a computer to implement the above method.
[0013] The other objects, features, and advantages of the present invention are specifically set forth in or will become apparent from the following detailed description of the invention when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic diagram of an MP3 file structure in which ID3Tag Ver1 is appended to music data;
[0015] FIG. 2 is a flowchart of a conventional method for reading the ID3Tag by an MP3 file player;
[0016] FIG. 3 is a schematic diagram of the conventional method for reading the ID3Tag by the MP3 file player;
[0017] FIG. 4 is a flowchart of a reading process of tag data of compressed data file according to the present invention;
[0018] FIG. 5 is a block diagram of an example of an MP3 file player; and
[0019] FIG. 6 is a schematic diagram of a process of the reading method of the ID3Tag of the MP3 file.
DETAILED DESCRIPTION
[0020] Exemplary embodiments of the present invention-are explained next with reference to the accompanying drawings. The present invention is not limited by these embodiments and modes of operation.
[0021] The method for reading tag data of a compressed data file according to the present invention can be applied to any compressed data file to which tag data of a fixed length containing information pertaining to the compressed data is appended at a predetermined position of the compressed data such as music data and video data containing compressed audio data and video data. For instance, the method can be applied to reading of tag data carried out by the compressed data player that reads compressed data file to which tag data of a fixed length is appended to the beginning of the compressed data or, as shown in FIG. 1 , to the end of the compressed data, and carries out predetermined processes such as playing the compressed data file. The compressed data in the explanation that follows can assumedly be stored in any optical recording medium such as a CD, or DVD, or any magneto optical recording medium such as an MD or a magneto optical disk (MO), or any magnetic recording medium such as the hard disk.
[0022] FIG. 4 is a flowchart of the reading process of tag data of compressed data file according to the present invention. When switching from the currently playing compressed data file to another compressed data file, the compressed data player calculates the starting position address of the tag data of the compressed data file to be accessed and searches for the calculated address of the tag data (step S 21 ). For example, if the tag data of a fixed length is appended to the beginning of the compressed data, the compressed data player searches for the starting portion address of the compressed data file to be accessed. If in the compressed data file the tag data of a fixed length is appended to the end of the compressed data, the compressed data player calculates the ending position address of the compressed data file by means of the starting position address and the size of the compressed data file to be accessed, deducts the size (fixed length) of the tag data from the ending position address to calculate the starting position address of the tag data, and searches for the calculated starting position address of the tag data.
[0023] The compressed data player reads the tag data from the found address (step S 22 ), retrieves the text data recorded in the data area, and displays the text data of the compressed data player on the display unit (step S 23 ). Following this, the compressed data player searches for the starting position address of the compressed data in the compressed data file to be accessed (step S 24 ), and starts the reading process of the compressed data (step S 25 ), thereby ending the reading process of the tag data of the compressed data file.
[0024] It is also possible to provide a computer program that causes a computer to read the tag data of a compressed data file appended to a predetermined position of the compressed data. The computer program can be provided either in installable form or executable form on a computer-readable recording medium such as a compact disk read only memory (CD-ROM), a floppy (Registered Trademark) disk, a DVD. Alternatively, the computer program can be stored on another computer connected to a network such as the Internet, and downloaded from the network. This enables the computer to load and execute the computer program.
[0025] According to the present embodiment, when switching from a currently playing compressed data file to another compressed data file, the compressed file player searches for the starting position address of the tag data of the other compressed data file, reads the tag data, and then searches for the starting position address of the compressed data, and performs the predetermined process. Consequently, when switching from one compressed data file to another, the duration up to the time when the processing of the other compressed data file begins is shortened.
[0026] A practical example will be explained below. In this practical example, an MP3 file shown in FIG. 1 is taken as an example of a compressed file. Precisely, the MP3 file includes music data compressed by means of MP3 method and a tag data ID3Tag Ver1 (hereinafter, “ID3Tag”) of a fixed length of 128 bytes appended to the end of the compressed music data. It is assumed that an MP3 file player is used for playing the compressed MP3 file.
[0027] FIG. 5 is a block diagram of an example of an MP3 file player. An MP3 file player 10 includes a reading unit 11 that reads the MP3 files recorded on a recording medium such as a CD, DVD, MD, or hard disk, a decoding unit 12 that decodes the music data of the MP3 file read by the reading unit 11 , an output unit 13 that outputs as a sound signal the decoded music data by either digital/analog conversion or amplification, a display unit 14 consisting of a display device such as liquid crystal display (LCD) that performs a predetermined display process, an input unit 15 consisting of either a keyboard, or various keys such as play, pause, cursor, etc. and that enables a user perform an input process, and a system controller 16 that controls the processes of the aforementioned parts. The system controller 16 consists of a central processing unit (CPU) 17 , a read only memory (ROM) 18 , and a random access memory (RAM) 19 . Upon receiving from the user an input via the input unit 15 , the CPU 17 reads from the ROM 18 the control programs or application programs required for the MP3 file player 10 , stores these control programs and application programs in a program storage area in the RAM 19 , and executes the various processes. The CPU 17 temporarily stores the various data that result from these processes in a data storage area in the RAM 19 . In this way the CPU 17 controls the various processes of the MP3 file player 10 . The system controller 16 executes an ID3Tag reading program to carry out the reading process of the ID3Tag of the MP3 file.
[0028] FIG. 6 is a schematic for explaining how the MP3 file player reads the ID3Tag of the MP3 file. The reference numerals in FIG. 6 correspond to the step numbers in the flowchart shown in FIG. 4 . Assume, for instance, that the user inputs via the input unit 15 an instruction to play the MP3 file 1 b while the MP3 file 1 a is playing. The system controller 16 calculates the starting position of the IDTag 3 b of the MP3 file 1 b from the starting point address and the size of the MP3 file 1 b as well as the fixed length of the ID3Tag, and the reading unit 11 searches the starting position of the ID3Tag 3 b of the MP3 file 1 b (step S 21 ). In other words, the system controller 16 determines the ending position address of the MP3 file 1 b from the starting position address and the size of the specified MP3 file 1 b, and the reading unit 11 determines the starting position address of the ID3Tag 3 b by deducting the predetermined length (that is, 128 bytes) from the ending position address.
[0029] The reading unit 11 then carries out the reading process of the ID3Tag 3 b (step S 22 ), and the system controller 16 displays the read data on the display unit 14 (step S 23 ). Once the reading process of the ID3Tag 3 b is completed, the reading unit 11 , searches for the starting position address of the MP3 file 1 b (step S 24 ) and starts the reading process of the music data 2 b (step S 25 ). When reading, the reading unit 11 first retrieves from the head data of the MP3 file, information such as bit rate, sampling rate, etc., required for playing the music data, followed by the music data 2 b. The decoding unit 12 carries out a decoding process on the read music data. The output unit 13 carries out the playing process of the music data by outputting sound signals, thereby ending the ID3Tag reading process.
[0030] A case of the user inputting, by means of the input unit 15 , the instruction to play the MP3 file 1 b while the MP3 file 1 a is playing has been presented as an example. However, the process of the MP3 file player 10 remains the same for playing the next MP3 file 1 b after the current MP3 file 1 a has finished playing.
[0031] If the user instructs, by means of play instruction, to play another MP3 file, in the conventional method, the reading unit 11 first searches for the starting point address of the requested MP3 file 1 , searches for and reads the starting point address of the ID3Tag 3 , and once again searches for the starting point address of the MP3 file 1 to play the music data 2 . On the contrary, in the present practical example, the reading unit 11 searches for the starting point of the ID3Tag 3 and follows it up with a search for the starting point of the MP3 file 1 , then starts reading the data, thus playing the MP3 file 1 . In other words, in the present practical example, as shown in FIG. 3 , the need for the reading unit 11 to access the starting point of the next MP3 file 1 is obviated when changing the MP3 file, thereby reducing the duration between the stopping of the earlier MP3 file and the starting of the music data 2 .
[0032] According to the present practical example, when there is an instruction for the currently playing MP3 file 1 to be changed, the starting point of the ID3Tag 3 of the MP3 file 1 to be played next is searched and read following which the starting point of the music data 2 of the MP3 file 1 is searched and played. Consequently, the duration between the stopping of the previous MP3 file 1 and starting of the next MP3 file 1 is reduced. Further, the display of the data stored in the ID3Tag 3 as well as the reduction of the duration up to the time the data is displayed is achieved without the user having to specify.
[0033] Although the invention has been described with respect to a specific embodiment 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 teaching herein set forth.
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A method for reading tag data is provided, involving reading a compressed data file that includes compressed data and tag data of a fixed length appended to the compressed data at a predetermined position, and performing a predetermined process based on the type of the compressed data. The reading process of the compressed data file includes first searching for the starting position of the tag data of the compressed data file and retrieving the tag data, followed by searching for the starting position of the compressed data.
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BACKGROUND OF THE INVENTION
This invention relates to an improved form of composite golf shaft. In particular, this invention is concerned with a golf shaft having a tubular metallic core having graphite fiber reinforcing layers superimposed thereon.
There are numerous factors which affect the performance characteristics of golf shafts such as weight and balance of the shaft, the flexibility of the shaft and the ability of the shaft to withstand shock. Additionally, of course, a golf shaft of optimum design must maintain its performance characteristics over a wide range of ambient weather conditions, and it should be resistant to moisture and other corrosive elements such as hand perspiration and the like.
In addition to the foregoing considerations, it is well known that there is a somewhat intangible, but nonetheless real and important, characteristic of a golf shaft referred to as the "feel" which has a very definite effect on the playability of the shaft as well as the commercial acceptance of the shaft.
A considerable amount of effort has been expended in the past to produce golf club shafts having the desired performance characteristics. Thus, golf club shafts have been made from wood, such as hickory, and metals, such as steel and aluminum. The wooden shafts have the advantage of not transferring vibrational shocks to the player when the ball is struck during play. On the other hand, the wooden shafts suffer from the disadvantage that they are not easily matched into a complete set. They are very much subject to changes in climatic weather conditions. Metal shafts generally are not susceptible to variations in physical characteristics and response to climatic changes; however, tubular metal golf shafts transfer a great amount of vibration to the player when the club head strikes the golf ball. Attempts have been made to remedy the deficiencies of the tubular golf shafts by coating the metal tube with a resin-impregnated glass fiber. Use of such resin-impregnated glass fiber coatings on tubular shafts, however, has the tendency to provide a dampening effect on the vibrations normally experienced. Nonetheless, such coatings have introduced other changes in the playing characteristics of the club. Indeed, one of the particular difficulties associated with fiber reinforced resin coatings on tubular metal shafts is associated with the significant difference in the physical properties of the two essential materials, i.e. the metal and the glass fiber. To get the requisite performance from the golf shaft, both materials must be combined in such a way as to operate harmoniously in producing the desired result. This has not been readily achieved in the past. Moreover, glass fiber reinforced metal tubes tend to require increased weight to maintain the requisite torsional and bending stiffness. Finally, it is worth noting that durability tends to be a problem when bonding dissimilar materials. Consequently, there still remains need for an improved golf shaft that will have the necessary strength and weight and which will permit the player to attain greater hitting force and control and which can be accurately adjusted to provide a set of matched golf clubs each having the same "feel".
SUMMARY OF THE INVENTION
According to the present invention, an improved golf shaft comprises at least two superimposed strips of sheet material of resin impregnated unidirectional continuous graphite fiber reinforcements in a resin matrix spirally wound on top of a tapered metal tubular shaft, each strip of resin impregnated unidirectional graphite fiber reinforcing material being quadrangular in shape with the fibers oriented substantially parallel to the axis of the quadrangular sheet. The fibers in the alternating strips of sheet material are in opposite angular relationship to the next adjacent strip. A layer of woven fiberglass is interposed between alternating strips of the resin-impregnated graphite fiber reinforcement. A layer of a structural adhesive is interposed between the first layer of resin impregnated unidirectional graphite fiber reinforcement material and the metal core. This structural adhesive is present in a predetermined specified amount effectively providing a buffering zone between two very dissimilar materials. The layers of resin are molecularly bonded one to the other as a result of curing at elevated temperatures.
In one embodiment of the invention, a sheet of resin impregnated unidirectional graphite fiber is circumferentially wound on the tubular shaft in the region where the butt section, in effect, begins to taper downwardly toward the top of the shaft so that the graphite fibers of the sheet material are oriented parallel to the longitudinal axis of the shaft. These longitudinal oriented fibers provide a predetermined bending profile for the shaft which will be explained in greater detail hereinafter.
The method of the present invention basically requires cutting a thin sheet of resin impregnated unidirectional graphite fibers into a predetermined flat pattern. A first layer of structural metal adhesive is applied to the underside of said flat pattern while a piece of fiberglass fabric cut to the same predetermined flat pattern is placed on the upper side of the resin impregnated graphite fiber. The resultant laminated quadrangular sheet is spirally wound around a tapered tubular metal core. Thereafter, a second layer of impregnated graphite fiber sheet material is cut into the same predetermined flat pattern as the first thin sheet of resin impregnated unidirectional graphite fiber. This quadrangular sheet of material is spirally wrapped over the first layer at an angle generally oppositely disposed with respect to the sheet of the first layer. After wrapping the material around the core, i.e. both the spirally wrapped layers and, if applicable, the optional circumferentially wrapped layer, the assembly is heated at temperatures in the range of about 100° to 150° C for 0.5 to 3 hours causing the resin layers in the various convolutions to bond to each other.
Various color and texture variations of the finished shaft are possible by proper use of pigments in the resin materials and by the proper use of paints and other cosmetic techniques well known in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates in reduced scale a tapered tubular core used in forming the golf shaft of the present invention.
FIG. 2 illustrates in reduced scale an alternate metal tubular core used in forming the golf shaft in accordance with the present invention.
FIG. 3 diagrammatically illustrates a sheet of resin impregnated graphite fiber reinforcing material used in forming the golf shaft of the present invention.
FIG. 4 diagrammatically illustrates a sheet of woven glass cloth used in forming the golf shaft of the present invention.
FIG. 5 is an enlarged fragmentary cross section of an oblong blank of laminated sheet material comprising a structural metal adhesive layer, a graphite fiber resin impregnated layer and a fiberglass cloth layer.
FIG. 6 is a diagrammatic illustration of the winding of an oblong blank of laminated material around the tubular metal core of the shaft of the present invention.
FIG. 7 is a fragmentary top plan view showing the spiral winding of two sheet materials on a tubular metal core and their relationship to each other in accordance with the present invention.
FIG. 8 is a fragmentary view partially cut away showing the various layers of material employed in the body portion of the preferred golf shaft of the present invention.
FIG. 9 diagrammatically illustrates a sheet of resin impregnated graphite fiber reinforcing material used in one embodiment of the present invention.
FIG. 10 is a diagrammatic fragmentary illustration of the winding of a sheet of resin impregnated continuous graphite fiber material near the butt portion of a golf shaft in one embodiment of the present invention.
FIG. 11 is an exaggerated diagrammatic illustration of the bending profile of a golf club having a shaft in accordance with one embodiment of the present invention.
FIG. 12 is an exaggerated diagrammatic illustration of the bending profile of a golf club having a shaft in accordance with another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, it should be noted that like reference characters designate corresponding parts throughout the several drawings and views.
The golf shaft of the present invention has a metal core in the form of a generally tapered hollow tube as is shown in FIG. 1. The core of the golf shaft need not be entirely tapered but may, for example, have a generally cylindrical tip section 10 and a cylindrical butt section 12 with a substantially tapered body portion 14. In the embodiment shown in FIG. 2, the butt section 12 of the tubular core is substantially cylindrical; the remainder of the metal core is tapered. Thus, at the tip of the core shown in FIG. 2, the taper of the body section begins immediately and continues from the very tip to the butt section. The butt section 12 is again cylindrical.
Although the tubular metal core is referred to as having separate sections, it should be understood that this metal core is indeed a unitary tubular member and that the sections referred to hereinabove merely refer to general areas along the length of the tube.
In order that the golf shaft will have the requisite strength and weight, it is preferred that the metal tube be fabricated from aluminum or magnesium alloys. Indeed, it is particularly preferred that the core be fabricated from the following aluminum alloys: 7178; 7075; 7049 and 7050. The foregoing numerical designations refer, of course, to U.S. alloy compositions. It is particularlly preferred that these alloys have a T-6 temper. Aluminum alloys having the foregoing compositions and temper are articles of trade readily available and can be shaped into tubular articles by standard techniques.
Typically, the tubular core will be about 46 inches in length and have an outer diameter at the butt end of no greater than about 0.570 inches and no less than about 0.560 inches. Typically, the butt diameter will be 0.570 inches. At the tip end of the metal core the outer diameter of the core will be in the range from about 0.260 to about 0.270 inches and preferably 0.270 inches. The wall thickness of the metal core at the butt end of the core will be in the range of 0.12 to 0.17 inches and preferably 0.17 inches. Both the length of the tip section 10 and butt section 12 will vary depending upon whether the shaft will be used in a wood or iron golf club and depending upon the type of flex desired. Typically, a tip section 10 can range anywhere from one inch to about 8 inches in length and the butt section 12 will range generally anywhere between 12 inches and 16 inches in length.
As mentioned previously, the tubular core is fabricated by well known techniques such as drawing or extruding a heavy walled cylindrical billet to the required dimensions.
In fabricating the composite golf shaft of the present invention, it is important that the metal core be completely clean to avoid any possible contaminants. The final cleaning of the metal generally is made with a material such as an alcohol or chlorofluorocarbon to remove traces of lubricants, grease, etc.
The golf shaft of the present invention has the metal core encased in a sheath of resin impregnated graphite and glass fiber fabric which is bonded to the core so that it is substantially integral therewith. This sheath of resin impregnated fiber material is actually fabricated from various layers of material which are ultimately bonded one to the other by curing of the resin contained therein.
In fabricating the golf shaft of the present invention, an oblong sheet, or gore, such as that shown in FIG. 3 is cut from a sheet of unidirectional graphite fibers impregnated with a plastic resin. As shown in FIG. 3, this gore 15 is cut in a quadrangular form wherein end edges 20 and 24 are parallel to each other but are different lengths. Lengthwise edges 26 and 28 are not parallel but provide a taper as they converge toward end edge 20. The graphite fibers 22 are perpendicular to the end edges 20 and 24. The resin impregnating the graphite fibers 22 is a thermo-setting resin. Suitable thermosetting resin materials include epoxy and polyester resins. Particularly gore 15 would be about 46 inches long and in the range of 1.9 to 2.2 inches at the edge 24 and in the range of 0.9 to 1.1 inches wide at the edge 20. Particularly, also, gore 15 would have a thickness of about 0.007 to 0.01 inches and contain from about 50 to about 60 volume percent of graphite fibers in the thermoset resin matrix. Preferably, the gore 15 used in the present invention has 54-58 volume percent graphite fibers in an epoxy resin matrix.
The epoxy resins are polyepoxides which are well known condensation products or compounds containing oxirane rings with compounds containing hydroxyl groups or active hydrogen atoms such as amines, acids and aldehydes. The most common epoxy resin compounds are those of epichlorohydrin and bis-phenol and its homologs.
The polyester resin is a polycondensation product of polybasic acids with polyhydric alcohols. Typical polyesters include polyterphthalates such as poly(ethylene terphthalate).
As is well known in the art, these thermoset resins include modifying agents such as hardeners and the like. Forming such compositions is not a part of the present invention. Indeed, the preferred modified epoxy resin impregnated graphite fibers are commercially available materials. For example, modified epoxy pre-impregnated graphite fibers are sold under the tradename of Rigidite 5209 and Rigidite 5213 by the Narmco Division of Celanese Corporation, New York, N.Y. Other commercial sources of resin pre-impregnated graphite fibers are known in the industry.
Returning again to the drawings, as can be seen in FIG. 4, a woven glass fabric layer, or gore, designated generally by reference 37 is provided. This gore 37 has the same dimensions as gore 15. In other words, end edges 30 and 34 are parallel to each other but are different lengths, whereas side edges 36 and 38 are not parallel and provide a taper as they converge toward end edge 30. This gore 37 will have a thickness of about 0.001 to about 0.002 inches and will consist of woven glass fabric, preferably a fiberglass fabric known in the trade as fiberglass scrim is used. An especially useful fiberglass scrim is style 107 sold by Burlington Glass Fabrics Company, New York. As can be seen, the fibers 32 of the woven fiberglass fabric are at angles of 0° and 90° with respect to end edges 30 and 34.
In fabricating the shaft, the layers of gores 15 and 37 are cut from stock material to the desired flat pattern. Each layer is cut to the same size and shape. Layer 37 is placed on top of gore 15. The underside of gore 15, as shown in FIG. 5, is provided a layer of structural metal adhesive 29. The metal adhesive is a material employed for bonding plastics to metal such as elastomeric modified epoxy and elastomeric modified phenol-urea type resins. One example of one type of adhesive is a polysulfide elastomer modified epichlorohydrin-bis-phenol resin. Many structural adhesives are commercially available, one of which is known as Metlbond 1133 which is an elastomer modified epoxy material sold by the Narmco Division of Celanese Corporation, New York, N.Y.; another is FM 123-2 sold by American Cyanamid Co., Wayne, N.J. The structural metal adhesive is applied to the underside of gore 15 by means of brushing or spraying, for example, when the physical consistency of the adhesive so permits, so as to cover the entire bottom surface of the gore 15. When the adhesive is a thin film sheet material, the gore can very simply be placed on top of the adhesive film. In any event, a first oblong layer of laminated sheet material is provided and, as shown in FIG. 5, is composed of structural adhesive 29, a layer of continuous graphite fiber in a resin matrix 15 and a woven fiberglass layer 37.
Conveniently, when the structural metal adhesive is in the form of a thin film of sheet material, a stock laminate of structural adhesive, resin impregnated graphite fibers and glass scrim can be made and the laminate cut to the dimensions of gore 15.
It is especially important in the practice of the present invention that the weight of structural metal adhesive layer employed be kept in the range of about 0.027 to 0.033 pounds per square foot; and, indeed, it is particularly preferred that the weight of the adhesive layer 29 to be about 0.03 pounds per square foot. Experience has shown in attempting to fabricate suitable golf shafts that the resultant shaft will not be able to handle the strains to which it is subjected during strenuous play if less than 0.027 pounds per square foot of adhesive is employed. On the other hand, if more than 0.033 pounds per square foot of adhesive is employed, the shaft loses the desired degree of flexibility. Moreover, the requisite amount of adhesive enhances durability of the shaft of the present invention. Finally, while not wishing to be bound by any theory, it should be noted that the graphite fiber reinforcing material and the metal core have vastly different coefficients of expansion which must be in some way able to perform with each other as a single unit. Apparently, the amount of adhesive that is applied is most important in assuring not only the proper bonding of the plastic resin to the metal but assuring the cooperation of the torsional rigidity of the metal tubing with the longitudinal stiffness of the graphite fiber reinforcement.
In any event, the oblong laminated material consisting of structural adhesive 29, resin impregnated graphite fiber layer 15 and glass fabric layer 37 is spirally wound as a single laminated layer 60 as is shown in FIG. 6 around the tubular metal core. It should be noted that the adhesive layer is placed in contact with the tubular metal core and that the laminate 60 is so arranged with respect to the longitudinal axis of the metal core that the continuous graphite fibers can be considered to be arranged at an angle varying generally between 5° and 15° with respect to the longitudinal axis. This angle of orientation is shown as θ 1 in FIG. 6.
A second oblong sheet of resin impregnated graphite fiber material is cut having the same dimensions as gore 15. This second sheet is shown in FIG. 7 by reference 51. As is shown in FIG. 7, the second graphite fiber layer 51 is wrapped in a spiral direction around the metal core so as to overlap the first laminated layer 60. More particularly, it should be noted that the second graphite fiber layer 51 is wrapped spirally at an angle oppositely disposed with respect to the fibers in the first layer. This relationship is also brought out in FIG. 8 wherein the first layer 11 shown therein is the metal tubular core upon which is next shown layer 29 of structural metal adhesive followed by layer 15 in which the graphite fibers 22 form an angle shown as θ 2 with respect to the longitudinal axis of the metal tube. θ 2 is generally in the range of 5° to 15°. The next layer 37 consists of woven glass fabric. The fibers 32 can be seen to be at 0° and 90° with respect to the longitudinal axis. Finally, the top layer 51 of graphite fiber reinforced resin has graphite fibers 22 which as a result of winding form an angle θ 3 ranging from -5° to about -15°. In all instances, the magnitude of θ 2 and θ 3 are the same and they are merely opposite in sign.
In wrapping the laminate 60 around the metal tubular core, it is particularly preferred that there by very little overlap. Indeed, it is most preferred if each spiral wrapping abutt against the preceding spiral wrapping. However, an overlap of about 1/16 inch can be tolerated. This is also true in the spiral wrapping of layer 51.
Optionally, prior to spirally wrapping the layer 51 on the shaft, a layer of resin impregnated unidirectional graphite fiber sheet material is circumferentially wound on the shaft in the region where the butt section meets the tapered body section so that the unidirectional fibers are oriented at an angle of 0° with respect to the longitudinal axis of the shaft. Thereafter layer 51 is spirally wound on the shaft as described above.
As can be seen in FIG. 9, this butt insert has unidirectional continuous graphite fibers 92 that are parallel to the lengthwise edge 98. The end 94 of the butt insert is not straight but rather sawtoothed. This is most important in avoiding an abrupt change in the bending profile of a shaft including such an insert. The length of this butt insert is in the range of about 8 to 12 inches and the width is equal to the circumference of the tube to be wrapped with the butt insert. This butt insert can be cut of the same material as gore 15. If an appropriate pinking shears is employed in making the end cuts, the requisite sawtooth pattern will be obtained. The preferred height of the teeth is about 1 inch. As shown in FIG. 10, the butt insert is positioned and circumferentially wrapped around the tubular core so that the graphite fibers 98 are oriented at 0° with respect to the longitudinal axis of the shaft.
After winding laminated layer 60, optional butt insert if applicable, and graphite fiber reinforced layer 51 around the core, these materials can be held in place by means of cellophane tape, for example. Alternatively, the assembly of core and external plastic impregnated fiber reinforcing material can be held in place by a wrapping of a polypropylene heat shrinkable film (not shown) which serves, in effect, as a mold and which is subsequently removed as hereinafter described.
After wrapping the metal core with the requisite layers of material, the assembly is placed in an oven and heated to a temperature sufficient to cause a bonding of the separate layers and the various convolutions to each other. The temperature at which the assembly is heated depends upon a number of factors including the resin which is used to impregnate the graphite fibers. These temperatures are well known. Typically, for modified epoxy resin impregnated graphite fiber the temperature will be in the range of about 100° C to about 180° C and preferably from about 140° C.
If an external polypropylene wrapping film is used to hold the various layers around the metal core, this is removed very simply by manually peeling it away from the surface of the shaft.
Surface imperfections, if there are any, on the shaft can be removed by sanding and grinding or the like. Finally, the shaft can be fitted with a grip and club head. Optionally, the shaft can, prior to being fitted with the grip and club head, be painted to provide the desired color appearance.
Continuous unidirectional graphite material generally displays very low stretch or elongation factors compared with tubular metal materials such as aluminum and steel and the like. The composite shaft of the present invention as a result of the inclusion of graphite fibers and the particular angle of orientation referred to herein has exceptional recovery. In other words, when the golf club is swung on a backswing, the shaft tends to bend backwards, and, on the downswing, the club head is behind the hands of the hitting area. Then the shaft begins to restore itself and the club accelerates into the hitting area. This is generally referred to as the "club head recovery." Because the graphite fibers in the shaft of the present invention have a low stretch or elongation factor compared with conventional shaft materials, the shaft restores itself at a much higher rate. This results in a higher club head speed at impact. Moreover, the club head does not slow down significantly after impact. This increase in club head speed means more energy at impact and that means more carry on drives. The composite shaft of the present invention, however, also has a metal tubular core which provides the torsional rigidity. Thus, lateral shot dispersions for numerous players are substantially reduced by virtue of the metal tubular core. Significantly, the graphite fibers in the core by virtue of the structural metal adhesive interposed between these materials perform cooperatively rather than independently, thereby providing for vast improvement in the subject golf shaft.
Another significant feature of the shaft of the present invention is the significant stiffness provided at relatively low weight. A golf club employing a shaft of the present invention will have a total weight lower than any other commercially available golf club of the same head size. Moreover, for a given head size a golf club with the shaft of this invention has a lower center of gravity, thereby placing the mass in the hitting zone. Thus, for a given swing speed there is more energy, for greater drives.
Referring now to FIG. 11, an exaggerated bending profile of a golf club having a shaft of the present invention, without the butt insert, is shown. As can be seen, the bending profile of this shaft begins much higher along the length of the shaft. In contrast thereto, a golf club which has a shaft of the present invention which includes a butt insert has a bending profile, as shown in FIG. 12, beginning much lower along the length of the shaft. It has been found that an average player having a relatively slow swing can improve his game by using a shaft having a butt insert in accordance with the present invention whereas a player with a stronger swing is more suited to a golf shaft having the higher bending profile.
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A novel golf shaft having a metal core and a graphite fiber reinforced sheath thereon is provided. The shaft has a predetermined orientation of the graphite fibers. In one embodiment, some longitudinal fibers are located in the region where the butt section of the shaft begins to taper downwardly thereby lowering the bending profile of the shaft compared with a shaft not having the longitudinal fibers. The method of fabricating the shaft also is disclosed.
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BACKGROUND OF THE INVENTION
The invention relates to an apparatus for supplying medication to the human or animal body, comprising a reservoir for the medication and a conveyance and dosing unit for transporting the medication from the reservoir to a discharge port. The apparatus can be implanted in the body or worn externally on the body.
Apparatus for supplying medication which can be worn on the body of a patient and, in particular, which is suitable for implantation in the body of the patient, should be as small and lightweight as possible. A major demand is also that the medication filled into the reservoir have a sufficiently long stability period in order to achieve refill intervals for the medication which are as long as possible. Apparatus of the type initially cited is known wherein a supply of the liquid medication is stored in high concentration and smallest volumes of the liquid medication are continuously transported, dosed by the reservoir, by a conveyance and dosing unit to the opening of a discharge catheter. However, such apparatus is only suitable for medications which are sufficiently soluble in a liquid which can be tolerated by the body and which are also sufficiently stable over a long period in contact with the apparatus materials at body temperature. In the case of many medications, such as, in particular, insulin, heparin and other polypeptides, however, only relatively low degrees of solubility are manifest and/or stability problems occur at high concentrations. In apparatus for medications of this type, the refill interval for the liquid medication is hence relatively short and there is an overall restriction in the applied use of the apparatus on the patient. Furthermore, in the case of apparatus having a larger supply of liquid medication in the reservoir, there is always the danger that, in case of error, the entire fluid medication will leak out of the reservoir into the patient's body. An overdose of medication such as this, particularly in the case of the administering of insulin during diabetes therapy, can result in severe harm to the patient.
SUMMARY OF THE INVENTION
Accordingly, it is the object of the invention to realize an apparatus for the supply of medication to the human or animal body, in the reservoir of which it is possible to store larger quantities of medication without incurring the risk of leakage of the liquid medication.
The object is inventively achieved by virtue of the fact that the medication is stored in the reservoir in a solid form, and that a solvent is capable of being supplied to the solid medication for the purpose of dissolving the solid medication to an infusion fluid which can be discharged by the conveyance and dosing unit via the exit port. Preferably, body fluid can be used as the solvent for the solid medication, which body fluid is drawn to the solid medication by the conveyance and dosing unit in a predeterminable dose via a semipermeable membrane in the apparatus housing. In another embodiment of the invention, a special fluid is used as the solvent of the solid medication which is stored in an additional reservoir which preferably has a refill opening in the apparatus housing.
The apparatus in accordance with the invention proceeds from the fact that in solid form, the majority of medications are stable for long periods of time, and manifests a minimum solubility in a body-compatible liquid; particularly, in water. Thus, by means of a complete dissolution of the solid medication only directly prior to its being discharged into the patient's body, the disadvantageous stability problems of the liquid medications having high concentration in the case of the known infusion apparatus do not occur. In the apparatus according to the invention, the solid medication can be stored in a sufficient amount in the reservoir in an amorphous or crystalline state for the entire time of applied use of the apparatus on the patient. The transcutaneous refilling of medication in the case of the implanted apparatus is thereby completely avoided. In the apparatus in accordance with the invention, the solvent flows around the solid medication for a sufficiently long period of time until the solution has reached a state of complete saturation. The saturated solution is then released into the body in measured doses. The flow which is induced by the pump simultaneously defines the rate of release of the medication, since the solubility is essentially constant given the minimal body temperature fluctuations.
Further details and advantages of the invention will be apparent from the following description of sample embodiments in conjunction with the accompanying sheet of drawings; other objects, features and advantages will be apparent from this detailed disclosure and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal sectional view illustrating a first sample embodiment wherein body fluid is drawn (or suctioned) in by means of a pump; and
FIG. 2 is a sectional view showing a second sample embodiment wherein an additional reservoir for a solvent is present.
DETAILED DESCRIPTION
In FIG. 1, reference numeral 1 designates a housing in which a pump 2, as the delivery and dosing unit, units 3 and 4 for control circuits and energy supply (battery), and a reservoir 5 for the medication are located. Pump 2 is connected via a conduit 6 with a large-area, semi-permeable membrane 7 in the housing wall. It can be useful to envelop an absorbent wick, which is placed in the patient's body, with the semipermeable membrane 7, in order to increase the absorption surface for the body fluid. The semi-permeable membrane 7 and/or the wick advantageously have hydrophilic properties. Via semipermeable membrane 7, which is formed from such a material that only low molecular substances, preferably molecules up to a size of those of water, are allowed to pass through, body fluid is drawn in from the vicinity of the apparatus and conveyed via conduit 8 to reservoir 5. In reservoir 5, there is disposed a block 9 of solid medication which can fill the entire reservoir 5. On both sides of the block, there are arranged close-meshed filters. The infusion fluid saturated with medication reaches the discharge port 12 of housing 1 at which a catheter 13 is arranged.
In FIG. 2, the housing of the apparatus is designated with 14, which, in turn, comprises a pump 15, units 16 and 17 for control and energy supply (battery) and a reservoir 18 for the solid medication. In addition, an additional reservoir 19 for the solvent is arranged in the housing 14 which is connected with pump 15 via conduit 20. Via an additional conduit 21, reservoir 19 is connected to a refill adapter 22 in the apparatus housing. The solvent is conveyed from receptacle 19 via conduit 20 and a conduit 23 to reservoir 18 in which the medication block 24 is disposed. On both sides of medication block 24, there are again arranged close (or narrow) meshed filters 25 and 26. A catheter 28 is connected to the discharge 27 of housing 14.
The apparatus housings 1 and 14 are formed from a material capable of implantation such as high-grade steel or titanium. Preferably, housings 1 and 14 will form flat capsules of the type used for heart-pacemaker housings which are readily capable of being introduced in the patient's body. The medication blocks 9 and 24 in the reservoirs 5 and 18 of the illustrated apparatus are to manifest as large a surface as possible in order to guarantee a sufficiently long contact period of the solvent with the medication and, in this manner, produce a fully saturated infusion fluid. This is achieved by virtue of the fact that block 9 or 24, which fills out the entire volume of the reservoir 5, or 18, respectively, is constructed to be porous and has continuous channels passing through the entire block from the inlet to the outlet side thereof. In the case of a crystalline medication, this condition is already satisfied by compressing the individual crystallites. The close-meshed filters 10, 11, or 25, 26, prevent a floating away of small solid medication particles which can be separated by the solvent from the entire block. Preferably suitable as the conveyance and dosing unit 2, or 15, respectively, are cylinder pumps with stepping motor drive or also an electro-osmotic pump, as already described in detail in the patent literature.
The apparatus according to the sample embodiment described in FIG. 1 can be of the smallest possible construction. It is particularly suited for implantation in the patient's body. An apparatus according to the sample embodiment described in FIG. 2 is suited for an optional construction of an apparatus capable of implantation or capable of being worn externally on the body of the patient. In this apparatus, solvents other than water can also be employed. This can be of advantage if the medication, for example, is not soluble in body fluid or water, if reactions with the body fluid can take place, or if an additional opening of the apparatus housing leading to the body is to be avoided. Nevertheless, the advantages remain as compared with the apparatus of the prior art wherein liquid medication is stored in a reservoir. The solid medication is likewise dissolved only directly prior to discharge into the patient's body and, as a consequence, only a short term contact of the dissolved medication with the apparatus material will take place. Thus, the long term stability of the medication fluid is not a necessary secondary requirement. Moreover, in the apparatus in accordance with the invention, the same amount of solvent lasts longer than in the case of the apparatus of the prior art, since solutions generally are stable over a long period of time only when reliably far from saturation. Thus, in the apparatus according to the sample embodiment of FIG. 2, correspondingly more medication will be conveyed per unit of volume of fluid because of the higher solute concentration which is feasible. In addition, the refilling of solvent is less dangerous than the refilling of a medication solution. Whereas this is entirely unproblematic in the case of an apparatus worn externally on the patient's body, in the case of an implanted apparatus, during the transcutaneous refilling of fluid, the conditions are also more readily controllable than in the case of the apparatus of state of the art. It is easier to keep the solvent sterile than a medication fluid. Also, the solvent can be selected to be of such a body compatible nature that, in the case of error, the fluid leaking out will not present any danger to the patient. In the latter case, even during a spontaneous discharge of the entire fluid, the solvent will not even be entirely saturated with medication.
The inventive apparatus can also be supplemented to form an adaptively controlled or self-regulating apparatus by means of selection of a suitable controlled variable, such as, for example, the blood sugar concentration. In this instance, the supply of the medication is no longer controlled by a program which is input in the apparatus in the form of a program transmitter (or generator), or controlled externally by means of remote control; but on the contrary, the supply of the medication is controlled by a special sensor with an associated control system and nominal (setpoint) value input. Additional sensors, for example for temperature, are also conceivable which can take into account the increasing solubility of the solvent for the medication at higher temperatures.
The pump 2 has its intake side connected to conduit 6 and its output side supplying pure solvent to conduit 8. The pump 15 is similarly connected between conduits 20 and 23. Each pump 2, 15 may comprise a stricture or roller pump operated by a step motor. The step motor and stricture pump have already been described in the patent literature. Alternatively, each pump 2, 15 can be an electro-osmotic pump such as shown in U.S. Pat. No. 3,894,538 issued July 15, 1975.
The pump control 3, 16 for the step motor may correspond to that given in German Offenlegungsschrift 25 13 467 (U.S. Ser. No. 669,459) and the rate of the step pulse generator may be controlled from a temperature sensor (such as 21) so as to correct the transport rate or capacity of the pump 2, 15 in accordance with the temperature-dependent solubility curve of the solvent for the solid medication 9, 24. Thus the pump 2, 15 operates at a rate such that a fully saturated solution results at all transport rates of the pump 2, 15, regardless of variations in body temperature.
It will be apparent that many modifications and variatons may be effected without departing from the scope of the novel concepts and teachings of the present invention.
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In the illustrated embodiments, medication is stored in an implantable housing in solid form, and solvent is supplied to the solid medication to form the infusion fluid as needed for maintaining the desired dosage rate. The rate of supply of solvent may be controlled to insure a saturated solution of the medication under all operating conditions. The solvent may be the local bodily fluid which enters the housing via a semipermeable membrane, or a sealed solvent reservoir may be provided within the housing.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to security on public networks such as the Internet and more generally on any network when using personal tokens such as smart cards for authentication of users.
Many protocols have been proposed for authenticating a user holding a smart card in a network.
2. Description of the Related Art
Current SSL (Secure Sockets Layer) strong authentication is based on smartcard and certificates and is routinely used for authentication, without need for contacting a certificate authority that signed the certificate of the smart card.
One problem however arises in such scheme because of such unneeded contact with a certificate authority.
Indeed the smart card issuer appears to be never asked for consent before a service provider performs authentication of the smart card. In other words, the authentication process by way of a smart card is a benefit to any service provider, including any service provider who has no commercial agreement with the smart card issuer. A smart card therefore becomes a commonly benefiting authenticating tool for any entity, including competitors of the smart card issuer.
It is the case with standard SSL using Public Key Infrastructure (PKI) cryptography. Any server can request the client to authenticate itself using smart card PKI, while the smart card contains a private key and the associated certificate and any server can receive the user certificate and thereby check the validity of the user signature.
SUMMARY OF THE INVENTION
An aim of the invention is to allow smart card issuers to control each authentication made on their smart cards, while still relying on the standard SSL arrangements which are currently available in software and hardware on most servers.
This aim is achieved by way of a personal token, typically a smart card, as recited in the appended claims. An assembly comprising such token and an authentication method are also recited in the claims which both target the same principal aim.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages, aims and features related to the invention will be discussed throughout the following detailed description, which is made with referenced to the appended figures, among which:
FIG. 1 depicts an architecture of an authenticating arrangement according to the invention,
FIG. 2 depicts an authentication process according to the invention.
In the following example, a remote SSL server will be called IDP, thereby referring to IDentity Provider.
DETAILED DESCRIPTION OF THE INVENTION
This example relates to a SSL link which is used in order to authenticate a user using a smart card 10 on the internet via his PC (personal computer) 20 . Any other kind of personal token, also called portable token, may replace such a smart card, like a USB token or a mass memory token including authenticating data.
Authentication with the smart card as an SSL client is performed as follows.
The PC of an end user typically embeds a web browser 21 which is triggered for accessing a remotely based web site via an IT server 40 . A browser embedded in the smart card can equally be used for accessing the web site.
Such web site typically requires a login and the user or the smart card 10 typically selects the login link.
The PC 20 is presently equipped with a proxy 22 which is dedicated to IDP servers. Such proxy 22 is hereby called an IDP proxy.
In the present example, the client side SSL connection is not performed by the PC browser 21 , but by the IDP proxy 22 using its own built-in but standard SSL layer.
By selecting the login link, the PC 20 and its browser 21 are therefore redirected to the IDP proxy 22 on the client PC.
Then the IDP proxy 22 opens an SSL connection with the IDP server 30 . This SSL connection is secured by the card 10 .
The SSL connection uses a card certificate 11 . The SSL connection is successful if the card certificate 11 is a valid dongle certificate and is not in the Certificate Revocation List.
The IDP proxy 22 has a built-in implementation of SSL which is preferably independent from the known protocols MS-CAPI and PKCS#11. These known protocols use to pick the authenticating certificate 11 up from the card 10 and store it in the memory of the PC 20 . The same remark can be done with the SSL built-in client of Internet Explorer or Netscape which uses to offer a strong authentication using the card certificate 11 as transferred into the PC 20 .
By using such a different protocol, this prevents from storing the certificate in a registry or a file which is outside from the card 10 , and a third-party thereby cannot perform strong authentication using the card through preliminary transfer of the certificate into the PC 20 .
If the SSL connection is successful, the IDP server 30 looks-up the identity of the end-user from a dongle ID which is contained in the certificate 11 , and the IDP server 30 then returns a SAML token to the IDP proxy 22 .
The IDP proxy 22 then redirects the browser 21 to the service provider site with the SAML token.
From then on the browser 21 can access the protected site with the returned SAML token.
Before the SSL connection is rendered successful, an SSL authentication of the client is carried out as explained hereafter.
Thanks to the following arrangements, such SSL connection can exclusively be negotiated with the particular IDP server 30 .
This exclusivity is ensured by using the public key of the IDP server 30 which has been stored in the card 10 at a previous step, for example at the personalization step of the smart card, during the manufacturing process, or even by Over-The-Air updating of the card memory. The server public key is presently stored in the server certificate 12 which is stored in the card in the same way as the card certificate 11 .
As will be explained hereafter, storing the public key of the IDP server or any other server-specific information in the card 10 allows to prevent that any third-party servers may initiate a non agreed SSL connection with the smart card.
At the stage where an SSL connection is to be initiated between the IDP proxy 22 and IDP server 30 , an SSL handshake occurs, during which the server certificate 12 from a server-hello message is used to check the server signature. This pertains to the standard SSL implementation.
To enforce server verification, the card 10 contains the server certificate 12 as a fingerprint or reliable authenticator element and the IDP Proxy requests the card to check the server certificate on the basis of the stored fingerprint 12 .
Once the identity of the IDP server 30 is checked in the card 10 , a ClientKeyExchange message is generated in the card.
As a preferred example, the IDP public key of the IDP server is stored in the card 10 and is used to generate the ClientKeyExchange message.
To this end, the card 10 completes a usual hash processing of the data with a signature process of the data on the basis of IDP dependant data, i.e. the public key of the server 30 in the present example.
A strong authentication specifically dedicated to the given IDP server 30 is thereby ensured by previous storage of the public key of the server in the card, and by performing the final phase of the SSL hash cryptography in the card with the prestored public key of the IDP server.
Such final phase which consists in performing a server specific signature is however preferably done before performing client signature (CertificateVerify message).
The signature of the ClientKeyExchange message with IDP dependent data provides two main advantages.
The SSL connection can only be rendered successful with the specific IDP server 30 which also contains such IDP server dependent data, as far as those data are necessary in the server 30 for interpreting the content of the ClientKeyExchange message.
The public key of the card can therefore not be used for any other purpose than performing an SSL connection with the specific IDP server.
When performing signature of the message, the card 10 implements a part of the SSL protocol dedicated to the wanted IDP server and related to server public key. It means that the card signature will be valid for the wanted server 30 but not for other servers that do not own the correct server private key. Such card 10 can therefore not be used in an unauthorized environment.
Alternatively, the used IDP dependent data may constitute either part of the message or an encrypting tool of the message which it is necessary to know for interpreting the message.
The public key of the server 30 is preferably the unique key that will transport SSL key materials to the server 30 .
Practically, the IDP server upon reception of the card certificate 12 during the SSL connection verifies the validity of the certificate in the CRL (Certificate Revocation List), and performs an identity lookup from the card id contained in such certificate 12 .
If the certificate 12 is valid, the SSL connection can be used to send back a SAML token to the IDP proxy as explained before and then the IDP proxy is redirecting the browser 21 to a service provider site, thereby inviting the PC browser 21 to connect to the service provider 40 with the SAML token.
The site of the service provider is asserting the validity of the SAML token with the IDP server 30 and if successful, the service provider is initiating an SSL connection without client certificate with the browser of the PC.
The service provider 40 can be hosted in the same IDP server 30 which was connected to the proxy 21 or can be hosted in another remote server.
Although the strong authentication can only be performed with the allowed SSL server, the authentication remains mainly a standard SSL authentication.
The server public key is preferably the key which is stored in the card 10 , and not a key which may be transmitted by the server 30 during the SSL server-hello message, i.e. before initiation of the authentication process. This prevents third-party servers to initiate an SSL connection with the IDP proxy and to perform a strong authentication using the card.
Furthermore, due to the fact that in this particular example a standard SSL protocol is used which requires no heavy server-side custom of software or hardware, the SSL client implements the standard SSL protocol with client and server certificates, and is mainly supported on the shelf by most server software and hardware components.
The description has been made with reference to a smart card. However the invention relates also to other type of portable tokens for personal authentication, such a USB sticks or mass memory cards.
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The invention relates to a personal token ( 10 ) for authentication in a network comprising a piece of software for initiating an SSL connection by generating a message authenticating said token to a remote server ( 30 ) characterized in that the piece of software controls the processing of the message so as to use of a data ( 12 ) which is prestored in the token ( 10 ) and which is specifically associated with the remote server ( 30 ) so that the message can be interpreted only by the specific remote server ( 30 ).
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending application 09/330,465, filed on Dec. 28, 2002 which itself is a continuation of 09/820,569 filed Mar. 29, 2001 (granted Jul. 29, 2003 as U.S. Pat. No. 6,599,971). This parent application is herein entirely incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to compounds and compositions comprising specific metal salts of hexahydrophthalic acid (hereinafter HHPA) in order to provide highly desirable properties within thermoplastic articles. The inventive HHPA derivatives are useful as nucleating and/or clarifying agents for such thermoplastics, and are practical to produce and handle. Such compounds provide excellent crystallization temperatures, stiffness, and acid scavenger compatibility within target polyolefins. Also, such compounds exhibit very low hygroscopicity and therefore excellent shelf stability as powdered or granular formulations. Thermoplastic additive compositions and methods of producing polymers with such compounds are also contemplated within this invention.
BACKGROUND OF THE PRIOR ART
[0003] All U.S. patents cited below are herein fully incorporated by reference.
[0004] As used herein, the term “thermoplastic” is intended to mean a polymeric material that will melt upon exposure to sufficient heat but will retain its solidified state, but not prior shape without use of a mold or like article, upon sufficient cooling. Specifically, as well, such a term is intended solely to encompass polymers meeting such a broad definition that also exhibit either crystalline or semi-crystalline morphology upon cooling after melt-formation. Particular types of polymers contemplated within such a definition include, without limitation, polyolefins (such as polyethylene, polypropylene, polybutylene, and any combination thereof), polyamides (such as nylon), polyurethanes, polyesters (such as polyethylene terephthalate), and the like (as well as any combinations thereof).
[0005] Thermoplastics have been utilized in a variety of end-use applications, including storage containers, medical devices, food packages, plastic tubes and pipes, shelving units, and the like. Such base compositions, however, must exhibit certain physical characteristics in order to permit widespread use. Specifically within polyolefins, for example, uniformity in arrangement of crystals upon crystallization is a necessity to provide an effective, durable, and versatile polyolefin article. In order to achieve such desirable physical properties, it has been known that certain compounds and compositions provide nucleation sites for polyolefin crystal growth during molding or fabrication. Generally, compositions containing such nucleating compounds crystallize at a much faster rate than unnucleated polyolefin. Such crystallization at higher temperatures results in reduced fabrication cycle times and a variety of improvements in physical properties, such as, as one example, stiffness.
[0006] Such compounds and compositions that provide faster and/or higher polymer crystallization temperatures are thus popularly known as nucleators. Such compounds are, as their name suggests, utilized to provide nucleation sites for crystal growth during cooling of a thermoplastic molten formulation. Generally, the presence of such nucleation sites results in a larger number of smaller crystals. As a result of the smaller crystals formed therein, clarification of the target thermoplastic may also be achieved, although excellent clarity is not always a result. The more uniform, and preferably smaller, the crystal size, the less light is scattered. In such a manner, the clarity of the thermoplastic article itself can be improved. Thus, thermoplastic nucleator compounds are very important to the thermoplastic industry in order to provide enhanced clarity, physical properties and/or faster processing.
[0007] As an example, dibenzylidene sorbitol derivatives are common nucleator compounds, particularly for polypropylene end-products. Compounds such as 1,3-O-2,4-bis(3,4-dimethylbenzylidene) sorbitol (hereinafter DMDBS), available from Milliken Chemical under the trade name Millad® 3988, provide excellent nucleation and clarification characteristics for target polypropylenes and other polyolefins. Other well known nucleator compounds include sodium benzoate, sodium 2,2′-methylene-bis-(4,6-di-tert-butylphenyl) phosphate (from Asahi Denka Kogyo K. K., known as NA-11), aluminum bis[2,2′-methylene-bis-(4,6-di-tert-butylphenyl)phosphate] (also from Asahi Denka Kogyo K. K., known as NA-21), talc, and the like. Such compounds all impart high polyolefin crystallization temperatures; however, each also exhibits its own drawback for large-scale industrial applications.
[0008] For example, of great interest is the compatibility of such compounds with different additives widely used within typical polyolefin (e.g., polypropylene, polyethylene, and the like) plastic articles. For instance, calcium stearate is a very popular acid neutralizer present within typical polypropylene formulations to protect the stabilizing additives (such as light stabilizers, antioxidants, etc.) from catalyst residue attack. Unfortunately, most of the nucleator compounds noted above also exhibit deleterious reactions with calcium stearate within polyolefin articles. For sodium, and other like metal-ions, it appears that the calcium ion from the stearate transfers positions with the sodium ions of the nucleating agents, rendering the nucleating agents ineffective for their intended function. As a result, such compounds sometimes exhibit unwanted plate-out characteristics and overall reduced nucleation performance (as measured, for example, by a decrease in crystallization temperature during and after polyolefin processing). Other processing problems are evident with such compounds as well.
[0009] Other problems encountered with the standard nucleators noted above include inconsistent nucleation due to dispersion problems, resulting in stiffness and impact variation in the polyolefin article. Substantial uniformity in polyolefin production is highly desirable because it results in relatively uniform finished polyolefin articles. If the resultant article does not contain a well-dispersed nucleating agent, the entire article itself may suffer from a lack of rigidity and low impact strength.
[0010] Furthermore, storage stability of nucleator compounds and compositions is another potential problem with thermoplastic nucleators and thus is of enormous importance as well. Since nucleator compounds are generally provided in powder. or granular form to the polyolefin manufacturer, and since uniform small particles of nucleating agents is imperative to provide the requisite uniform dispersion and performance, such compounds must remain as small particles through storage. Certain nucleators, such as sodium benzoate, exhibit high degrees of hygroscopicity such that the powders made therefrom hydrate easily resulting in particulate agglomeration. Such agglomerated particles may require further milling or other processing for deagglomeration in order to achieve the desired uniform dispersion within the target thermoplastic. Furthermore, such unwanted agglomeration due to hydration may also cause feeding and/or handling problems for the user.
[0011] These noticeable problems have thus created a long-felt need in the thermoplastic industry to provide nucleating/clarifying agents that do not exhibit the aforementioned problems and provide excellent peak crystallization temperatures for the target thermoplastics themselves, particularly with a wide variety of typical and necessary acid scavenger additives. To date, the best compounds for this purpose remain those noted above. Unfortunately, nucleators exhibiting exceptionally high peak crystallization temperatures, low hygroscopicity properties, excellent dispersion and concomitant clarity and stiffness, as well as compatibility with most standard polyolefin additives (such as, most importantly, calcium organic salt acid scavengers) have not been accorded the different thermoplastic industries. Such problems are not limited to polyolefins and are common within all thermoplastic applications in which nucleating agents are used.
Objects of the Invention
[0012] Therefore, an object of the invention is to provide a nucleator compound and compositions thereof that exhibit excellent calcium stearate compatibility within target thermoplastic articles and formulations. A further object of the invention is to provide a thermoplastic nucleating agent that provides excellent high peak crystallization temperatures, for example, to polypropylene articles and formulations, and also exhibits extremely low hygroscopicity in order to accord an extremely good shelf-stable additive composition. Another object of the invention is to provide an easily dispersed nucleator compound such that said polyolefin exhibits very high stiffness and good clarity. Additionally, it is an object of this invention to provide a nucleator compound or composition which may be used in various thermoplastic media for myriad end-uses.
[0013] Accordingly, this invention encompasses metal salts of a compound conforming to Formula (I)
[0014] wherein M 1 and M 2 are the same or different and are selected from at least one metal cation of calcium, strontium, lithium, and monobasic aluminum, and wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 are either the same or different and are individually selected from the group consisting of hydrogen, C 1 -C 9 alkyl [wherein any two vicinal (neighboring) or geminal (same carbon) alkyl groups may be combined to form a carbocyclic ring of up to six carbon atoms], hydroxy, C 1 -C 9 alkoxy, C 1 -C 9 alkyleneoxy, amine, and C 1 -C 9 alkylamine, halogens (fluorine, chlorine, bromine, and iodine), and phenyl. The term “monobasic aluminum” is well known and is intended to encompass an aluminum hydroxide group as a single cation bonded with the two carboxylic acid moieties. Furthermore, form each of these potential salts, the stereochemistry at the asymmetric carbon atoms may be cis or trans, although cis is preferred.
DETAILED DESCRIPTION OF THE INVENTION
[0015] As noted above, in order to develop a proper thermoplastic nucleator for industrial applications, a number of important criteria needed to be met. The inventive calcium, strontium, monobasic aluminum, and lithium HHPA salts meet all of these important requirements very well. For instance, these inventive compounds do not hydrate readily and thus granular or powder formulations of such a salt do not agglomerate or clump together. The cost benefits from such shelf stability are apparent since there is little if any need to separate agglomerated powders upon introduction to thermoplastic processing equipment. Furthermore, as discussed in greater detail below, these inventive salts provide excellent high peak crystallization temperatures in a variety of polyolefin and polyester formulations, particularly within random copolymer polypropylene (hereinafter RCP), homopolymer polypropylene (hereinafter HP), impact copolymer polypropylene (hereinafter ICP), syndiotactic polypropylene (s-PP), polyethylene terephthalate (hereinafter PET), polyamides (such as nylons), and any combinations thereof. Additionally, such inventive salts provide high stiffness (modulus) characteristics to the overall final polyolefin product without the need for extra fillers and reinforcing agents. Lastly, and of great importance within the polypropylene industry, such inventive salts do not react deleteriously with calcium stearate co-additives. Such a property, combined with the other attributes, is highly unexpected and unpredictable.
[0016] Such inventive compounds thus provide excellent nucleating capability. Sodium salts of certain aromatic and cycloaliphatic carboxylic acids have been discussed within the prior art, most notably within U.S. Pat. No. 3,207,739 to Wales. Broadly disclosed, the patentee includes metal salts of a number of such compounds, most particularly sodium, although Group I and II metals are also broadly discussed. However, patentee specifically states that aromatic benzoates, in particular sodium benzoate, are the best compounds for polyolefin nucleation purposes. Furthermore, patentee mentions strontium as a cation for benzoate alone and specifically teaches away from the utilization of calcium salts due to heat processing problems. Additionally, patentee equates Group I and II metals as cations for his preferred benzdates; however, as discussed below in greater detail, it is evident that other Group II metals, such as magnesium and barium, are highly ineffective with HHPA as polyolefin nucleators. Lastly, it has now been found that in comparison with patentee's decidedly preferred sodium benzoate, the inventive compounds provide more beneficial properties, including, without limitation, less susceptibility to plate-out and blooming on the mold during polyolefin article formation, lower hygroscopicity, and again of greater importance, less reactivity with calcium stearate thereby permitting greater amounts of both compounds to function in their intended capacities within the target polyolefin formulation.
[0017] The inventive HHPA salts are thus added within the target thermoplastic in an amount from about 0.01 percent to 2.0 percent by weight, more preferably from about 0.2 to about 1.5 percent, and most preferably from about 0.05 to 1.0 percent, in order to provide the aforementioned beneficial characteristics. It may also be desirable to include up to 50% or more of the active compound in a masterbatch, although this is not a restriction. Optional additives within the inventive HHPA salt-containing composition, or within the final thermoplastic article made therewith, may include plasticizers, stabilizers, ultraviolet absorbers, and other similar standard thermoplastic additives. Other additives may also be present within this composition, most notably antioxidants, antimicrobial agents (such as silver-based compounds, preferably ion-exchange compounds such as ALPHASAN® antimicrobials from Milliken & Company), antistatic compounds, perfumes, chlorine scavengers, and the like. These coadditives, along with the nucleating agents, may be present as an admixture in powder, liquid, or in coinpressed/pelletized form for easy feeding. The use of dispersing aids may be desirable, such as polyolefin (e.g., polyethylene) waxes, stearate esters of glycerin, montan waxes, and mineral oil. Basically, the inventive metal HHPA compounds may be present (up to 20% by weight or more) in any type of standard thermoplastic (e.g., polyolefin, most preferably) additive form, including, without limitation, powder, prill, agglomerate, liquid suspension, and the like, particularly comprising the dispersing aids described above. Compositions made from blending, agglomeration, compaction, and/or extrusion may also be desirable.
[0018] The term polyolefin or polyolefin resin is intended to encompass any materials comprised of at least one semicrystalline polyolefin. Preferred examples include isotactic and syndiotactic polypropylene, polyethylene, poly(4-methyl)pentene, polybutylene, and any blends or copolymers thereof, whether high or low density in composition. The polyolefin polymers of the present invention may include aliphatic polyolefins and copolymers made from at least one aliphatic olefin and one or more ethylenically unsaturated co-monomers. Generally, the co-monomers, if present, will be provided in a minor amount, e.g., about 10 percent or less or even about 5 percent or less, based upon the weight of the polyolefin. Such conionomers may serve to assist in clarity improvement of the polyolefin, or they may function to improve other properties of the polymer. Higher amounts of co-monomer (for instance, ethylene, e.g., 10-25% or more), may also be present in the polyolefin to engender greater impact resistance (hereinafter impact copolymer, or ICP's). Other polymers or rubber (such as EPDM or EPR) may also be compounded with the polyolefin. Other co-monomer examples include acrylic acid and vinyl acetate, etc. Examples of olefin polymers whose transparency and crystallization temperature can be improved conveniently according to the present invention are polymers and copolymers of aliphatic mono-olefins containing 2 to about 6 carbon atoms which have an average molecular weight of from about 10,000 to about 2,000,000, preferably from about 30,000 to about 300,000, such as, without limitation, polyethylene (PE), linear low density polyethylene (LLDPE), isotactic polypropylene (I-PP), syndiotactic polypropylene (s-PP), random copolymer polypropylene (RCP), crystalline ethylenepropylene copolymer (ICP), poly(1-butene), poly(4-methylpentene), poly(1-hexene), poly(1-octene), and poly(vinyl cyclohexene). The polyolefins of the present invention may be described as basically linear, regular polymers that may optionally contain side chains such as are found, for instance, in conventional, low density polyethylene. Although polyolefins are preferred, the nucleating agents of the present invention are not restricted to polyolefins, and may also give beneficial nucleation properties to polymers such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and polyethylene naphthalate (PEN), as well as polyamides such as Nylon 6, Nylon 6,6, and others. Generally, any thermoplastic composition having some degree of crystalline content may be improved with the nucleating agents of the present invention.
[0019] The compositions of the present invention may be obtained by adding the inventive HHPA salt (or combination of salts or composition comprising such salts) to the thermoplastic polymer or copolymer and merely mixing the resultant composition by any suitable means. The composition may then be processed and fabricated by any number of different techniques, including, without limitation, injection molding, injection blow molding, injection stretch blow molding, injection rotational molding, extrusion, extrusion blow molding, sheet extrusion, film extrusion, cast film extrusion, foam extrusion, thermoforming (such as into films, blown-films, biaxially oriented films), thin wall injection molding, and the like into a fabricated article.
[0020] The nucleated thermoplastic is intended to be utilized as, for instance and not by limitation, medical devices, such as pre-filled syringes for retort applications, intravenous supply containers, and blood collection apparati; food packages; liquid containers, such as for drinks, medicines, shampoos, and the like; apparel cases; microwaveable articles; shelves; cabinet doors; mechanical parts; automobile parts; sheet; pipes and tubes; rotationally molded products; blow-molded products; fiber (spun or nonwoven); compression molded products; basically any thermoplastic article wherein the effects of nucleation may be advantageous.
Preferred Embodiments of the Invention
[0021] Examples of the particularly preferred metal salts of HHPA within the scope of the present invention and compositions thereof are presented below.
[0022] Production of Inventive HHPA Salts
EXAMPLE 1
[0023] Cis-Calcium HHPA:
[0024] To an 8-L cylindrical kettle fitted with a mechanical paddle stirrer and thermometer was added water (4 L) and calcium hydroxide (481 g, 6.49 moles) with stirring at room temperature. To this slurry was added cis-hexahydrophthalic anhydride (1 kg, 6.49 moles) and the slurry was heated to 50° C. After stirring with heat for 5 hours, the mixture became quite thick, at which time the pH of the aqueous phase was found to be about 7. The white product was collected by suction filtration, washed with copious amounts of water, and dried in a vacuum oven overnight at 140° C. The dry weight was 1270 grams (93% yield) having a melting point greater than about 400° C. The IR and NMR spectra were consistent with the expected product.
EXAMPLE 2
[0025] Cis-Strontium HHPA:
[0026] To an 500-mL round bottom flask with a mechanical stirrer and reflux condenser was added cis-hexahydrophthalic anhydride (15.4 g, 100 mmol), water (200 mL), and sodium hydroxide (16 g, 400 mmol) and the mixture heated to 50° C. After stirring with heat for 2 hours, a solution of strontium chloride hexahydrate (26.7 g, 168 mmol) was added and a white flocculate appeared immediately. The white product was collected by suction filtration, washed with copious amounts of water, and dried in a vacuum oven overnight at 110° C. The dry weight was 25 grams (97% yield) with a melting point in excess of about 400° C. The IR and NMR spectra were consistent with the expected product.
EXAMPLE 3
[0027] Cis-Dilithium HHPA
[0028] To a 1-L 3-necked round bottom flask fitted with a reflux condenser, mechanical stirrer, and thermometer was added water (300 mL), lithium hydroxide monohydrate (17.7 g, 421 mmol), and cis-hexahydrophthalic anhydride (30.8 g, 200 mmol). After heating at reflux for 3 hours, the reaction mixture was cooled and then poured into acetone (500 mL). No precipitate formed, and the solvents were removed by rotary evaporation to give a white powder. The powder was washed on a filter with 50 mL of cold water, and the solid was dried in a vacuum oven at 85° C. overnight. The dry weight as about 37 grams (100%), with a melting point greater than about 350° C. IR and NMR analysis were consistent with that of the expected product.
EXAMPLE 4
[0029] Cis-Monobasic Aluminum HHPA
[0030] To a 500-mL round bottom flask with a mechanical stirrer was added cis-disodium HHPA (10 g, 46.2 mmol) and water (100 mL). When homogeneity was obtained, a solution of aluminum sulfate (15.4 g, 23 mmol) in water (100 mL) was added, at which time a white flocculate formed immediately. After stirring at 50° C. for 30 minutes, the pH was adjusted to 9, the white solid was collected via suction filtration, washed with water (200 mL), and dried in a vacuum oven overnight at 100° C. The dry weight equaled 8.7 grams (88%) with a melting point of greater than about 400° C. IR and NMR analysis were consistent with that of the expected structure.
EXAMPLE 5 (COMPARATIVE)
[0031] Cis-Magnesium HHPA
[0032] To a 500-mL Erlenmeyer flask with a magnetic stirring bar was added water (200 mL) and cis-disodium HHPA (20 g, 92.4 mmol) with stirring. After homogeneity was obtained, a solution of magnesium sulfate (11.1 g, 92.4 mmol) in water (100 mL) was slowly added. After stirring for 3 hours, the solvent was removed by rotary evaporation, affording a white solid. The sodium sulfate by-product was removed by sonicating the powder in methanol (300 mL), filtering, and drying in a vacuum oven at 110° C. overnight. Dry weight=17 grams (95%), mp>400° C. IR and NMR analysis were consistent with that of the expected product.
EXAMPLE 6 (COMPARATIVE)
[0033] Cis-Barium HHPA
[0034] To a 500-mL round bottom flask with a mechanical stirrer was added cis-hexahydrophthalic anhydride (15.4 g, 100 mmol), water (200 mL), and sodium hydroxide (16 g, 400 mmol). When homogeneity was obtained, a solution of barium chloride (20.8 g, 100 mmol) in water (50 mL) was added, at which time a white flocculate formed immediately. After stirring for 30 minutes, the white solid was collected via suction filtration, washed with water (100 mL), and dried in a vacuum oven overnight at 115° C. Dry weight=30.7 grams (99%), mp>400° C. IR and NMR analysis were consistent with that of the expected structure.
EXAMPLE 7 (COMPARATIVE)
[0035] Cis-Disilver HHPA
[0036] To a 500-mL round bottom flask with a mechanical stirrer was added cis-disodium HHPA (20 g, 92.4 mmol) and water (100 mL). When homogeneity was obtained, a solution of silver nitrate (31.39 g, 184.8 mmol) in water (100 mL) was added, at which time a white flocculate formed immediately. After stirring for 30 minutes, the white solid was collected via suction filtration, washed with water (200 mL), and dried in a vacuum oven overnight at 110° C. Dry weight=27.8 grams (78%), mp>400° C. IR and NMR analysis were consistent with that of the expected structure.
EXAMPLE 8 (COMPARATIVE)
[0037] Cis-Dipotassium HHPA
[0038] To a 500-mL round bottom flask with a stir bar and reflux condenser was added cis-hexahydrophthalic anhydride (44 g, 285.4 mmol), water (200 mL), and potassium hydroxide (32 g, 570.8 mmol). When homogeneity was obtained, the solution was heated at reflux for 2 hours. The solution was cooled, and the solvent removed via rotary evaporation. The white solid was washed with acetone (250 mL), filtered and dried in a vacuum oven overnight at 100° C. Dry weight=59.8 grams (84%), mp>400° C. IR and NMR analysis were consistent with that of the expected structure. The sample proved to be too hygroscopic for testing in plastic (see Table 3 for hygroscopicity results).
[0039] Production of Nucleated Polyolefins with Inventive HHPA Salts
[0040] Before molding into polypropylene plaques, one kilogram batches of target polypropylene pellets were produced in accordance with the following table:
Component Amount Polypropylene homopolymer (Himont Profax ® 6301) 1000 g Irganox ® 1010, Primary Antioxidant (from Ciba) 500 ppm Irgafos ® 168, Secondary Antioxidant (from Ciba) 1000 ppm Acid Scavenger (either Calcium Stearate, Lithium Stearate or as noted DHT4-A) Inventive HHPA salts as noted
[0041] The base resin (polypropylene homopolymer, hereinafter “HP”) and all additives were weighed and then blended in a Welex mixer for 1 minute at about 1600 rpm. All samples were then melt compounded on a Killion single screw extruder at a ramped temperature from about 204° to 232° C. through four heating zones. The melt temperature upon exit of the extruder die was about 246° C. The screw had a diameter of 2.54 cm and a length/diameter ratio of 24:1. Upon melting the molten polymer was filtered through a 60 mesh (250 micron) screen. Plaques of the target polypropylene were then made through extrusion into an Arburg 25 ton injection molder. The molder was set at a temperature anywhere between 190 and 260° C., with a range of 190 to 240° C. preferred, most preferably from about 200 to 230° C. (for the Tables below, the standard temperature was 220° C.). The plaques had dimensions of about 51 mm×76 mm×1.27 mm, and due to the mold exhibiting a mirror finish the resultant plaques exhibited a mirror finish as well. The mold cooling circulating water was controlled at a temperature of about 25° C. The same basic procedures were followed for the production of plaques of impact copolymer polypropylene (ICP, Table 2).
[0042] Flexural modulus testing (reported as 1% Secant Modulus) was performed on the above mentioned plaques using an MTS Sintech 1/S: 40″ instrument with a span of 49 mm, a fixed deflection rate of 1.28 mm/min, a nominal sample thickness of 1.27 mm, and a nominal sample width of 50 mm in conformance with ASTM D790.
[0043] Nucleation capabilities were measured as polymer recrystallizati6n temperatures (which indicate the rate of polymer crystal formation provided by the presence of the nucleating additive) by melting the target plaques, cooling the plaques at a rate of about 20° C./minute, and recording the temperature at which polymer crystal re-formation occurs (Tc). Crystallization half-time (T1/2) is also a useful parameter which can determine to what extent a nucleating agent might reduce molding cycle times. In this test, the target plaques (ICP) were melted at 220° C., then quenched at a nominal rate of 200° C./min to 140° C., at which time the crystallization temperature at half height was measured. Control plaques without nucleating additives, as well as with NA-11 and NA-21 (from Asahi Denka) and sodium benzoate were also produced for comparative purposes for some or all of the above-noted measurements.
[0044] Tables 1 and 2 below show the performance data of several inventive HHPA salts in terms of peak crystallization temperature (T c ), percent haze, and flexural modulus (all temperatures listed below have a statistical error of +/−0.5° C., and all haze measurements have a statistical error of +/−0.25 haze units), and crystallization half-time (T1/2). The acid scavengers added were as follows: calcium stearate (CS), dihydrotalcite (commercial product from Kyowa Chemical known as DHT4-A), and lithium stearate (LS); such compounds were added in amounts of about 400-800 ppm within the target polypropylene compositions for formation of the test plaques, while the inventive HHPA salts were added at a concentration of 0.25% by weight unless otherwise noted. An asterisk (*) indicates no measurements were taken.
EXPERIMENTAL TABLE 1 Nucleation Performance of Inventive Salts in Homopolymer Polypropylene Nucleator Added Acid Scavenger 1% Secant Modulus, Plaque # (Ex. # from above) Added T c (° C.) Haze (%) MPa (std. Dev.) 10 1 CS{circumflex over ( )} 121 38 2209 (16.6) 11 1 DHT4-A{circumflex over ( )} 122 53 2077 (8.3) 12 1 LS{circumflex over ( )} 121 38 2190 (37.5) 13 2 CS 120 43 2129 (17.9) 14 2 DHT4-A 122 51 2060 (15.7) 15 2 LS 120 37 2209 (3.3) 16 3 DHT4-A 121 65 2023 (1.3) 17 3 LS 121 61 1997 (25) 18 4 LS 121 56 2022 (6.9) (Comparatives) 19 5 DHT4-A 117 55 2026 (23.4) 20 5 LS 114 67 1952 (18.3) 21 6 DHT4-A 116 99 1892 (3.7) 22 6 CS 115 78 1926 (4.2) 23 7 DHT4-A 119 58 * 24 Sodium Benzoate None 120 60 * 25 Sodium Benzoate CS 116 62 * 26 (control) None CS 112 64 1691 (18)
[0045] Thus, the inventive HHPA salts exhibited more consistently high peak crystallization temperatures, as well as lower haze and more consistent high flexural modulus measurements than the comparative examples, particularly upon the inrtroduction of highly desirable acid scavengers.
EXPERIMENTAL TABLE 2 Crystallization Half-Time of Example 1 vs. Comparative Examples in ICP Cryst. Temp Additive (DSC Crystallization Concentration peak Half-time Plaque # Additives (ppm) max.) (minutes) 27(comparative) Control — 115 — (None) 28 Example 1 2500 123 4.81 29 (comparative) DMDBS 2500 126 2.83 30 (comparative NA-11 1000 126 2.52 31 (comparative) Sodium 2500 123 8.05 Benzoate 32 (comparative) NA-21 2200 123 10.44
[0046] Thus, the inventive calcium HHPA salt exhibited acceptable peak crystallization temperatures and crystallization half-time measurements as compared the prior art nucleators.
[0047] Hygroscopicity Testing
[0048] These tests were carried out on the milled products to give adequate surface area for moisture uptake. Two grams of each example were spread out on a watch glass and weighed immediately after drying in a vacuum oven. The samples were then placed in a controlled humidity (65%) environment and the weight was taken each day for 7 days. The percent weight gain was defined as the percent moisture uptake at 7 days. Table 3 below summarizes the results:
EXPERIMENTAL TABLE 3 Hygroscopicity of Compounds Example # % Water Absorbed 1 0.20 sodium benzoate (Comparative) 1.20 8 (Comparative) 38.00
[0049] It is clear from the above data that the inventive compound from Example 1 exhibits greatly reduced hygroscopicity over that of the prior art as well as a higher molecular weight Group I metal salt (dipotassium).
[0050] Production of Nucleated PET with Example 1 (5000 ppm)
[0051] Additives were compounded with a C. W. Brabender Torque Rheometer at 5000 ppm into Shell Cleartuff™ 8006 PET bottle grade resin having an IV of 0.80. All resin was dried to less than 20 ppm water. Samples were taken, pressed, and rapidly cooled into 20-40 mil films. All samples were dried at 150° C. under vacuum for 6 h prior to analysis. 5 mg samples were analyzed under nitrogen on a Perkin Elmer System 7 differential scanning calorimeter using a heating and cooling rate of 20° C./min. T c data was collected after holding the samples at 290° C. for 2 min. before cooling. The data is shown below in Table 4:
EXPERIMENTAL TABLE 4 Polymer Crystallization Temperature of Example 1 in PET Sample T c (° C.) Control 155 Example 1 180
[0052] Thus, the inventive compound of Example lexhibited much improved nucleation of polyester over the control with no nucleator compound.
[0053] Having described the invention in detail it is obvious that one skilled in the art will be able to make variations and modifications thereto without departing from the scope of the present invention. Accordingly, the scope of the present invention should be determined only by the claims appended hereto.
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Compounds and compositions comprising specific metal salts of hexahydrophthalic acid (HHPA) in order to provide highly desirable properties within thermoplastic articles are provided. The inventive HHPA derivatives are useful as nucleating and/or clarifying agents for such thermoplastics, are practical and easy to handle. Such compounds provide excellent crystallization temperatures, stiffness, and acid scavenger compatibility within target polyolefins. Also, such compounds exhibit very low hygroscopicity and therefore excellent shelf stability as powdered or granular formulations. Thermoplastic additive compositions and methods of producing polymers with such compounds are also contemplated within this invention.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to a fan-rotor combination for a cooling blower of a motor vehicle, in particular with low blower power, wherein the fan-rotor combination has a rotor of an electric motor and a fan fastened to the rotor.
[0002] In the field of cooling blowers for internal combustion engines with electronically commutated electric motors, in the prior art, the fans are always fastened to the rotor by means of screws. Here, the fan lies on the rotor and the screws fasten the fan to the rotor (see FIG. 1 ). Here, use is usually made of three screws, which are preferably screwed in with torque monitoring.
SUMMARY OF THE INVENTION
[0003] It is an object of the invention to provide an improved fan-rotor combination. Here, the fan-rotor combination according to the invention should be of simple construction and cheap to manufacture. Furthermore, it should preferably be possible for the fan-rotor combination to be assembled manually without the use of tools or machines and in a short period of time, and said fan-rotor combination should furthermore have a small number of components. Here, the fan-rotor combination may preferably be designed for a low blower power and adapted to the demands of the emerging markets, such as for example a simple and robust design.
[0004] The object of the invention is achieved by means of a fan-rotor combination for a cooling blower of a motor vehicle.
[0005] The fan-rotor combination according to the invention has a rotor of a motor or of an electric motor and has a fan fastened to the rotor. Here, the fan is fixed to the rotor without the aid of additional components, in particular screws, or materially separate components, wherein the fan is fastened to the rotor preferably by means of an easily detachable positively locking connection. Said mechanical connection may if appropriate have non-positively locking attributes. The fastening of the fan to the rotor takes place on an axial portion and/or a radial portion of the rotor. Furthermore, the electric motor is preferably an electrically commutated external-rotor electric motor.
[0006] According to the invention, a mechanical connection between the rotor and the fan is realized exclusively through the respective design of the rotor and/or of the fan. A connecting partner, which is required for the fastening of the fan to the rotor, of the fan and/or of the rotor is a constituent part, in particular a materially integral constituent part, of the fan and/or of the rotor respectively. Here, the connecting devices required for the fastening preferably extend through one another and are if appropriate secured. Here, the securing means are preferably constituent parts of the fan and/or of the rotor and are likewise preferably connected to the fan and/or to the rotor in a materially integral manner, for example by means of webs formed as predetermined breaking points.
[0007] In one embodiment of the invention, the fan has a detent device which engages into a corresponding detent device of the rotor. In a further embodiment, the fan has an elastically flexible snap-in hook which is snapped into a corresponding recess of the rotor. Here, a locking position of the snap-in hook can be secured by means of a locking pin or bolt. Furthermore, in one embodiment of the fan-rotor combination, the fan and the rotor can be fixed to one another by means of a bayonet locking connection. Here, the bayonet hooks may in turn be secured by means of securing pins or bolts.
[0008] Furthermore, in one embodiment of the invention, the fan may have a fastening projection which is preferably composed of plastic and which projects through a passage recess in the rotor. Here, that portion of the fastening projection which projects through the passage recess is deformed, which may be realized for example by means of an electrode, a heating element, a sonotrode or an anvil. In another embodiment of the invention, the rotor has a fastening lug which extends through a passage recess in the fan. That portion of the fastening lug which projects through the passage recess is deformed, in particular bent over. Furthermore, in an additional embodiment of the invention, the fan may have an internal thread which is screwed onto an external thread of the rotor.
[0009] The embodiments of the invention may self-evidently also be kinematically reversed. Furthermore, they may also, including a kinematic reversal, be combined with one another. Furthermore, the invention is not restricted to the automotive field, but rather may also be applied to other fields such as for example heating blowers or dust extraction hoods.
[0010] The invention yields a significant cost reduction, because in comparison with the prior art, three components, specifically the screws, are omitted because the function of torque transmission to the fan and the positioning of the fan on the rotor are realized exclusively by means of the design of the fan and of the rotor. In this way, axial installation space for the screw heads is eliminated, as a result of which the application is simplified owing to a reduction in required installation space.
[0011] The snap-in or pressing-in processes can be carried out in a short time period and with less assembly outlay than a screw connection, as a result of which the assembly time for the fan is reduced. Furthermore, as a result of the fact that the metallic rotor is tightly clasped by a plastic hub, vibrations of the rotor are damped and blower noise is reduced. The fastening concept according to the invention permits manual assembly without additional aids and can therefore be used worldwide without great expenditure. As a result of the omission of components which require great outlay in ensuring quality, the creation of the individual components of the fan fastening according to the invention can be more easily localized.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention will be explained in more detail below on the basis of exemplary embodiments and with reference to the appended drawing, in which:
[0013] FIG. 1 shows a sectional side view of a fan-rotor combination according to the prior art in an assembled state;
[0014] FIG. 2 shows a sectional side view of a first embodiment according to the invention of a fan-rotor combination before the assembly thereof;
[0015] FIG. 3 shows a sectional side view of the fan-rotor combination from FIG. 2 in an assembled state;
[0016] FIG. 4 shows a cut-away axial side view of a second embodiment according to the invention of a fan-rotor combination after the assembly thereof;
[0017] FIG. 5 shows a perspective detail view of the fan-rotor combination from FIG. 4 before the insertion of securing pins;
[0018] FIG. 6 shows a sectional side view of a third embodiment according to the invention of a fan;
[0019] FIG. 7 shows a plan view of a third embodiment according to the invention of a rotor;
[0020] FIG. 8 shows a plan view of the fan from FIG. 6 ;
[0021] FIG. 9 shows a cut-away sectional side view of a first assembly step of the third embodiment of the fan-rotor combination;
[0022] FIG. 10 shows, analogously to FIG. 9 , a second assembly step of the fan-rotor combination;
[0023] FIG. 11 shows, analogously to FIG. 10 , a third assembly step of the fan-rotor combination;
[0024] FIG. 12 shows, analogously to FIG. 11 , a fourth assembly step of the fan-rotor combination;
[0025] FIG. 13 shows a sectional side view of the third embodiment of the fan-rotor combination in an assembled state;
[0026] FIG. 14 shows a sectional side view of a fourth embodiment according to the invention of a fan-rotor combination before the assembly thereof;
[0027] FIG. 15 shows a sectional side view of the fan-rotor combination from FIG. 14 in an assembled state;
[0028] FIG. 16 shows a sectional side view of a fifth embodiment according to the invention of a fan-rotor combination before the assembly thereof;
[0029] FIG. 17 shows a sectional side view of the fan-rotor combination from FIG. 16 in an assembled state;
[0030] FIG. 18 shows a sectional side view of a sixth embodiment according to the invention of a fan-rotor combination before the assembly thereof; and
[0031] FIG. 19 shows a sectional side view of the fan-rotor combination from FIG. 18 in an assembled state.
DETAILED DESCRIPTION
[0032] The fan-rotor combination 1 or fan fastening 1 according to the invention illustrated in the drawing is characterized in that the components to be mechanically connected to one another, for example for cooling an internal combustion engine, that is to say a rotor or motor rotor 10 of an electric motor 30 and a fan 20 , are fixed to one another by means of positive locking in the axial direction A and radial direction R without an additional screw. For this purpose, at least one connecting device 100 , 200 (for example a detent device such as a detent hook or a detent recess; a snap-in hook; a bayonet hook; a claw; an undercut; a fastening projection such as for example a lug, a dome, a peg, a pin, a bolt, a rib; a thread, a notch etc.—and a device corresponding thereto) is provided on/in the fan 20 and/or on/in the rotor 10 , which connecting device(s) serve(s) for fastening the fan 20 to the rotor 10 . All the components required for the functioning fan-rotor combination 1 originate from the two individual components fan 20 and rotor 10 , that is to say according to the invention, no materially separate components or other components aside from the fan 20 and the rotor 10 are used. In particular, the following embodiments of the invention may be realized:
[0033] In the first embodiment of the invention illustrated in FIGS. 2 and 3 , the fan 20 has, as a connecting device 200 , at least one but preferably at least two mutually opposite detent hooks 210 which project inwardly from a fan hub 22 and which engage into corresponding connecting devices 100 , designed as detent recesses 110 , of the rotor 10 on the axial portion 13 thereof. It is self-evidently also possible for the detent hooks to be provided on the rotor 10 and for the detent recesses to be provided on the fan 20 . Here, the respective snap-in contour 110 , 120 or detent device 110 , 120 may be of partially, sectionally or fully encircling form.
[0034] FIGS. 4 and 5 show details of the second embodiment according to the invention of the fan-rotor combination 1 , wherein the respective connecting devices 100 , 200 are formed as passage recesses 120 in a radial portion 14 of the rotor 10 and as snap-in hooks 220 , designed preferably as bending beams, of the fan hub 22 . Here, a radial portion of the fan 20 lies on the radial portion 14 of the rotor 10 , wherein the snap-in hooks 220 project substantially perpendicularly from the radial portion of the fan 20 and engage into the passage recesses 120 of the radial portion 14 of the rotor 10 . Here, the snap-in hooks 220 are preferably distributed substantially over a (segment of a) circle, wherein in each case two directly adjacent snap-in hooks 220 have their backs to one another, that is to say the two hook contours of the snap-in hooks 220 point away from one another. In each case two such adjacent snap-in hooks 220 engage at the longitudinal side into a passage slot 120 (passage recess 120 ) which widens with increasing radius.
[0035] The snap-in hooks 220 may be secured by means of securing pins 222 , wherein either a securing pin 222 is pushed in between two directly adjacent snap-in hooks 220 , which securing pin, like that mentioned below, may then be materially integrally connected to the fan hub 22 via webs formed as predetermined breaking points, or a separate securing pin 222 may be provided for each snap-in hook 220 . In the latter case, it is preferable for a mount 224 in the form of a guide 224 or support 224 , which is preferably formed materially integrally with the fan hub 22 , to be provided for each securing pin 222 . Here, the respective mount 224 extends into the respective passage recess 120 of the rotor 10 , and the corresponding securing pin 222 is pushed in between the respective snap-in hook 220 and the respective mount 224 . It is self-evidently also possible for the snap-in hook 220 and passage recesses 120 to be interchanged.
[0036] In the third embodiment of the invention, see FIGS. 6 to 13 , use is made of a lockable bayonet connection (connecting devices 100 , 200 ) of the fan 20 to the rotor 10 , in particular of the respective radial portions. Here, the fan hub 22 has, projecting away from its radial portion in the direction of the rotor 10 , at least one but preferably three bayonet hooks 230 which are arranged on a circular path and which can engage into bayonet recesses 130 , which correspond to said bayonet hooks, of the rotor 13 . Furthermore, on the circular path of the bayonet hooks 230 , the fan 20 has securing pins 232 which are integrally formed therewith by means of webs formed as predetermined breaking points, which securing pins secure a bayonet connection against self-release. Again, a kinematic reversal may self-evidently be realized.
[0037] FIGS. 9 to 12 show such a realization of the bayonet connection. Firstly, the bayonet hooks 230 are inserted into the bayonet recess 130 until the radial portion of the fan 20 lies on the radial portion 14 of the rotor 10 ( FIG. 9 ). The fan 20 and rotor 10 are then rotated relative to one another about their common axis of rotation A until the bayonet hooks 230 engage under the rotor 10 ( FIG. 10 ). That portion of the respective bayonet recess 130 which is opened up between the respective bayonet hook 230 and the rotor 10 is occupied by the pressing-in of a securing pin 232 ( FIG. 11 ), such that the fan 20 can no longer rotate relative to the rotor 10 ( FIGS. 12 and 13 ).
[0038] In the fourth and fifth embodiment of the fan-rotor combination 1 according to the invention, the fastening of the fan 20 to the rotor 10 is realized by means of deformed component regions of the fan 20 (fourth embodiment) and of the rotor 10 (fifth embodiment). Here, the fan 20 and/or the rotor 10 have/has component regions, lugs etc. which are deformed by a joining process (if appropriate thermally assisted, for example heating by means of ultrasound, hot air etc.) and thereby secure the component fastening. A reverse approach in each case may self-evidently also be used.
[0039] In the fourth embodiment of the invention illustrated in FIGS. 14 and 15 , the fan 20 has, projecting from its radial portion in the direction of the rotor 10 , at least one fastening projection 240 (connecting device 200 ) which may be designed for example as a pin, bolt, rib, dome or peg. For assembly, the fastening projections 240 of the fan 20 are plugged through passage recesses 140 (connecting device 100 ) in the radial portion 14 of the rotor 10 , and the portions which extend through the passage recesses 140 are subsequently plastically deformed by means of a deformation element 40 , which may take place for example using the abovementioned method.
[0040] In the fifth embodiment of the invention illustrated in FIGS. 16 and 17 , the rotor 10 has, projecting away from its radial portion 14 , at least one lug 150 (connecting device 100 ); the fan 20 has at least one passage recess 250 (connecting device 200 ) which corresponds to said lug and by means of which the fan 20 can be threaded onto the lug(s) 150 . During the mounting of the fan 20 on the rotor 10 , those portions of the lugs 150 which extend through the passage recesses 250 are bent over and thereby fix the fan 20 to the rotor 10 .
[0041] In the final illustrated embodiment of the invention ( FIGS. 18 and 19 ), the fan 20 or the fan hub 22 and the rotor 10 have, as corresponding connecting devices 100 , 200 , in each case one thread 160 , 260 by means of which the fan 20 and rotor 10 can be directly screwed to one another. Here, the respective thread 160 , 260 is an integral constituent part of the respective component. Here, it is preferable for the fan 20 to have an internal thread 260 and for the rotor 10 to have an external thread 160 . Here, the threads are preferably oriented such that a rotating rotor 10 “screws into” the fan 20 .
[0042] All the embodiments of the invention may comprise domes, ribs, beads, hooks, notches, bulges etc. integrated on the rotor 10 and/or on the fan 20 for the purpose of undercut anchoring, torque transmission, positioning and/or simplification of assembly or joining processes. Optionally, the fastening of the rotor 10 and fan 20 may be secured against self-release of component parts (in particular snap-in hooks) by means of additional pressing, calking, (if appropriate thermally assisted) deformation or shearing-off of component regions (for example securing pins or bolts).
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The invention relates to a combined blower/rotor ( 1 ) for a cooling fan of a motor vehicle, especially one having a reduced fan output. Said combined blower/rotor comprises a rotor ( 10 ) of an electric motor ( 30 ) and a blower ( 20 ) fastened to the rotor ( 10 ), said blower ( 20 ) being fixed to the rotor ( 10 ) without screws.
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BACKGROUND OF THE INVENTION
1. Field of the Invention:
The present invention relates to a muffler for an internal combustion engine, and more particularly to a muffler for use as part of an internal combustion engine.
2. Description of the Prior Art:
Internal combustion engines are generally coupled with silencers or mufflers for expanding and compressing an exhaust gas emitted from the engine to dissipate the energy of the exhaust gas for attenuating the sound produced thereby. The muffler normally comprises an outer box of sheet steel defining therein an expansion chamber. However, the outer box of sheet steel cannot provide sufficient heat and sound insulation, and is relatively heavy. There has been proposed a muffler composed of an outer box of sheet steel and a layer of glass wool applied to the inner wall surface of the outer box. Although the proposed muffler can attain a certain degree of heat and sound insulation, it is complex in construction and also has an increasd weight.
The outer box of a muffler may be constructed of a sound insulation material formed by baking inorganic or organic fibers. Since muffler outer boxes are generally in the form of an elongate tube with front and rear ends closed, it may be advantageous in the manufacturing process to form a plurality of separate bodies of a sound insulation material and then join the formed separate bodies with an adhesive, thereby constructing a muffler outer box.
The muffler outer box is strongly subjected to the influence of heat and pressure variations when in use, and hence is required to have a mechanical strength great enough to withstand these stresses. Where the outer box is composed of the joined separate bodies of formed sound insulation material, the joined portions of the outer box are mechanically weaker than the rest of the outer box.
The present invention has been made in an effort to solve the above conventional problem.
SUMMARY OF THE INVENTION
According to the present invention, a muffler for an internal combustion engine includes an outer box composed of a plurality of separate bodies made of a formed sound insulation material and having portions joined by an adhesive, the outer box having an inlet for introducing an exhaust gas from the internal combustion engine and an outlet for discharging the exhaust gas, and a reinforcing member mounted on the joined portions to seal and reinforce the same.
Accordingly, it is an object of the present invention to provide a muffler for internal combustion engines which is simple in construction, has a good sound insulation capability, is lightweight, and sufficiently mechanically strong.
The above and other objects, features and advantages of the present invention will become more apparent from the following description when taken in conjunction with the accompanying drawings in which preferred embodiments of the present invention are shown by way of illustrative example.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal cross-sectional view of a muffler according to a first embodiment of the present invention;
FIG. 2 is a fragmentary perspective view, partly in a radial or transverse cross section, of the muffler shown in FIG. 1;
FIG. 3 is a transverse cross-sectional view of a muffler according to a second embodiment of the present invention;
FIG. 4 is a view similar to FIG. 2, showing a muffler according to a third embodiment of the present invention;
FIG. 5 is a longitudinal cross-sectional view of a muffler according to a fourth embodiment of the present invention;
FIG. 6 is a cross-sectional view taken along line 6--6 of FIG. 5;
FIG. 7 is a view similar to FIG. 2, showing a muffler according to a fifth embodiment of the present invention;
FIG. 8 is a view similar to FIG. 2, showing a muffler according to a sixth embodiment of the present invention;
FIG. 9 is a view similar to FIG. 3, showing a muffler according to a seventh embodiment of the present invention;
FIG. 10 is a view similar to FIG. 3, showing a muffler according to an eighth embodiment of the present invention;
FIG. 11 is a view similar to FIG. 2, showing a muffler according to a ninth embodiment of the present invention;
FIG. 12 is a cross-sectional view taken along line 12--12 of FIG. 11;
FIG. 13 a view similar to FIG. 2, showing a muffler according to a tenth embodiment of the present invention;
FIG. 14 is a cross-sectional view taken along line 14--14 of FIG. 13;
FIG. 15 is a view similar to FIG. 1, illustrating a muffler according to an eleventh embodiment of the invention;
FIG. 16 is a view similar to FIG. 1, illustrating a muffler according to a twelfth embodiment of the invention;
FIG. 17 is a view similar to FIG. 2, illustrating a muffler according to a thirteenth embodiment of the present invention;
FIG. 18 is a view similar to FIG. 2, showing a muffler according to a fourteenth embodiment of the present invention;
FIG. 19 is a view similar to FIG. 2, showing a muffler according to a fifteenth embodiment of the present invention;
FIG. 20 is a longitudinal cross-sectional view of a muffler according to a sixteenth embodiment of the invention;
FIG. 21 is an end elevational view of the muffler shown in FIG. 20;
FIG. 22 is a longitudinal cross-sectional view of a muffler according to a seventeenth embodiment of the invention; and
FIG. 23 is a cross-sectional view taken along line 23--23 of FIG. 22.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 show a muffler in accordance with a first embodiment of the present invention, the muffler being generally designated by the reference numeral 1. The muffler 1 has a tubular outer box 2 having front and rear ends closed and composed of a pair of lateral separate bodies 3, 3 of a formed sound insulation material. The formed sound insulation material constituting each of the separate bodies 3, 3 has an inner porous layer 3a and an outer tight layer 3b.
Each of the separate bodies 3 is formed as follows:
Inorganic or organic fibers such as long glass fibers, ceramic fibers, or the like are cut off and mixed together into wad, which is then pressed by rolls and needled into a mat. Thereafter, the mat is impregnated with a binder such as water glass. The fibrous mat is coated, on its surface serving as an outer surface of a separate body, with a solution of a thermosetting resin such as phenolic resin, epoxy resin, polyester, or the like. The mat is then placed in a mold of a given shape and baked. The coated solution of thermosetting resin is hardened into the tight layer 3b with the other portion serving as the porous layer 3a, thus forming the separate body 3 which is open at one side.
The separate body 3 has recesses 4, 5, 6 respectively in front end, intermediate, and rear end portions thereof.
For assembling the separate bodies 3, 3 into the muffler 1, the inner surfaces of the recesses 4, 5, 6 in one of the separate bodies 3 are coated with a thermally resistant adhesive 7, for example. An exhaust pipe 8 is fitted in the recess 4, a separator 10 with a connector pipe 9 supported thereby is fitted in the recess 5, and a tail pipe 11 is fitted in the recess 6. The inner surfaces of the recesses 4, 5, 6 in the companion separate body 3 are also coated with the adhesive 7. The adhesive 7 is also coated on the inner surfaces of outwardly projecting flanges 12 of the separate bodies 3, 3. The separate bodies 3, 3 are then joined together with the flanges 12, 12 held in abutment against each other. The bonded separate bodies 3, 3 now form the tubular outer box 2. The exhaust pipe 8 is inserted through and held by the front end portion of the outer box 2, the interior of which is divided by the separator 10 into a first expansion chamber 13 and a second expansion chamber 14. The tail pipe 11 is inserted through and held by the rear end of the outer box 2. Each of the connector pipe 9, the separator 10, and the tail pipe 11 is constructed of the same formed sound insulation material as that which the separate bodies 3, 3 are made of.
After the outer box 2 has been assembled, reinforcing members 15 are mounted by the adhesive 7 on outer surfaces of the flanges 12, 12 of the separate bodies 3, 3. Each of the reinforcing members 15 is formed of a resin or sheet steel and has a channel-shaped cross section gripping the flanges 12, 12 laterally together.
With the above embodiment, the outer box 2 of the muffler 1 is constructed of the joined separate bodies 3, 3 of a formed sound insulation material, and the connector pipe 9, the separator 10, the tail pipe 11 are also made of the same formed sound insulation material. Therefore, the muffler 1 is greatly reduced in weight and has an increased sound insulation capability. Since the reinforcing members 15 are mounted on the joined portions or flanges 12, the areas joined by the adhesive 7 are large, making the overall muffler 1 more rigid and and well sealed.
FIG. 3 shows a muffler 21 according to a second embodiment of the invention. The muffler 21 has an outer box 22 composed of separate bodies 23, 23 each made of a formed sound insulation material and composed of an inner porous layer 23a and an outer tight layer 23b. The separate bodies 23, 23 have flanges 24, 24 joined together by an adhesive 27 and covered on their outer surfaces with reinforcing members 25. The flanges 24, 24 are stitched with fibers 26 for increased bonding strength and sealing capability.
FIG. 4 illustrates a muffler 31 according to a third embodiment of the invention. The muffler 31 has an outer box 32 composed of separate bodies 33, 33 each made of a formed sound insulation material and composed of an inner porous layer 33a and an outer tight layer 33b. The separate bodies 33, 33 have flanges 34, 34 joined together by an adhesive 37 and gripped by reinforcing members 35 each having a channel-shaped cross section. Each of the reinforcing members 35 has a pair of spaced legs 35a, 35a connected together by rivets 36 extending therethrough for higher bonding strength and sealing capability.
A muffler 41 according to a fourth embodiment is illustrated in FIGS. 5 and 6. The muffler 41 has an outer box 42 comprising a pair of separate bodies 43, 43 each composed of an inner porous layer 43a and an outer tight layer 43b, the separate bodies 43, 43 having respective integral flanges or lugs 44, 44 projecting from upper central portions thereof. The separate bodies 43, 43 are joined together by an adhesive 47, with the lugs 44, 44 serving as a hanger stay 46. The hanger stay 46 has a bolt attachment hole 48 in which a damping rubber tube 49 is fitted. A web-shaped reinforcing member 45 is bonded to outer surfaces of the joined portions of the separate bodies 43, 43. The muffler 41 thus has an attachment, or the hanger stay 46, of an increased mechanical strength.
According to a fifth embodiment shown in FIG. 7, a muffler 51 has an outer box 52 composed of separate bodies 53, 53 bonded by an adhesive 57 and each comprising an inner porous layer 53a and an outer tight layer 53b. A web-shaped reinforcing member 55 is bonded by the adhesive 57 to outer surfaces of the joined portions of the separate bodies 53, 53.
FIG. 8 shows a sixth embodiment in which a muffler 61 has bonded separate bodies 63, 63, and tight layers 63b thereof have an elongate recess 64 of a prescribed width defined by cutting off abutting portions of the separate bodies 63, 63. A web-shaped reinforcing member 65 is fitted and bonded in the recess 64 by an adhesive 67. The reinforcing member 65 has an outer surface lying flush with an outer surface of the outer box 62. The muffler 61 thus constructed provides a sightly appearance as well as increased rigidity.
FIG. 9 is illustrative of a muffler 71 according to a seventh embodiment of the invention. The muffler 71 comprises an outer box 72 composed of a pair of bonded separate bodies 73, 73 with an web-shaped reinforcing member 75 bonded by an adhesive 77 to outer surfaces of the joined portions of the separate bodies 73, 73 for increased rigidity and sealing capability. In addition, inner porous layers 73a, 73a of the separate bodies 73, 73 have slanted abutting surfaces joined together in overlapping relation for effective thermal insulation.
As shown in FIG. 10, a muffler 81 according to an eighth embodiment comprises separate bodies 83, 83 including porous layers 83a, 83a having stepped abutting portions 84 joined in complementarily meshing relation by an adhesive 87. A web-shaped reinforcing member 85 is attached to outer surfaces of the joined portions of the separate bodies 83, 83. The muffler 81 of FIG. 10 provides increased rigidity and effective thermal insulation.
FIGS. 11 and 12 illustrate a muffler 91 according to a ninth embodiment of the invention. While in each of the previous embodiments the outer box is composed of transversely separate bodies, divided by a plane lying along the axis of the outer box, the muffler 91 of the ninth embodiment comprises an outer box 92 composed of tubular longitudinally separate bodies 93, 93, divided by a plane lying perpendicularly to the axis of the outer box. Each of the separate bodies 93, 93 includes an inner porous layer 93a and an outer tight layer 93b. A front end of one of the separate bodies 93 is joined by an adhesive 97 to a rear end of the other separate body 93, and an annular reinforcing member 95 is disposed around outer surfaces of the joined portions.
According to a tenth embodiment illustrated in FIGS. 13 and 14, a muffler 101 has an outer box 102 composed of longitudinally separate bodies 103, 103. The outer box 102 has an annular recess 104 defined by cutting off a rear circumferential edge portion of an outer tight layer 103b of one of the separate bodies 103 and a front circumferential edge portion of an outer tight layer 103b of the other separate body 103. An annular reinforcing member 105 is fitted in the annular recess 104 and bonded by an adhesive 107 to the separate bodies 103, 103. The reinforcing member 105 and the outer box 102 have outer surfaces lying flush with each other. The muffler 101 has larger bonding areas for increased mechanical strength and sealing capability, and also a sightly appearance.
FIG. 15 shows a muffler 111 constructed in accordance with an eleventh embodiment of the invention. The muffler 111 includes an outer box 112 comprising a pair of longitudinally separate bodies 113, 113 bonded together by an adhesive 117 partly at slanted and overlapped surfaces of inner porous layers 113a, the joined portions being sealed by an annular reinforcing member 115 disposed around the outer box 112.
According to a twelfth embodiment shown in FIG. 16, a muffler 121 has an outer box 122 composed of a pair of longitudinally separate tubular bodies 123, 123 including respective porous layers 123a, 123a having stepped portions overlapped and bonded together by an adhesive 127. The joined portion are surrounded by an annular reinforcing member 125. With the tubular separate bodies partially overlapped, rhe mechanical strength and thermal insulation of the muffler 121 are increased.
As shown in FIG. 17, a muffler 131 according to a thirteenth embodiment of the invention has an outer box 132 composed of two transversely separate bodies 133, 133, open at one side, joined together by an adhesive 137. Each of the separate bodies 133, 133 is made of a formed sound insulation material and composed of an inner porous layer 133a and an outer porous layer 133b. There are small clearance gaps defined between confronting ends of the porous layers 133a, 133a of the separate bodies 133, 133. A reinforcing member 135 of a T-shaped cross section is disposed within the outer box 132 and has a leg 135a inserted in each of the clearance gaps. The porous layers 133a, 133a, and the reinforcing member 135 are bonded together by the adhesive 137. With this construction, the muffler 131 is sightly since the reinforcing member 135 is not exposed to view.
FIG. 18 illustrates a muffler 141 according to a fourteenth embodiment of the invention. The muffler 141 has an outer box 142 composed of separate bodies 143, 143 including porous layers 143a, 143a and tight layers 143b, 143b which have joined portions positionally displaced transversely from each other and also from a central axis of the outer box 142. Between the porous layers 143a, 143a, there are defined clearance gaps in which legs 145a of cross-sectionally T-shaped reinforcing members 145 are inserted and bonded by an adhesive 147. The staggered arrangement of the joined surfaces of the porous layers 143a, 143a and the joined surfaces of the tight layers 143b, 143b is effective in increasing the sealing capability and rigidity.
A muffler 151 according to a fifteenth embodiment of the invention is shown in FIG. 19. The muffler 151 comprises a pair of separate bodies 153, 153 of a formed sound insulation material, each composed of an inner porous layer 153a and an outer tight layer 153b. The separate bodies 153, 153 have two pairs of integral flanges 154, 154 with inner surfaces thereof held against and bonded to each other by an adhesive 157. The abutting flanges 154, 154 in each pair are covered with a channel-shaped reinforcing member 155 disposed on outer surfaces thereof. A reinforcing member 156 of a T-shaped cross section is disposed within the muffler 151 and has a leg 156a inserted through the inner porous layers 153a up to a point between the flanges 154, 154, the leg 156a being bonded to the flanges 154, 154.
The mechanical strength of the muffler 151 is thus increased by the reinforcing members 155, 156 disposed on outer and inner surfaces of the flanges 154, 154.
FIGS. 20 and 21 show a muffler 161 according to a sixteenth embodiment of the invention. The muffler 161 has an outer box 162 supported by an inner structural member 163 of an iron-based material. Ihe inner structural member 163 is composed of a front end plate 164, a rear end plate 165, a separator 166, a connector pipe 167, and a tail pipe 168. The inner structural member 163 is integrally connected to an attachment stay 169 and an exhaust pipe 160.
According to a seventeenth embodiment illustrated in FIGS. 22 and 23, a muffler 171 includes an outer box 172 supported by an inner structural member 163 of an iron-based material. The inner structural member 163 comprises a separator 174, a punched plate 175, and a front end plate 176, and is integrally coupled to an attachment stay 177, a connector pipe 178, and an exhaust pipe 179.
With the sixteenth and seventeenth embodiments, the outer box is highly resistant to undue stresses because it is supported and stiffened by the inner structural member.
The present invention has been described by way of example only. The reinforcing members are not limited to the shapes and materials referred to above. The outer layer of the sound insulation material has been described as the tight layer which is formed of a thermosetting resin. However, the tight layer may be dispensed with, and the separate body may be composed solely of the porous layer.
With the arrangement of the present invention, the muffler is lightweight and has excellent sound insulation characteristics since the outer box of the muffler is constructed of a formed sound insulation material. As the outer box is composed of joined separate bodies of the formed sound insulation material, the outer box can easily be assembled. With the reinforcing members disposed on hte joined portions, the joined areas are widened to increase the mechanical strength and sealing capability of the joined portions. Better sound insulation can be provided by constructing the formed sound insulation material to have an outer tight layer.
Although there have been described what are at present considered to be the preferred embodiments of the present invention, it will be understood that the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all aspects as illustrative, and not restrictive. The scope of the invention is indicated by the appended claims rather than by the foregoing description.
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A muffler for an internal combustion engine includes an outer box composed of a plurality of separate bodies made of a formed sound insulation material and having portions joined by an adhesive, the outer box having an inlet for introducing an exhaust gas from the internal combustion engine and an outlet for discharging the exhaust gas, and a reinforcing member mounted on the joined portions to seal and reinforce the same. The muffler is simple in construction, has a good sound insulation capability, is lightweight, and sufficiently mechanically strong.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This document claims priority to French Application Number 05 51050, filed Apr. 25, 2005 and U.S. Provisional Application No. 60/675,890, filed Apr. 29, 2005, the entire contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a device that makes it possible to package and dispense a product designed to be shaken before being dispensed. The invention is particularly advantageous with a product that includes at least two mutually immiscible phases.
BACKGROUND OF THE INVENTION
Discussion of Background
Particularly in the cosmetic sector, some products are composed of at least two mutually immiscible phases having different densities. Examples are certain fragrances, hair care products, skin care products and the like. Before being dispensed, such products are preferably shaken in order to mix them as homogeneously as possible. In order to mix them, the user shakes the device in all directions, but it is not always easy by this means alone to achieve a homogeneous mixture.
EP1005915 discloses the use of a ball in a container for mixing the product contained in the container before dispensing it. The ball is free inside the container and therefore when the container is shaken it strikes the walls of the container.
U.S. Pat. No. 6,170,711 describes a product packaging and dispensing assembly that includes a product dispensing member having a dip tube. A magnetic component is provided in the dispensing member, as close as possible to the dispensing orifice, to expose the product to a magnetic field before it is dispensed. The magnetic component may be in the form of for example a cylinder or sphere surrounding the tube, around which it can slide freely. The magnetic component floats on the upper surface of the liquid so as to remain as close as possible to the dispensing member.
SUMMARY OF THE INVENTION
There is a need to provide a device for packaging and dispensing a product, particularly a product comprising two mutually immiscible phases, which will enable the product to be mixed with ease before it is dispensed.
There is also a need to provide such a device that is easy to assembly. There is also a need to provide such a device having improved aesthetic qualities.
According to the invention, these objects can be achieved by a device for packaging and dispensing a product such as a cosmetic product. According to a preferred example, such a device includes a container forming a holder for the product, with a dispensing element surmounting the container. A dip tube is provided for supplying product to the dispensing element, with the dip tube being connected to the dispensing element by a first end. In addition, a body is able to slide along the dip tube. Further, the dip tube includes, at a distance from its first end, an element forming a stop piece for the body in such a way as to limit the movement of the body along the dip tube.
The body that moves along the dip tube enables the product to be mixed when the device is shaken before the product is dispensed. Since the body is held on the dip tube, there is no risk of the moving body damaging the container when it is being shaken even if the material used for the moving body is relatively hard and the material for the container is more fragile.
According to an example of an embodiment, the element forming the stop piece limits the travel of the moving body along the dip tube when the device is shaken. Moreover, during assembly of the device, the element forming the stop piece can enable the moving body, which has been fitted onto the dip tube, to be kept in place before the dip tube is attached to the dispensing element. The dispensing element fitted with the dip tube and moving body can easily be handled with little or no risk of the moving body being lost, in particular before it is delivered on a container filling line.
By way of example, the element forming the stop piece can be situated at a second end of the dip tube, remote from the first end. This arrangement will maximize the length of travel of the moving body and can optimize the stirring of the product.
The moving body may be, for example, cylindrical, spherical or olive-shaped. It may of course have any other shape.
The moving body can be made in one piece or, alternatively, be made up of several pieces assembled together around the dip tube.
Also by way of example, the moving body can be made of a material selected from plastics, pressed glass, stainless steel and zamak. The material can also be plastic-coated.
The dispensing element can be, for example, a pump, and the pump may be mounted on the container, for example by snap-fastening, screwing or crimping.
The dispensing element may be surmounted by a push-button, which optionally can include a release arrangement, for example, in the form of a nozzle. Alternatively, the push-button may have a simple product outlet orifice. It may for example be in the form of a spout, at the end of which an outlet orifice is formed.
According to an example, the container may be made of a transparent material so that the product contained in the container can be seen from the outside. The container may for example by made of glass. By selecting the color of the product, and in particular of the different phases, if any, and the color of the moving body, a dispensing device having an attractive aesthetic appearance can be obtained from a transparent container.
Also by way of example, the container may contain a product composed of at least two mutually immiscible phases having different densities, with at least one of the phases being liquid. For example, the product may include a liquid phase and a particulate phase whose density is different from that of the liquid phase. The particulate phase may be in the form of a powder, microcapsules or nanocapsules, pigments, fillers or nacres. Alternatively, by way of example, the product may comprise an aqueous liquid phase and an oily liquid phase.
The device is particularly useful for packaging and dispensing a cosmetic product such as a fragrance.
As should be apparent, the invention can provide a number of advantageous features and benefits. It is to be understood that, in practicing the invention, an embodiment can be constructed to include one or more features or benefits of embodiments disclosed herein but not others. Accordingly, it is to be understood that the preferred embodiments discussed herein are provided as examples and are not to be construed as limiting, particularly since embodiments can be formed to practice the invention that do not include each of the features of the disclosed examples.
BRIEF DESCRIPTION OF THE DRAWINGS
In addition to the features discussed above, a number of other features or advantages will become apparent from the description herein of non-restrictive illustrative embodiments described with reference to the accompanying figures, in which:
FIG. 1 is a perspective view of one embodiment of a packaging and dispensing assembly according to the invention; and
FIG. 2 is a cross section through the device seen in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the drawings, examples of embodiments of the invention will now be described. The example illustrated in FIG. 1 includes a container 10 in the form of a bottle, which may be of glass, with the bottle being surmounted by a dispensing element 20 and a push-button 30 for operating the dispensing element 20 in such a way as to dispense the product through a dispensing orifice 32 .
The container 10 contains a fluid product to be dispensed, such as a more or less viscous liquid product. Examples of such products include a cosmetic product such as a fragrance, a sun-screen product, a hair care product, or a moisturizing product for the skin.
The product preferably includes at least two phases that are not permanently miscible with each other.
The products in the container may, for example, be two immiscible oily phases having different densities; an oily phase and an aqueous phase; or an oily phase and a hydroalcoholic phase. Thus, because of the density difference between the two immiscible phases, the heavy phase will sink to the bottom of the container, while the light phase will float on top of the heavy phase. The rate of phase separation can depend on the density difference between the two phases. When the contents of the container are shaken, a more or less homogeneous “mixture” of the two phases forms as a dispersion, suspension or emulsion. When this is left to stand, the phases “unmix” or separate because of the difference between their densities.
Another possibility is a liquid phase and a particulate (e.g. solid) phase. The particles may be heavier or lighter than the liquid phase. Such particles may be in the form, for example, of a powder, microcapsules or nanocapsules, pigments, fillers or nacres.
The two phases may be separated, either for aesthetic reasons (two different colors) or for reasons of incompatibility of the compounds of each of the phases.
In the illustrated preferred example, the container containing the product is elongated along an axis X. It has a side wall 11 with one end closed by a base 12 and the other end 13 terminating in an open neck to which the dispensing element 20 is fitted. In the illustrated example, the cross section of the container is circular, approximately constant throughout the axial height of the container, and narrowing to the neck at the top 13 in such a way as to form a shoulder. In the example illustrated, the cross section of the container has a small diameter compared with its axial height and forms a container having a tubular shape. The container may of course be of any other shape, and have any other section.
According to one example, the container is transparent so that the product contained inside it, and in particular the two phases separated at rest, can be seen. By selecting the colors of the different phases and that of the moving part, an attractive aesthetic effect can be obtained from an ordinary transparent container. Alternately, a portion of the container could be transparent. A portion or all of the container could also be partially transparent (e.g., translucent).
The dispensing element 20 which surmounts the container is in the form of a pump. The push-button 30 designed to operate the pump includes a release arrangement or outlet arrangement in the form of a nozzle 31 which defines the dispensing orifice 32 . Other release/outlet arrangements may be used. Examples include a grille or other outlet orifice, a frit, an applicator end piece, etc.
The pump 20 may be mounted on the container 10 , or on an intermediate mounting part, for example by crimping, screwing or force-fitting. The pump 20 , which is not shown in detail in the figures, includes a pump body into which feeds a first end 41 of a dip tube 40 designed to carry the product from the container to the pump.
As can be seen in FIG. 1 , the dip tube 40 extends from the pump 20 approximately along the axis X. In the illustrated example, the dip tube 40 includes, remote from the end 41 fixed to the dispensing head, an open free end 42 through which the product contained in the container can be sucked up into the pump body.
A moving body 50 is fitted around the dip tube in a sliding fit so as to move the product and encourage the phases of the product to mix together. The moving body 50 is advantageously made of a much denser material than the product P to be dispensed. The reason for this is that the greater the difference between the density of the body and that of the product, the more quickly the body will move through the product to mix the different phases.
The moving body 50 may for example be a cylinder of revolution with a central opening to allow it to sit around the dip tube. The moving body is made in one piece. It may alternatively be made from two or more parts connected together.
In accordance with the invention, the moving body could also be of any other shape. The body may for example be spherical, olive-shaped, helical, a torroid, star-shaped, etc. If desired, the shape of the container may then be chosen to suit that of the body, so for example a container may be chosen with a cross section of the same shape as that of the body. The central hole may also be other than circular in shape. For example, a shape that contributes to the desired aesthetic effect can preferably be chosen.
To keep the sliding body on the tube, a stop piece 60 is provided. In the illustrated example, the stop piece is preferably provided at the end 42 of the tube situated towards the base of the container.
In the example illustrated, the stop piece 60 is a separate component, for example, force-fitted onto the dip tube at its end 42 .
Alternatively the stop piece may be integral with the dip tube. In particular, it may be formed by an increase in the thickness of the wall of the tube.
In the example illustrated, the stop piece 60 is located at the end of the tube situated towards the base of the container. The stop piece may also be formed at a distance from the ends of the tube. However, it is preferable to give the sliding body the greatest possible distance to move.
In one particular illustrative embodiment, by way of example, the container has an axial height of approximately 13 cm and a diameter of approximately 2 cm. The outside diameter of the dip tube is approximately equal to 1.6 mm. The stop piece 60 has an outside diameter of approximately 4 mm. The moving body has an outside diameter approximately equal to 7 mm and an axial height approximately equal to 12 mm. The moving body is made of PCTA.
Also, according to an example, the product to be dispensed is a fragrance containing two immiscible phases or components of different densities. The heavier phase or component is colorless and the lighter phase is colored. Thus, the components have different color properties. Alternately, the components could have two different colors or two different color densities to provide different color properties. The dip tube and the stop piece are also transparent so as to pass almost unnoticed, while the moving body is colored. Thus, at rest, when the two phases are separated, a colored product can be seen in the top of the container and a colorless product in the bottom. In this position, the moving body is resting on the stop piece, towards the base of the container, so that the eye sees a colored body in the middle of a colorless product. Since the dip tube and the stop piece are colorless, the impression given is of a moving body floating inside the container, because the stop piece is raised somewhat above the base of the container.
By way of example, when assembling the device, the tube 40 with the moving body 50 sitting on it is force-fitted to the pump body, equipped with the push-button, while the moving body is retained by the stop piece 60 .
Such a pre-assembled assembly described in the preceding paragraph can easily be delivered on the container filling line with no risk of losing the moving body which is held in place on the dip tube. Once the container has been filled with the product, the pre-assembled assembly can be fixed to the container neck after first inserting the tube down inside the container.
To dispense the product, the user shakes the device by, for example, turning the head first up then down several times, until the two phases are mixed. He can then dispense the product in the conventional way, operating the pump by means of the push-button.
In the above detailed description, reference has been made to preferred embodiments of the invention. Clearly, variants may be made to this without departing from the invention as claimed below. 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 device for packaging and dispensing a product such as a cosmetic product. A preferred example of the device includes a container forming a holder for the product, and a dispensing element surmounting the container. A dip tube is provided for supplying product to the dispensing element, with the dip tube being connected to the dispensing element by a first end. In addition, a body is able to slide along the dip tube. Further, the dip tube includes, at a distance from its first end, an element forming a stop piece for the body in such a way as to limit the movement of the body along the dip tube.
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BACKGROUND
The invention relates to the use of special brighteners for preparing coating slips, coating slips per se and their use for the production of brightened papers.
Optical brighteners are used mainly for brightening paper or textiles or as an additive to detergents. The brightening of uncoated papers or untreated coating papers can be effected by beater use and/or surface application of optical brighteners, which are usually present for this purpose in dissolved form. In the production of coated papers, the addition of optical brighteners to the coating slip is customary, so that, in the finished coated paper, the optical brightener is also present in the pigment layer applied to the paper. Coated papers are particularly suitable for the production of high-quality prints. In addition to good printability properties, their quality is therefore assessed mainly according to optical properties, such as gloss and whiteness. There is a progressive trend toward coated papers having high whitenesses and therefore the desire for optical brighteners which are as effective as possible as coating slip components.
The most customary and most widely used paper brighteners are those of the formula (I)
in which
M represents Na, K or optionally substituted ammonium.
If the use of the so-called tetrasulfo type and hexasulfo type shown in formula (I) in paper coating is compared, saturation behavior with respect to the CIE whiteness is found above certain added amounts of brightener of the tetrasulfo type. In other words, when larger amounts are used, no further increase in whiteness is found and there may even be adverse effects on the CIE whiteness. This saturation behavior occurs with the use of the hexasulfo type as a rule only when substantially larger amounts are used compared with the tetrasulfo type. Consequently, higher whitenesses can generally be realized with hexasulfoflavonate brighteners than with tetrasulfoflavonate brighteners. The effect of saturation is also referred to as greening. The greening level, e.g., the point above which the use of increasing amounts of brightener result in virtually no further increase in whiteness, can be derived, for example, from the a*-b* diagram, a* and b* being the color coordinates in the CIE Lab system.
Since the greening in the case of hexasulfo types occurs only when relatively large amounts are used, the hexasulfoflavonate brightener shown in formula (I) and also other hexasulfoflavonate brighteners are particularly suitable for the production of coated, highly white paper. The exact application amounts at which the greening occurs in the case of tetra- and hexasulfoflavonate brighteners depend on the composition of the respective coating slip, inter alia on its carrier content.
On recycling coated papers, for example, for reuse of coated waste in the paper mill, the coated paper is beaten again, the brightener not fixed to the fibers initially going into solution from the coat and partly coating paper fibers. The increased solubility of the hexasulfoflavonate brighteners is disadvantageous in this context, since brightener not fixed to fibers acts as an interfering anionic substance in the circulation water of the paper machine and reduces the effect of cationic paper chemicals, such as retention aids or engine sizes, resulting in additional consumption of these paper chemicals.
There is therefore the desire for improved optical brighteners for brightening coating slips, in particular coating slips, with which higher whitenesses can be realized than with the use of customary di- and tetrasulfo types, such as those shown in formula (I), but which lead to a lower load of interfering substances in the circulation water of the paper machine than hexasulfo types on recycling of coated papers.
The brightening of coating slips based on synthetic co-binders is of primary importance. Natural co-binders, in particular starch, are not very suitable for top coats or single coats, owing to their swelling behavior on contact with aqueous liquids. As a result of the swelling, the quality of the printed image is reduced when printing on the coated paper. Starch is therefore preferably used as a co-binder in preliminary coats in the case of multiply coated papers, whereas synthetic co-binders are preferred in the case of singly coated papers or top coats. In the case of single coats or top coats, the whiteness requirements are generally higher than in the case of preliminary coats.
EP-A 192 600 states that certain polyethylene glycol-containing brightener formulations are particularly suitable as coating slip additives. However, only latex binders in combination with natural co-binders are used explicitly for coating slips.
Surprisingly, it has now been found that a certain class of bistriazinylflavonate brighteners having 2 or 4 sulfo groups meet these requirements in an outstanding manner in coating slip systems which contain synthetic co-binders.
SUMMARY
The invention relates to a method for brightening an aqueous coating slip that contains at least one latex binder and at least one synthetic co-binder different therefrom comprising treating the coating slip with an optical brightener of the formula (II):
in which
Y denotes a radical of the formula
and
R 1 represents C 1 -C 6 -alkyl and
R 2 represents H, or
R 1 represents H and
R 2 represents C 1 -C 6 -alkyl and, independently thereof,
R 3 represents H, methyl, ethyl, CH 2 CH 2 OH or CH 2 CH 2 OCH 3 ,
R 1′ represents C 1 -C 6 -alkyl and
R 2′ represents H, or
R 1′ represents H and
R 2′ represents C 1 -C 6 -alkyl and, independently thereof,
R 3′ represents H, methyl, ethyl, CH 2 CH 2 OH or CH 2 CH 2 OCH 3 and
R 4 represents C 1 -C 4 -alkyl,
Z denotes H or SO 3 M, it being possible for the sulfo groups to be in the o-, m- or p-position, and
M denotes H or one equivalent of a cation selected from the group consisting of Li, Na, K, Ca, Mg, ammonium and ammonium which is mono-, di-, tri- or tetrasubstituted by the radicals C 1 -C 4 -alkyl or C 2 -C 4 -hydroxyalkyl,
and thereby brightening the latex binder. The latex binder has at least one synthetic co-binder that differs from the latex binder.
In another embodiment, the invention relates to a coating slip comprising:
(a) at least one white pigment,
(b) at least one latex binder,
(c) at least one synthetic co-binder differing therefrom and
(d) at least one brightener of the formula (II).
In another embodiment, the invention relates to a method for making a coated paper comprising applying to a paper substrate a coating slip comprising (a) at least one white pigment, (b) at least one latex binder, (c) at least one synthetic co-binder differing therefrom and (d) at least one brightener of the formula (II), and thereby making the coated paper.
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
The invention therefore relates to the use of optical brighteners of the formula (II):
in which
Y denotes a radical of the formula
R 1 represents C 1 -C 6 -alkyl and
R 2 represents H, or
R 1 represents H and
R 2 represents C 1 -C 6 -alkyl, and, independently thereof,
R 3 represents H, methyl, ethyl, CH 2 CH 2 OH or CH 2 CH 2 OCH 3 ,
R 1′ represents C 1 -C 6 -alkyl and
R 2′ represents H, or
R 1′ represents H and
R 2′ represents C 1 -C 6 -alkyl, and, independently thereof,
R 3′ represents H, methyl, ethyl, CH 2 CH 2 OH or CH 2 CH 2 OCH 3 and
R 4 represents C 1 -C 4 -alkyl,
Z denotes H or SO 3 M, it being possible for the sulfo groups to be in the o-, m- or p-position, and
M denotes H or one equivalent of a cation selected from the group consisting of Li, Na, K, Ca, Mg, ammonium or ammonium which is mono-, di-, tri- or tetrasubstituted by the radicals C 1 -C 4 -alkyl or C 2 -C 4 -hydroxyalkyl for brightening aqueous coating slips containing at least one latex binder and at least one synthetic co-binder differing therefrom.
In a preferred embodiment, the synthetic co-binder is not a latex binder. Regarding the brightener of the formula (II), mixtures of said possibilities for M are also suitable. Preferred optical brighteners are those of the formula (II) where
R 1 is H, R 2 is linear C 1 -C 6 -alkyl and R 3 is H.
Further preferred optical brighteners are those of the formula (II) where
R 1′ is H, R 2′ is a linear C 1 -C 6 -alkyl and R 3′ is H and R 4 is H or methyl.
Particularly preferred is the use of the optical brightener of the formula (IIa):
in which
M has the above-mentioned meaning.
The particularly preferred brighteners of the formula (IIa) and related structures are known per se. Thus, GB-A 896 533 describes the preparation of this brightener and the use in beater and size press applications for brightening paper.
The brighteners used according to the invention may be used in the form of an aqueous solution which substantially contains dissolved brightener salts, water and optionally standardizing agents. Furthermore, they can be used as aqueous carrier-containing formulations which substantially contain dissolved brightener salts, water and carrier substances.
It is also possible to use the brighteners used according to the invention in the solid form, for example as powder or granules. It is advantageous if the brighteners go into solution before application of the coating slip. The dissolution process of the brighteners can be combined with preparation of the coating slip and powders or granules are used.
The brighteners used according to the invention are prepared by known methods, as described, for example, in GB-A 896 533 or in EP-A 860 437, for example from about 2 mol of cyanuric chloride, about 1 mol of 4,4′-diaminostilbene-2,2′-disulfonic acid or of a corresponding salt, about 2 mol of aniline, sulfanilic acid or a corresponding salt and about 2-2.5 mol of the amines corresponding to the substituent Y. After the end of the reaction, the crude solution in the corresponding brightener can be desalinated, for example by suitable membrane separation methods, and concentrated, as described, for example, in EP-A-992 547. Preferred membrane separation methods are ultrafiltration, diffusion dialysis and electrodialysis. However, it is also possible to isolate the resulting brightener as a solid, for example by salting out or acid addition and precipitation as a dye acid. The solid formed can then be isolated, for example, on a filter press and optionally further purified by washing.
For the preparation of the brightener preparation suitable for use, the brightener can also be isolated from solution in the form of a powder, for example by spray drying, further additives, such as dispersants, dedusting agents, etc. optionally being added before the drying.
Aqueous preparations can be prepared from crude solutions, from concentrated and desalinated solutions or from water-containing press cakes. To build up particularly good whiteness, it is advantageous to incorporate so-called carrier substances into the aqueous brightener preparations.
The aqueous brightener preparations preferably contain
a) from about 10 to about 40% by weight of at least one brightener of the formula (II),
b) from 0 to about 30% by weight of standardizing agent,
c) from 0 to about 2% by weight of inorganic salts and
d) from about 23 to about 90% by weight of water,
the sum of the components a) to d) being from about 95 to 100% by weight, based on the preparation.
Customary standardizing agents are, for example, urea, diethylene glycol, triethylene glycol, propanediol, glycerol, ε-caprolactam, ethanolamine, diethanolamine and triethanolamine. In each case, preparations free of standardizing agents are preferred.
The aqueous brightener preparations preferably likewise contain:
a) from about 5 to about 40% by weight of at least one brightener of the formula (II),
b) from about 1 to about 50% by weight of at least one carrier substance,
c) from 0 to about 2% by weight of inorganic salts and
d) from about 3 to about 94% by weight of water,
the sum of the components a) to d) being from about 95 to 100% by weight, based on the preparation.
Suitable carrier substances are in general hydrophilic polymers having the ability to form hydrogen bridge bonds. Preferred carrier substances are polyvinyl alcohols, carboxymethylcelluloses and polyethylene glycols having a number average molecular weight of from about 200 to about 8,000 g/mol, as well as any desired mixtures of these substances, it being possible for these polymers optionally to be modified. Preferred polyvinyl alcohols are those having a degree of hydrolysis of >85%, and preferred carboxymethylcellulose are those having a degree of substitution DS of >0.5. Polyethylene glycols having a number average molecular weight Mn of from about 200 to about about 8,000 g/mol are particularly preferred.
For example, natural, derivatized or degraded starches, alginates, casein, proteins, polyacrylamides, polyacrylic acids, hydroxyalkylcellulose and polyvinylpyrrolidone are furthermore suitable.
Independently of the carrier content of the coating slip, as a rule more advantageous whiteness build-up curves are realized with such formulations than with carrier-free brightener preparations.
In addition, the carrier-free as well as carrier-containing preparations may contain small amounts, usually amounts of less than about 5% by weight, of further auxiliaries, such as dispersants, thickeners, antifreezes, preservatives, complexing agents, etc., or organic byproducts from the brightener synthesis which were not completely removed during the working up.
The carrier-containing preparations may additionally contain standardizing agents for increasing the solubility and shelf life.
The carrier-free aqueous brightener preparations are prepared in general by adjusting a brightener solution (crude or membrane-filter) with a base to a neutral to weakly alkaline pH, optionally adding and dissolving one or more standardizing agents and optionally diluting with water to the desired final concentration. If the brightener is used in the form of a water-moist press cake, a certain amount of press cake is completely dissolved in water with addition of base and with stirring and optionally at elevated temperatures, and optionally adjusted to the desired concentration by further addition of water.
Preferred bases for this purpose are alkali metal hydroxides, demineralized water being preferred for dilution. The pH established is in the range from about 7 to about 11, preferably from about 8 to about 10. Temperatures of from about 25 to about 80° C. are customary for the dissolution.
The carrier-containing preparations are prepared in general in an analogous manner, the carrier substance also being added at any desired time during the preparation process. If the carrier substance is added in solid form, it is generally completely dissolved with stirring and optionally at elevated temperatures, so that a homogeneous liquid preparation forms. The viscosity of the carrier-containing preparations at room temperature is preferably less than about 3,000 mPas. The customary dissolution temperature is in the range from about 25 to about 100° C.
Concentrated, aqueous brightener preparations are usually characterized by the so-called E1/1 value. For this purpose, the extinction of a highly dilute solution of the preparation is determined by the customary UV/V is spectroscopy methods known to a person skilled in the art, in a 1 cm cell at a certain wavelength. This wavelength corresponds to the long-wave absorption maximum of the respective brightener molecule. In the case of flavonate brighteners, it is about 350 nm. The E1/1 value then corresponds to the imaginary extinction value estimated for a 1% strength solution.
The E1/1 values of the brightener preparations used according to the invention are preferably from about 50 to about 180, particularly preferably from about 70 to about 140.
The coating slips to be brightened according to the invention contain, as latex binder, for example latices based on styrene/butadiene, styrene/acrylate or vinyl acetate. These polymers can optionally be modified by further monomers, such as acrylonitrile, acrylamide, α,β-unsaturated carboxylic acids, such as acrylic acid, methacrylic acid, itaconic acid or maleic acid, acrylates, vinyl esters, ethylene, vinyl chloride, vinylidene chloride, etc. In general, however, all customary latex binders which are used for the preparation of paper coating slips are suitable. The coating slips contain, as synthetic co-binders differing from these, for example, carboxymethylcellulose, hydroxyalkylcellulose and/or polyvinyl alcohol and acrylate-based synthetic thickeners.
Preferred latex binders are those based on styrene/butadiene. Preferred synthetic co-binders are polyvinyl alcohols, in particular those having a degree of hydrolysis of >85%, and in particular a Brookfield viscosity of 2-80 mPas (measured on a 4% strength aqueous solution at 20° C.), carboxymethylcelluloses, in particular those having a degree of substitution of >0.5, and in particular a Brookfield viscosity of from about 5 to about 5000 mPas (measured on a 2% strength aqueous solution at 25° C.) and mixtures of these two substances.
The coating slips to be brightened according to the invention preferably furthermore contain white pigments.
Customarily used white pigments are calcium carbonate in natural or precipitated form, kaolin, talc, titanium dioxide, satin white, aluminum hydroxide and barium sulfate, often also in the form of mixtures.
First, dispersants may be mentioned as optional further ingredients of the coating slips to be brightened according to the invention. Polyacrylates, polyphosphates and Na citrate are customary here. In principle, polyaspartic acid is also suitable. Further possible additives are crosslinking agents. Examples of these are urea/formaldehyde resins, melamine/formaldehyde resins, glyoxal and ammonium/zirconium carbonate. In principle, wet strength agents based on polyamidoamine/epichlorohydrin resins, glyoxalated polyacrylamides or hydrophilized polyisocyanates, as described, for example, in EP-A-825 181, are also suitable as crosslinking agents. Finally, antifoams, biocides, complexing agents, bases for pH adjustment, Ca stearate, optical brighteners other than those of the formula (II) and shading dyes may be mentioned as further possible additives. Sometimes surface sizes are also added for imparting water repellency to the coating slip. Examples of these are polymer solutions based on styrene/acrylic acid, styrene/maleic anhydride or oligourethanes, and polymer dispersions based on acrylonitrile/acrylate or styrene/acrylate. The latter are described, for example in WO-A-99/42490.
The coating slips according to the invention which are to be brightened contain the latex binder preferably in an amount of from about 3 to about 20% by weight and the synthetic co-binder in an amount of from about 0.1 to about 3% by weight, based in each case on the white pigment of the coating slip.
The invention furthermore relates to an aqueous coating slip, e.g., an aqueous pigment preparation, comprising
at least one white pigment, at least one latex binder, at least one synthetic co-binder differing therefrom and at least one brightener of the formula (II).
Preferably, the amount of latex binder (calculated as dry substance) is from about 3 to about 20% by weight, in particular from about 5 to about 15% by weight, independently thereof the amount of co-binder is from about 0.1 to about 3% by weight, in particular from about 0.5 to about 1.5% by weight, and likewise independently thereof the amount of brightener of the formula (II) is from about 0.025 to about 1% by weight, based in each case on the amount of white pigment.
The preferred embodiments for white pigment, latex binder, co-binder, brightener and other additives, as described above, are applicable.
The coating slip preferably additionally contains at least one dispersant, in particular in an amount of from about 0.05 to about 1% by weight, based on the white pigment in the coating slip. Suitable dispersants are preferably polyacrylic acid and corresponding salts. The water content of the coating slip is preferably from about 30 to about 50% by weight, based on the total amount of coating slip.
The invention furthermore relates to the use of the coating slips according to the invention for the production of coated papers.
The coating slips can preferably be applied to the paper once or several times by all application methods suitable for this purpose, such as by knife coating in various embodiments, air brush, blade, roll-coater, film press, casting methods, etc. The immobilization and drying of the coating slip is usually effected initially by contactless hot-air and/or IR drying, followed as a rule by contact drying by means of heated rolls. Calendering for compaction, smoothing or influencing the gloss of the coated paper, for example by means of a calender, is then usually carried out.
Suitable uncoated base papers or untreated coating papers, boards and cardboards are in principle papers, boards and cardboards produced from bleached or unbleached, wood-containing or wood-free, waste paper-containing and deinked fibers. These may furthermore contain mineral fillers, such as natural or precipitated chalk, kaolin, talc or annalines. The uncoated papers, boards and cardboards can be engine sized and/or surface sized, with the result that, inter alia, the penetration and the adhesion of the coating slip are influenced. Customary engine sizes are alkylketene dimers (AKD), alkenylsuccinic anhydride (ASA) and a combination of rosin size and alum, and customary surface sizes are the abovementioned polymer solutions based on styrene/acrylic acid, styrene/maleic anhydride or oligourethanes, and polymer dispersions based on acrylonitrile/acrylate or styrene/acrylate. For controlling the desired whiteness properties of the resulting coated paper, the base papers can be brightened in the beater and/or surface brightened, for which purpose, for example, flavonate brighteners are used.
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
77.6 g of a membrane-filtered aqueous concentrate having an E1/1 value of 161 and a pH of 8.5, which contains the brightener of the formula (IIa) in the form of the Na salt, were mixed with 22 g of demineralized water while stirring at room temperature and adjusted to pH 9.0 with about 10% strength sodium hydroxide solution. A carrier-free brightener preparation having an E1/1 value of 125 in the form of a yellow-brownish, homogenous liquid was obtained. This corresponds to a content of (IIa) of about 23% by weight.
Example 2
65.2 g of a membrane-filtered aqueous concentrate having an E1/1 value of 161 and a pH of 8.5, which contained the brightener of the formula (IIa) in the form of the Na salt, were mixed with 31 g of polyethylene glycol 1550 (average molecular weight Mn 1550 g/mol) while stirring at room temperature. For this purpose, the polyethylene glycol 1550 which is waxy at room temperature was heated to about 60° C. before the addition, melted during this procedure and added in the form of hot liquid at about 60° C. 3.5 g of demineralized water were furthermore added and the pH is adjusted to 9.0 with 10% strength sodium hydroxide solution. The preparation was then heated to 50° C. while stirring and stirred for 30 min at this temperature. After cooling to room temperature, a carrier-containing brightener preparation having an E1/1 value of 105 in the form of a yellow-brownish, fluorescent, homogeneous liquid was obtained. This corresponded to a content (IIa) of about 19% by weight.
Example 3
(Not According to the Invention)
The procedure is as in Example 2, but another brightener type was employed and the following amounts were used: 64.8 g of a membrane-filtered aqueous concentrate having an E1/1 value of 162 and a pH of 8.6, which contained the tetrasulfo type brightener of the formula (I) in the form of the Na salt 31 g of polyethylene glycol 1550 4 g of demineralized water.
A carrier-containing brightener preparation having an E1/1 value of 105 and a pH of 9.0 in the form of a yellow-brownish, fluorescent, homogeneous liquid was obtained. This correspondeds to a content of the tetrasulfo type brightener of about 18% by weight.
Example 4
(Not According to the Invention)
The procedure is as in Example 1, but the brightener used was the tetrasulfo type of the formula (I) in the form of the Na salt.
The brightener preparation had an E1/1 value of 125. This corresponded to a brightener content of about 21% by weight.
Use Example 1
A paper coating slip was prepared from the following components:
100 parts of white pigment (chalk/kaolin mixture)
6.5 parts of Baystal P7110 as a binder, calculated as dry substance (styrene/butadiene latex from Polymerlatex GmbH)
1.5 parts of Finnfix 10 as a synthetic co-binder (carboxymethylcellulose from Noviant)
0.25 part of Polysalz® S as a dispersant based on polyacrylic acid (BASF AG)
Water
10% strength sodium hydroxide solution.
The CMC Finnfix 10 used had an active content of 98%. The Brookfield viscosity of a 4% strength solution, measured at 25° C., is 50-200 mPas.
The amount of water and the amount of sodium hydroxide solution were chosen so that a solids content of 57% and a pH of 9.0 result.
The coating slip was divided into 10 parts and 0.4%, 0.8%, 1.2%, 1.6% and 1.8% of the brightener preparation from Example 1 were added to 1 part each and then stirred for 10 min. The amounts added were based on the solids content of the coating slip. For comparison, the same amounts of the brightener preparation from Example 4 were added to 1 part each of the coating slips in the same manner.
The brightened coating slips obtained were applied by means of a laboratory knife coater (from Erichsen, K-Control-Coater, model K 202) to wood-free base papers having a basis weight of about 80 g/m 2 . The coated papers were dried for 1 min at 95° C. on a drying cylinder and then stored for 3 h at 23° C. and 50% relative humidity. The measurement of the parameters L*, a*, b* and the determination of the CIE whiteness were then carried out using a whiteness meter (Datacolor Elrepho 2000).
The values obtained are listed in Tables 1 and 2.
TABLE 1
Brightener preparation from Example 1 (E1/1 = 125)
Amount (%)
CIE whiteness
L*
a*
b*
0.4
101.80
94.12
0.81
−3.60
0.8
108.00
94.24
1.11
−4.89
1.2
111.50
94.34
1.26
−5.63
1.6
114.50
94.42
1.34
−6.25
1.8
116.10
94.46
1.37
−6.62
TABLE 2
Brightener preparation from Example 4 (E1/1 = 125)
Amount (%)
CIE whiteness
L*
a*
b*
0.4
102.10
94.11
0.74
−3.69
0.8
107.70
94.33
0.97
−4.81
1.2
110.04
94.43
0.98
−5.36
1.6
113.30
94.55
0.97
−5.96
1.8
113.50
94.60
0.90
−6.04
It can be seen that employing the brighteners used according to the invention and having the same E1/1 in each case in the carboxymethylcellulose-containing coating slip led to better CIE whiteness values than the brightener from Example 4. The a*-b* values furthermore showed that greening begins from 1.6% in the case of the tetra type not according to the invention, whereas this was still not detectable up to 1.8% when the brightener according to the invention from Example 1 is used.
Use Example 2
The procedure is as in use Example 1 was practiced, except that a polyvinyl alcohol-containing coating slip of another composition was employed and the carrier-containing brightener preparations from Examples 2 and 3 were used in each case in added amounts of 0.8%, 1.6%, 2.4% and 3.2%, based on the solids content of the coating slip.
Composition of the coating slip:
100 parts of white pigment (chalk/kaolin mixture)
7.5 parts of Baystal P 7110 as a binder, calculated as dry substance (styrene/butadiene latex from Polymerlatex GmbH)
1 part of polyvinyl alcohol as a synthetic co-binder, calculated as dry substance
0.25 part of Polysalz® S as a dispersant (BASF AG)
Solids content: 65%, pH: 8.8.
The polyvinyl alcohol used was Polyviol LL 603 (Wacker-Chemie). This is a 20% strength aqueous solution of a polyvinyl alcohol having a degree of hydrolysis of 88% and a Brookfield viscosity of about 900 mPas at 20° C.
The coating slip was divided into 8 parts and the abovementioned amounts of brightener preparations from Examples 2 and 3 are added to one part each.
The whiteness parameters of the papers obtained are shown in Tables 3 and 4.
TABLE 3
Brightener preparation from Example 2 (E1/1 = 105)
Amount (%)
CIE whiteness
L*
a*
b*
0.8
97.90
94.30
1.15
−2.68
1.6
107.10
94.52
1.59
−4.59
2.4
111.50
94.62
1.83
−5.53
3.2
114.60
94.73
2.02
−6.16
TABLE 4
Brightener preparation from Example 3 (E1/1 = 105)
Amount (%)
CIE whiteness
L*
a*
b*
0.8
98.70
94.41
1.13
−2.79
1.6
104.50
94.55
1.27
−4.00
2.4
107.00
94.61
1.31
−4.52
3.2
109.70
94.73
1.42
−5.07
It can be seen that the brightener preparation according to the invention from Example 2 in the polyvinyl alcohol-containing coating slip showed substantially improved build-up behavior with respect to the CIE whiteness compared with the preparation from Example 3, which is not according to the invention.
Use Example 3
The procedure is as in use Example 1 was practiced, except that a polyvinyl alcohol-containing coating slip of another composition was employed and the brightener preparations from Example 1 were used in concentrations of 1%, 4.5% and 8%, based on the pigment content of the coating slip. The polyvinyl alcohol used was Polyviol® LL 603 (Wacker Chemie).
Composition of the coating slip:
100 parts of kaolin
24 parts of Acronal® S 320 D (BASF AG)
8 parts of polyvinyl alcohol, calculated as dry substance
0.3 part of Polysalz® s (BASF AG)
0.1 part of NaOH
Water
The water content was chosen so that a solids content of 50% results. The coating slip was divided into 3 parts and the above-mentioned amounts of the brightener preparation from Example 1 were added to one part each.
The whiteness parameters of the papers obtained are shown in Table 5.
Use Example 4
The procedure is as in use Example 3 was practiced, but, instead of 8 parts of polyvinyl alcohol, 8 parts of carboxymethylcellulose Finnfix® 10 (Noviant) were used.
The whiteness parameters of the papers obtained are shown in Table 5.
Comparative Example
(Analogous to Example C 1 of EP 192 600):
1 part, 4.5 parts and 8 parts (based on pigment) of the brightener preparation from Example 1 are incorporated into an aqueous coating slip. The coating slip had the following composition:
100 parts of kaolin
24 parts of Acronal® S 320 (BASF AG)
8 parts of starch, calculated as dry substance
0.3 part of Polysalz® S (BASF AG)
0.1 part of NaOH
Water
The water content was chosen so that a solids content of 50% results.
Papers were finished with the coating slips thus obtained, according to the procedure described in Example 1, and their whiteness parameters were determined. The results are shown in Table 5.
TABLE 5
Brightener preparation from Example 1 (E1/1 = 125)
Amount (%,
based on
CIE
pigment)
whiteness
L*
a*
b*
Use Example 3 (polyvinyl alcohol-containing coating slip):
1.0
106.10
94.10
1.29
−4.53
4.5
117.0
94.35
1.85
−6.81
8.0
120.6
94.43
1.97
−7.59
Use Example 4 (CMC-containing coating slip):
1.0
101.7
93.98
0.85
−3.60
4.5
109.2
94.16
1.17
−5.17
8.0
114.6
94.23
1.26
−6.34
Comparative Example (starch-containing coating slip):
1.0
98.3
93.93
0.67
−2.89
4.5
103.8
94.18
0.71
−3.98
8.0
107.4
94.45
0.38
−4.63
It can be seen that the brightener preparation from Example 1 in a coating slip which contains polyvinyl alcohol or carboxymethylcellulose as a co-binder leads to substantially higher whiteness values than in a starch-containing coating slip having the same co-binder content.
Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims.
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The use of optical brighteners of the formula (II):
in which
Y denotes a radical of the formula
and the other substituents have the meaning stated in the description, for brightening aqueous coating slips comprising at least one latex binder and at least one synthetic co-binder differing therefrom.
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FIELD OF THE INVENTION
The present invention relates to the field of cotton ginning apparatus and methods. More particularly the present invention deals with ginning cotton having "fuzzy seeds" and the removal of the longer fibers without substantial amounts of linter fibers. More particularly the present invention relates to a roller ginning apparatus wherein the cotton seed does not contact the gin roller.
BACKGROUND OF THE INVENTION
The predominant method of ginning cotton today involves the use of disk-like toothed members rotating side by side with ribs between the spaced-apart disks. The seed cannot pass through the gaps between the ribs whereas the lint fibers pass through the gaps as the lint is impaled on the teeth of the disk-like members. This process inherently breaks an appreciable percentage of fibers, and furthermore, the tips of the teeth on the disk-like members remove some of the short linter fibers and cut into some of the seed coats, creating seed coat fragments with fibers attached to them which are very difficult to remove in the later cleaning processes.
Another method of ginning cotton employs a cylindrical roller covered with an animal hide, such as walrus, or fiber-impregnated rubber packing-like material. This roller is pressed against a stationary "knife". Seed cotton is dropped onto the surface of the roller and the cotton fibers are drawn between the roller surface and the stationary knife while the seed are stripped back by the nose of the stationary knifes. Thus the lint fibers pass under the stationary knife and the seeds are ejected over the top of stationary knife. In the latest technology, a rotary bladed or finned cylinder (rotary knife) assists in bringing the seed cotton to the pinch point between the stationary knife and the roller and in pulling the seed away from the pinch point.
The roller ginning process has certain advantages over the saw ginning process but is not fully adaptable to ginning upland or fuzzy seed cotton. The advantages of the current roller gin processes over the saw gin processes over the saw gin process are that there is less fiber breakage and less "nepping" of the fibers. The disadvantage of the current roller ginning technology is the removal of some of the short linter fibers along with the desirable long fibers, and thus the lint contains a high percentage of short, undesirable fiber. Furthermore, on upland cotton, the current roller gin processes are even slower than they are in ginning extra long staple varieties of cotton that do not contain linter fibers.
New textile mill processes are also being introduced that are best exploited with more uniform fiber length, and less short fiber and neps in the fiber.
SUMMARY OF THE INVENTION
It is the object of the present invention to minimize seed damage in the ginning process.
Yet another object of the invention is to reduces stress and breakage of the cotton fibers during ginning.
Still another object of the invention is to provide lint fibers having more uniform length.
These objects and others are advantageously accomplished in the present invention through the use of a novel combination of elements wherein the see cotton does not contact the gin roller and a conventional "knife" or "saw" is not used. In the present invention, a stationary wall is disposed within the gin along the path of seed cotton input thereto. The wall has at least one slot therein formed transversely to the direction of travel of the seed cotton and having a width less than the minimum dimension of the cotton seed. Adjoining the slot is a member for urging seed cotton along the stationary wall past the slot. This member is preferably a vaned cylinder whose vanes pass the slot in the stationary wall at a distance less the diameter of the cotton seeds. The slot forms a passage through the wall to a ginning roll, or the like, mounted for rotation adjacent the wall. A sub-atmospheric pressure is maintained on the ginning roll side of the wall to draw air through the slot toward the ginning roll such that fibers from the seed cotton are drawn through the slot and engaged by the ginning roll. The wall thickness and slot contour are such that only fibers of a predetermined minimum length are engaged by the roll; therefore, all shorter fibers are left on the seed and a more uniform lint is produced. In some embodiments, a plurality of slots and ginning rolls are utilized to iteratively gin the seed cotton to assure that the desired fibers are removed.
BRIEF DESCRIPTION OF THE DRAWINGS
Apparatus embodying features of my invention are depicted in the accompanying drawings which form a portion of this application and wherein:
FIG. 1 is a sectional view taken transversely to axis of rotation of the feed member;
FIG. 2 is a partial sectional view showing the cooperation of the ginning roll, the slot, and one embodiment of the feed member;
FIG. 3 is a partial sectional view showing the cooperation of the ginning roll, the slot, and a second embodiment of the feed member;
FIG. 4 is a sectional view of a second embodiment taken transversely of the axis of rotation of the multiple feed members; and
FIG. 5 is a partial sectional view showing the cooperation of the ginning roll, the slot, and the feed member in the embodiment of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the apparatus 10 is shown with a feed chute 11 for directing cotton from a conventional feeder (not shown) which may be of the type now used in conventional gins. A stationary wall 12 is connected to the lower end of the feed chute 11 and forms one side of a lint removal chamber 13. The wall 12 has an outer surface 14 which is curved to cooperate with the outside diameter of a rotationally driven finned member 16 which urges the cotton from the feeder chute 11 along the wall 12 past a slot 17 therein formed generally parallel to the axis of rotation of the finned member 16 and transverse to the path of the cotton. The slot 17 allows communication between the chamber 13 and the region adjoining the finned member 16. Internal of the chamber and mounted for rotation along an axis parallel to the length of the slot 17 is a ginning roll 18 which is urged against the interior of wall 12 adjoining the slot 17 creating a nip point or line 20, shown more clearly in FIG. 5, along the interior of the wall adjoining the slot. Sub-atmospheric pressure is maintained within the chamber 13 by conventional fan members as are commonly used in gins to entrain lint in an airflow and which are not shown. An airflow through the slot 17 is thus induced in the apparatus.
Again referring to FIG. 1, in this embodiment, a single finned member 16 urges the seed cotton along the surface 14 of wall 12 such that the seed cotton passes a plurality of ginning points. Each ginning point includes a slot 17 and a cooperative ginning roll 18. The finned member 16 may include a generally cylindrical hub 19 mounted for rotation about an axis indicated by shaft 21 and carrying a plurality of evenly spaced radially extending vanes or fins 22. Each pair of fins 22 form a trough therebetween wherein seed cotton is received from chute 11. As the finned member 16 rotates in the direction of arrow A, a sweep element 23 mounted to the chute 11 levels the seed cotton within the troughs. It will be noted that the proximity of the fins 22 to the surface 14 and the accumulation of cotton in the trough and chute 11 may prevent substantial airflow toward the slot 17. Therefore, the hub 19 is constructed to permit indirect airflow therefrom to enhance the airflow through slot 17.
FIGS. 2 and 3 illustrate two embodiments which could permit such airflow. In FIG. 2, a plurality of perforations 24 are formed in the hub 19 intermediate fins 22 to permit airflow and in FIG. 3 the hub 19 and vanes 22 are formed by a plurality of angle-shaped members 26 mounted in spaced relation to permit airflow therethrough. It may be seen that the sub-atmospheric pressure within chamber 13 will draw fibers from the seed cotton through the slot 17 into engagement with the ginning roll 18 which will carry the fiber to the nip point 20. However, only those fibers having sufficient length to extend through the slot to the nip point will have ginning force exerted on them. It will be seen that the moving ginning roll 18 will exert pressure on the seed cotton by pulling the fibers through the nip point 20, therefore causing the seed cotton to accumulate along the outside of slot 17; however the fins 22 are constantly moving at an appropriate speed to urge the seed cotton along a path defined by surface 14. Thus the seeds are urged along a first path by the finned member 16 while the lint or fiber engaged with ginning roll 18 is urged along a second path which diverges from the first. As the seed and fiber are urged along their separate paths, the forces generated by the finned member 16 and the ginning roll 18 remove the fiber from the seed.
With reference to FIGS. 2 and 3, it will be noted that each slot 17 is formed by a pair of slot walls 17a and 17b. The slot wall 17a which adjoins the nip point 20 is termed the downstream wall and is convex in shape whereas slot wall 17b is concave. The force of ginning will take place over the downstream wall 17a and therefore the convex shape minimizes the fiber stress, thus reducing undesirable fiber breakage. In the known state of the art ginning apparatus, the stationary knife edge which serves to separate the seed from the fiber has a very sharp front edge which necessitates the fiber being subjected to much greater stress and potential breakage. Thus, it may be seen that the present construction reduces fiber stresses; and therefore, fiber breakage as well as providing a means for discriminating against shorter fibers which do not extend into the nip point 20.
Air drawn through slot 17 passes through the clearance between the ginning roll 18 and slot wall 17b and thus may be used to cool the surface of the ginning rolls 18. In the embodiment shown in FIG. 2, the ginning rolls 18 are members whose continuous surface contain fibrous material such as rubber impregnated with cotton fiber or walrus hide. However, the ginning rolls 18 may be formed as shown in FIG. 3 when the ginning roll 18 is discontinuous having a plurality of individually extending fibrous projections 18a which engage the fiber proximal the slot 17. In this embodiment, air is free to pass through slot 17 except when the slot 17 is obstructed by the projection 18a.
FIGS. 4 and 5 illustrate a second embodiment of my invention which enjoys certain advantages over the foregoing embodiment such as accessibility for adjustment and maintenance, and airflow through the slot 17 would not necessitate air passing through the finned members. With reference to FIG. 4, it may be seen that each slot 17 has associated therewith a finned rotary member 16' which may be similar in structure to the finned rotating members used in conventional roller ginning apparatus. The contour of the surface 14 does not encompass the periphery of the finned member 16, but rather is arcuate in a small region 30 downstream of the slot 17. The slots 17 in this embodiment are formed differently from the slots formed by slot walls 17a and 17b. In this embodiment, the slot walls 17c and 17d are generally straight sided and are formed at an acute angle relative to the upper part of surface 14. In this embodiment, the ginning roll 18 rotates counter-clockwise and engages the wall 12 adjoining the slot wall 17c whereas the finned member 16' urges the cotton seed downstream past slot wall 17d. Thus, the fiber and seed are urged along divergent paths which are nearly 180° apart, thereby minimizing the angular deflection of the fiber from the seed to the nip point 20.
The arcuate region 30 of the surface 14 follows closely the path of a fin 22 for a predetermined distance then suddenly drops away, thereby releasing any seed with fiber still reaching the nip point 20 so that such seeds may be pulled back to the slot 17 where additional fiber may be grasped at the nip point before the next fin 22 moves the seed away from the slot 17. Thus, the fins 22 keep the seed accumulation cleared from the slot 17 but do not eject the seeds until they have been ginned to the desired degree. When multiple slots are used, the arcuate region 30 may be long at the first slot and shorter at successive slots to control the degree of ginning desired at each slot.
In operation for either embodiment, seed cotton is introduced to the apparatus via chute 11 whereupon it is engaged by the finned member 16 or 16'. The finned member 16 or 16' is driven about its axis at a rate selected to allow the seed cotton to remain proximal each slot 17 for sufficient time for the optimum removal of fiber from the seed. The actual removal of the fiber is accomplished through the interaction of the ginning roll 18 grasping the fiber at the nip point 20, thereby urging the fiber along a path defined by the rotation of the roll 18 and the fin 22 urging the seed away from the slot 17 along a path defined by the outer surface 14 of the wall 12. The fibers are brought into engagement with the ginning roll 18 by an air flow through the slot 17 induced by sub-atmospheric pressure within the chamber 13. When solid-type ginning rolls 18 are used, the air drawn through the slot serves the tri-fold purpose of conveying fibers through the slot, cooling the ginning roll and doffing the lint as it passes counter to the rotation of the roll. In all embodiments of the invention, the fibers are protected from excessive angular change of direction intermediate the seed and the nip point, and the seeds never come in contact with the ginning roll 18. It should be clear from the foregoing that the wall thickness and shape of the slot 17 are such that fibers drawn into the slot 17 by the air stream which have a length less than the distance from the outside of the slot 17 to the nip point 20 will not be removed from the seed; thus, providing a lint of a more uniform fiber length than heretofore attainable with a roller gin.
While I have shown my invention in two forms, it will be obvious to those skilled in the art that it is not so limited but is susceptible of various changes and modification without departing from the spirit thereof.
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A roller gin capable of producing lint substantially free of linter fibers utilizes a wall construction to prevent the seed from contacting the ginning roll, a ginning slot in the wall through which an airflow draws the fibers. A ginning roll adjacent the slot on the opposite side of the wall grasps the fibers along a nip point formed between the roll and wall proximal the slot and urges the fibers along a path on one side of the wall while the seeds are urged along a divergent path on the other side of the wall.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a sectional hunting stand, adapted for ladder-like use or for A-frame use when mounted on an all terrain vehicle.
2. Description of Related Art
Elevated observation stands, providing a hunter secure seating and a wide visual range, are desirable when hunting deer and other game in forested areas, fields, and reforesting areas. The relatively easy access to these areas now provided by all terrain vehicles (ATVs) has encouraged the development of such stands to be used while mounted on ATVs.
Such de-mountable stands known to the inventor are of two major types. One such type, described in U.S. Pat. No. 4,800,986 to Hayes, and U.S. Pat. No. 4,787,477 to Dolan, requires front and rear leg members which create a modified "A" frame to support a seating platform between the leg members.
A second type, disclosed in U.S. Pat. No. 4,614,252 to Tarner, and U.S. Pat. No. 4,625,831 to Rodgers shows, mounted on an ATV, a single ladder element whose attached seat platform abuts a tree for fixed support.
The seating platforms of such stands have heretofore been fixed and unadjustable as to their angularity. The patent to Hayes appears capable of limited adjustment at what appears to be some sacrifice of stability.
SUMMARY OF THE INVENTION
The purposes of the present invention are to provide a hunting stand which: allows the angle of its seat platform to be adjusted to level the seat relative to the slope of the terrain; provides, by differing simple assembly of its elements, a high or low "A"-frame type stand, and a variable height single ladder stand which may be either ATV mounted or ground-standing and leaned against a tree; and which mounts and dismounts easily from rods affixed fore and aft on an ATV. Such purposes are achieved by use of the interactive parts (seat platform, ladder elements, and base connectors) of the present invention, each hereinafter described.
The seat platform of the present invention is comprised of elongated parallel members, spaced apart and running from front to back. The length of the parallel members at the seat platform back is symmetrically graduated from longer outer members to shorter inner members, forming an inwardly curved seat back adapted to fit against a tree.
Two pairs of downwardly projecting pivotable sockets, one pair provided at the seat front and one pair at the seat back, may be adjusted and fixed at a chosen angle relative to the seat platform. The seat sockets are so sized as to fit over the upper side rails of the ladder elements of the present invention.
Each ladder element of the present invention has three rungs attached to ladder sidepieces which extend higher than the highest rung and lower than the lowest rung. The ladder elements are so constructed that they are fittable onto each other, so that in combination they may form A-frame and single-ladder stands of varying heights.
Chosen ladder elements are equipped at their bases with novel grasping connectors, by which the ladder element may easily be manually mounted and demounted from bars affixed to an ATV. The connectors attach so as to allow the ladder element to pivot on these bars to accommodate various angles of the ladder sections resulting from insertion into the fixed-angle seat sockets.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of the underside of a leveling seat platform constructed from elongated parallel members whose sockets at the seat front are interconnected so as to be angularly adjustable by turnbuckle means, and whose sockets at the seat back are shown folded between the elongated parallel members.
FIG. 2 is a fragmentary view of a seat platform somewhat modified from FIG. 1, showing sector plates fitted with pins to adjust the angles of the sockets relative to the seat platform.
FIG. 3 is a view of a typical ladder element with its lower sidepiece ends inserted in simple sleeves, the left sleeve being shown partially broken away.
FIG. 4 is a partially broken-away side view of a base connector sleeve whose downwardly-extending uncompressed bent spring extends outward from, but is retained within the sleeve by a retention bolt, and whose grasping ends are positioned outward of a graspable rod on an ATV, shown in phantom lines.
FIG. 5 is a broken front view of the base connector sleeve of FIG. 4, whose sleeve is being driven downward so that the diagonal edge of its camming blade contacts the outer side of the bend of the bent spring, driving the blade outward.
FIG. 6 is a broken front view, similar to FIG. 5, showing the bent spring of the connector sleeve in its final grasping position with the sleeve driven fully downward about it so that the inner side of the bend of the bent spring is engaged by the top edge of the blade.
FIG. 7 is a side view of the base connector sleeve in position corresponding to FIG. 6.
FIG. 8 is a side view of such a leveling seat platform mounted for low A-frame use atop opposite ladder elements attached by base connector sleeves onto an ATV, the angle of the seat platform having been adjusted to compensate for downward slanting terrain, and a ladder element used as a stabilizer.
FIG. 9 is a view, principally from the front, of a ground support fitted within the sleeves of a ladder element.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides component parts which may be used to assemble an ATV-mounted A-frame hunting stand of different chosen heights whose seat platform may be leveled to compensate for hilly terrain on which the ATV may be parked; these component parts may also be used to assemble a single-ladder hunting stand of different chosen heights which may be either ATV-mounted or ground-standing. The component parts of the present invention are: a leveling seat platform, ladder elements, and easily mountable grasping base connector assemblies.
The seat platform 16 of the present invention, whose underside is shown in the isometric view of FIG. 1, is constructed of two outer elongated members 20, 20', two intermediate elongated members 22, 22' of length identical to the outer members 20, 20', and two shorter inner members 24, 24', all made from square metal tubing, and running spacedly parallel to each other from a seat platform front, generally designated 26, where their ends are evenly aligned, to a seat platform back, generally designated 28, where the two shorter inner members 24, 24' terminate inwardly of the intermediate members 22, 22' and outer members 20, 20', creating an inset adapted to fit against a tree trunk.
The inner elongated members 22, 22' and the intermediate elongated members 22, 22' are held uniformly apart by spacers 38 at both the seat front 26 and at the seat back 28; the intermediate elongated members 22, 22' and the outer elongated members 20, 20' are held similarly apart both at the seat front 26 and seat back 28 by hollow pivotable sockets 40, 40'. The elongated members 20, 20', 22, 22', 24, 24' are cross-drilled and connected, spacedly inward of the seat front 26, by a front cross-rod 34, and, spacedly inward of the seat back 28, by a back cross-rod 36, each rod 34, 36 extending through the separating spacers 38, 38' and sockets 40, 40' and secured by a nut 37, 37' at the outermost walls of the outer elongated members 20, 20'.
The pivotable hollow sockets 40, 40' at the seat front 26 are connected, as shown in FIG. 1, by a bar 44 extending between and welded to the front outer faces 42, 42' of the sockets 40, 40'. A screw adjustment turnbuckle 50 is connected to the bar 44 by an eye 49 and extends under the seat platform 16 to a bracket 52 mounted between the inner elongated members 24, 24', and located between the seat front 26 and back 28. Adjustment of the turnbuckle 50 fixes the angle of the sockets 40, 40' relative to the seat platform 16 thereby allowing it to be leveled relative to the terrain. Optionally, a second turnbuckle may extend from a similar bracket to a similar connected bar welded to the outer faces 42, 42' of the pair of sockets 40, 40' at the seat platform back 28.
An alternate construction for leveling the seat platform 16 is shown in fragmentary view in FIG. 2. Between outer elongated members 20, 20', and the intermediate elongated members 22, 22' on either side of each of the hollow sockets 40, 40', are mounted a pair of 90° sector plates 53, 53', the distance between the members 20, 20', 22, 22', so being increased as to accommodate the width of the plates. At their 90° intersections, the plates 53, 53' are mounted on the front cross-rod 34, and the curved outer edge of each of the plates 53, 53' is mounted on cross-bolts 56, 56' extending between the outer elongated members 20, 20' and the inner elongated members 22, 22' immediately inward of the seat platform front 26. Inwardly of the curved edge of each plate 53, 53' is a plurality of cross bores 58, 58' in identical arcuate patterns through which detent pins 59, 59', may be inserted on at least the outer sides of each socket 40 to limit its rotational movement and thereby fix the angle of the sockets 40, 40' relative to the seat platform 16.
All sockets 40, 40' are hollow and have identical interior width and depth and are so sized that they may receive the upper ends of the sidepieces 66, 66' of the ladder element 60 hereinafter described.
Each ladder element 60, as illustrated in FIG. 3, is constructed of square metal tubing and has at least three rungs, an uppermost rung 68, an intermediate rung 70, and a lowermost rung 72 extending between parallel sidepieces 62, 62' of constant cross-section. The sidepieces 62, 62' extend higher than the uppermost rung 68 and lower than the lowermost rung 72. Upper sidepiece ends 66, 66' of a ladder element 60 may be fitted into the pair of sockets 40, 40' at the front 26 or back 28 of the seat platform 16. At the lower end of each sidepiece 64, 64' a hollow sleeve 80 of constant cross-section having interior width and depth identical to the width and depth of the seat platform sockets 40, 40' enabling a slidable fit between the sleeve 80 and an upper sidepiece end 66 is fitted on, and alternately may be welded onto each ladder lower sidepiece end 64, 64' to extend as shown in the broken cross-section of FIG. 3, from the lowermost ladder rung 72 to substantially beyond the lower sidepiece ends 64, 64'.
Upper sidepiece ends 66, 66' of a ladder element 60 may be fitted into the downward-extending sleeves 80, 80' of an identical ladder element 60'; two or more of such ladder elements 60, 60' may thereby combine to form ladder sections 76 as hereinafter described and illustrated in FIG. 9.
The present invention contemplates the use of a plurality of ladder elements 60, all but two being fitted with the hollow sleeves 80, just described, these two being fitted with grasping base connector assemblies 100, hereinafter described.
For ATV-mounted use, the novel grasping base connector assemblies 100 of the present invention secure a hunting stand hereinafter described and illustrated in FIG. 8 as 160, assembled from a seat platform 16 and ladder elements 60, 60', to transverse, graspable front rods 152 and rear rods 154 mounted on an ATV 150. As illustrated in FIG. 4, each connector assembly 100 includes a hollow, rectangular sleeve-like member 102 fitted with a bent spring 120, a retention bolt 118 and latching means 129.
The sleeve-like member 102 is of constant cross-section, and its interior width and interior depth are identical to those of a connecting sleeve 80 and a seat platform socket 40. Outer walls of the sleeve-like member contain bolt-accommodating holes 115, 115', spacedly above the sleeve open lower end, and one outer wall contains spacedly above a bolt-accommodating hole 115 a vertical slot 116, hereinafter referred to.
The bent spring 120 is formed from metal narrower than the interior width of the sleeve-like member 102. It has a central bend 122 permanently set at an angle of less than 90° . From its bend 122 two opposing arms 124, 124' extend, each arm terminating in an opposing curved grasping portion 126, 126'. At the juncture between one arm 124' and its grasping portion 126' a stop 128 extends perpendicularly inward toward the opposing arm 124.
The spring is mounted by inserting its central bend 122, as shown in FIG. 4, into the open lower end of the sleeve-like member 102 beyond the bolt holes 115, 115'; it is there retained by insertion of the bolt 118 through the bolt holes 115, 115'. As long as the spring 120 is uncompressed, its grasping portions 126, 126' are spread more widely than the diameter of the rod hereinafter described.
In order to secure the bent spring 120 in a retracted compressed position within it, the sleeve-like member 102 is fitted with releasable latching means 129. A preferred latch, illustrated in FIG. 5, includes the vertical slot 116 through the sleeve-like member outer wall 106, a flat spring 130, and a camming blade 136 which may enter the sleeve-like member 102 through the slot 116 so that its top edge will extend horizontally into the sleeve-like member interior width. The lower end of the flat spring 130 is secured to the sleeve-like member outer wall 106 by the retention bolt 118.
The camming blade 136, shown cammed outward in FIG. 5, has a diagonal cam edge 138 whose lead angle may be approximately 30° from the flat spring 130, and a perpendicular top edge 144. The blade 136 may be formed integrally with the flat spring 130 by bending it perpendicular to one edge of the flat spring 130; a projecting release tab 140 may be bent perpendicularly outward from its other edge. The camming blade 136 may enter the sleeve-like member 102 through the slot 116 in the sleeve-like member outer wall, so that its top edge 144 extends horizontally into the sleeve-like member interior width.
Such grasping connector sleeve assemblies 100 are slidably fitted on, or welded onto, the lower sidepiece ends 64, 64' of those ladder elements 60 which are to be mounted on an ATV equipped with fore-and-aft mounted transverse rods 152, 154 respectively.
Referring to FIGS. 4 through 7, the curved grasping portions 126 of the uncompressed bent spring 120 of a connector 100 are positioned about an ATV-mounted rod 156. As shown in FIG. 5, downward movement of the sleeve-like member 102 toward the rod 152 compresses the bent spring 120, as the spring central bend 122 travels relatively upward into the sleeve-like member 102 to contact the diagonal edge 138 of the camming blade 136, forcing the blade 136 outward through the slot 116, to allow the spring central bend 122 to pass above the blade top edge 144. As the central bend 122 so passes, the flat spring 130 returns the camming blade 136 to within the sleeve-like member 102, the blade top edge 144 now being beneath the spring central bend 122, as shown in phantom in FIG. 6, thus to retain the bent spring 120 in compressed position so that its curved grasping portions are secured about the rod 152, as shown in side view in FIG. 7.
Demounting of the ladder element 60 is accomplished by manually pulling the release tab 140 outward, thereby moving the camming blade 136 outward through the slot 116 and releasing the bent spring 120. The sleeve-like member 102 may then be raised to permit the bent spring 120 to spread and release the bar 156.
The low A-frame hunting stand 160 illustrated in FIG. 8 shows the leveling seat platform 16 mounted atop opposing ladder elements 60, 60', the seat platform sockets 40, 40' at the seat front 26 fitted over the upper sidepiece ends 66, 66' of a ladder element 60, and the sockets 40, 40' at the seat back 28 fitted over the upper sidepiece ends 66, 66' of the opposing ladder element 60'. The grasping base connector assemblies 100, 100' affixed to the lower sidepiece ends 64, 64'αof the opposing ladder elements 60, 60' rotatably secure the stand 160 to transverse rods 156, 156' installed on the ATV 150.
The seat platform 16 may be leveled relative to sloping terrain on which the ATV 150 may be parked; this is done by adjustment of the turnbuckle 50 to fix the angle of the seat platform sockets 40, 40' relative to the seat platform 16. FIG. 8 illustrates in phantom lines the angularity of the seat platform 16 and ladder elements 60 prior to such adjustment, and in solid lines, their angularity after adjusting. The curved grasping portions 126, 126' of the connector assembly may pivot on the rods 152, 154 to accommodate the chosen angle of the sockets 40, 41 and ladder elements 60, 60' inserted therein.
The embodiment illustrated in FIG. 8 shows two ladder elements 60, 60', on each side of the seat 16. The height of the stand may, as should be obvious, be increased by interpositioning a third ladder element 60, 60' on each side.
A single ladder hunting stand, not shown, may be assembled by mounting a single ladder element 60 or a ladder section 76 of two or more ladder elements 60, 60' onto the forward rods 152 of the ATV 150. The seat platform 16 may then be mounted atop the ladder upper sidepiece ends 66, 66' by the sockets 40, 40', on the seat front 26 and the inset seat back 28 leaned against a tree trunk.
To brace the ATV 150 against deflection when such a stand is climbed on, a ladder element 60 fitted with grasping base connector assemblies 100, 100' may be attached, as shown in FIG. 8, to the rod of an ATV rack assembly which extends beyond the ATV fender, and so rotated as to contact the ground.
For use independent of an ATV, a ladder element or elements 60 may be erected on the ground support 140, made of square metal tubing and illustrated in FIG. 9. It includes two side rails 141, 141', each having a vertically extending portion 142 of the same exterior width and depth as the interior width and depth of a connecting sleeve 80, and an outward and downward extending leg 144. The side rails 141, 141' are connected between their vertically extending portions 142, 142' by an upper rung or rungs 148 and between their outward extending legs 144, 144' by a longer lower rung 150.
To assemble a single ladder ground stand, not shown, a ladder element 60 or a ladder section 72, having lower sidepiece ends 64, 64' fitted with connecting sleeves 80, may be mounted atop the ground support vertically extending members 142, 142', as shown in broken view in FIG. 9. The seat platform 16 may then be mounted and leaned against a tree as for the ATV-mounted single ladder stand previously described.
As various modifications may be made in the constructions herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be taken as illustrative rather than limiting.
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Interactive component parts for assembling an ATV-mounted hunting stand of either the "A"-frame type or tree-leaning type, or alternatively as a ground-standing tree-leaning hunting stand. It includes a leveling seat platform, ladder elements, quick-grasping base connector assemblies, and a ground support. The seat platform has angularly-adjustable sockets so sized as to fit onto the upper ends of ladder elements, whose lower ends may have sleeves to allow these ladder elements to be mounted atop other ladder elements. Base connector sleeve assemblies allow ladder elements to be quickly and easily mounted on and demounted from rods attached to an ATV; they are free to pivot about these rods. When such ladder elements are so mounted on an ATV as an A-frame hunting stand, changing the angularity of the seat sockets effects seat leveling. For ground-standing ladder use, a broad ground support may be inserted into the lowest ladder element.
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RELATED APPLICATIONS
[0001] This application claims priority as a divisional of U.S. patent application Ser. No. 15/021,385, filed Mar. 11, 2016, titled “METHOD AND SYSTEM FOR PREPARING HIGH PURITY LITHIUM CARBONATE,” which is a 35 USC 371 national phase entry of PCT/CN2014/086344, filed Sep. 12, 2014, titled “HIGHLY EFFECTIVE THERMAL ENERGY RECOVERY METHOD AND SYSTEM, AND HIGH-PURITY LITHIUM CARBONATE PREPARATION METHOD AND SYSTEM BASED ON SAME,” the entire contents of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The invention relates to a high-efficiency heat energy recycling method and system applicable to plateau areas, and more particularly, to remote plateau areas.
BACKGROUND
[0003] In plateau areas, more particularly in remote plateau areas, the population generally is sparse, the temperature difference between the day and the night is large, infrastructures are weak, the traffic is inconvenient, and the water and electricity supply is seriously inadequate. But at the same time, vast mineral resources are also stored in the plateau areas to be developed.
[0004] Salt lakes in the plateau areas contain a variety of high-value mineral salts, such as lithium, potassium and other salts of strategic significance. But the content of the mineral salts in the salt lake is generally low, so that it is more difficult for large scale exploitation and utilization. Limited by adverse natural conditions, exploitation technologies in recent years mainly include salt lake water bay salt method, deposit exploitation method and the like, the bay salt method of which is the most environmentally-friendly exploitation method.
[0005] During the course of mining the mineral salts via the bay salt method, the processes of crystallization directly affect the mining efficiency. In general, the salt lake bittern is subjected to several processes such as bittern preparation, concentration, crystallization and the like, the production cycle lasts up to 10 months, and the production efficiency is low. Accelerating the crystallization of the mineral salts is beneficial for shortening the exploitation time and improving the yield.
[0006] The existing method for accelerating crystallization is mainly natural evaporation of a solar pond. The method is focused on utilizing the sunshine to increase the temperature of the bittern and accelerate the separation of the mineral salts. But the method seriously depends on the natural weather and is affected by the intensity of sunshine, wind and rain and other factors, has a certain limitation to improve the yield, and still does not change the condition of “living depending on the weather” fundamentally.
[0007] The solar energy is a clean energy and it is more abundant in sunny areas. The reasonable utilization of the solar energy is beneficial for solving a problem of energy shortage.
[0008] As the structure of a solar photo-thermal device is simple, the solar energy may be generally converted into heat energy only by a thermal collecting board. And the conversion efficiency is higher, up to above 60%. A variety of civil solar photo-thermal devices has been developed at present, such as various solar water heaters which have achieved good results.
[0009] According to the existing solar photo-thermal device, a medium may only be heated to no more than 100° C. generally, and the use in the areas where the altitude is low and the average temperature is higher may be met. However, the solar photo-thermal device is not applicable to the very cold and high-altitude areas, and furthermore, may not be applied to industrial production.
[0010] Currently, the lack of a solar photo-thermal device applicable to plateau areas potentially increases the difficulty to utilize the abundant solar energy in the plateau areas.
SUMMARY
[0011] An object of the invention is to provide a high-efficiency heat energy recycling method and a high-efficiency heat energy recycling system applicable to plateau areas.
[0012] The invention adopts the technical solution as follows.
[0013] A high-efficiency heat energy recycling method includes the following steps:
[0000] 1) utilizing a concentrated solar photo-thermal device to heat heat-transfer oil to more than 120° C. for standby application;
2) heating a liquid heat conducting medium in a water tank hot end and bittern in a preheating pool via the solar photo-thermal device, and guiding the preheated bittern into a temperature rising kettle;
3) absorbing heat from the cold end of the water tank via a high temperature heat pump, releasing heat to the temperature rising kettle via the hot end of the water tank, and heating the bittern in the temperature rising kettle to the temperature required;
4) guiding the bittern in the temperature rising kettle into a reaction kettle, applying a vacuum for decompressing concentration, guiding the heated heat-transfer oil into a heat exchanger in the reaction kettle to rapidly, additionally heat the reaction kettle, guiding the vapor produced by decompressing concentration in the reaction kettle into the heat exchanger in the preheating pool for cooling, and collecting the distilled water obtained into a distillate tank;
5) guiding the high temperature supernatant after crystallization in the reaction kettle into a cold end crystallization kettle via a pipeline, performing heat exchange between the cold end of the water tank and the cold end crystallization kettle via the heat exchanger, cooling the high temperature supernatant, and guiding the cooled and crystallized normal temperature or low temperature supernatant into a supernatant sedimentation tank;
6) heating the distilled water with the heat-transfer oil, scouring coarse crystallized salts in the reaction kettle, and guiding high temperature scouring liquor into a scouring liquor thermal insulation kettle; and
7) optionally, flushing the device and the pipeline of the system which are contacted with the bittern using the heated distilled water or the hot scouring liquor after sedimentation as necessary.
[0014] As a further improvement of the invention, the normal temperature scouring liquor is returned to the lake after recycling the heat energy in the scouring liquor.
[0015] As a further improvement of the invention, the liquid heat conducting medium at the cold end of the water tank and the hot end of the water tank is independently water or heat-transfer oil.
[0016] A high-efficiency heat energy recycling system applicable to plateau areas includes a preheating pool, a temperature rising kettle, a reaction kettle, a cold end crystallization kettle, a scouring liquor thermal insulation kettle and a supernatant sedimentation tank, wherein the preheating pool, the temperature rising kettle, the reaction kettle, the cold end crystallization kettle and a distillate tank are all provided with a heat exchanger, and the scouring liquid thermal insulation kettle is internally provided with a thermostat. The preheating pool is provided with a pipeline connecting to the temperature rising kettle, the temperature rising kettle is provided with a pipeline connecting to the reaction kettle, the reaction kettle is provided with a pipeline connecting to the cold end crystallization kettle and the scouring liquor thermal insulation kettle, and the cold end crystallization kettle is provided with a pipeline connecting to the supernatant sedimentation tank.
[0017] The system is further provided with a heat-transfer oil tank, which is connected with a concentrated solar photo-thermal device for heating heat-transfer oil, and a closed heat-transfer oil pipeline connecting to the heat exchanger in the reaction kettle and the heat exchanger in the distillate tank.
[0018] The hot end of the water tank and the preheating pool are connected with a solar photo-thermal device for supplying heat thereto.
[0019] A high temperature heat pump is arranged between the hot end of the water tank and the cold end of the water tank. The heat exchanger is arranged between the hot end of the water tank and the temperature rising kettle. The heat exchanger is arranged between the cold end of the water tank and the cold end crystallization kettle.
[0020] The reaction kettle is connected with a vacuum device, which is provided with a heat exchanger guiding vapor into the preheating pool and a pipeline extending to the distillate tank. The distillate tank is provided with a pipeline guiding the distilled water into the reaction kettle and the scouring liquor thermal insulating kettle.
[0021] As a further improvement of the invention, the preheating pool is comprises at least two preheating pools connected in series.
[0022] As a further improvement of the invention, the hot end of the water tank is connected with a heating device for supplying heat thereto in an auxiliary manner.
[0023] As a further improvement of the invention, the high temperature heat pump used in the above-mentioned system is provided with:
[0000] a multipoint thermal balance heat exchanger generating hot water via heat exchange, wherein the multipoint thermal balance heat exchanger is provided with a cold water input end, and hot water output from an output end is accessed to the hot end of the water tank through a water pump and a check valve;
a heat pump compressor, wherein coolants compressed and output by the heat pump compressor are provided for the multipoint thermal balance heat exchanger through an evaporator and a throttle in sequence, and the coolants are output from the multipoint thermal balance heat exchanger and then are inhaled by the heat pump compressor for circulation; and
the multipoint thermal balance heat exchanger is comprises a plurality of groups of heat exchangers connected in series, and a cross runner is arranged among various groups of heat exchangers.
[0024] As a further improvement of the invention, the hot water output end of the multipoint thermal balance heat exchanger is provided with a temperature control valve, and the output of the temperature control valve is connected with the water pump.
[0025] As a further improvement of the invention, a vapor-liquid separator is arranged between the heat pump compressor and the evaporator.
[0026] As a further improvement of the invention, the cold water input end of the multipoint thermal balance heat exchanger is provided with a dirt remover.
[0027] As a further improvement of the invention, the coolants used for the high temperature heat pump are ternary composite coolants with a mass ratio of R124:R245a:R22=3:3:1.
[0028] The high temperature concentrated solar thermal collector that is used by matching with the above-mentioned system or used independently includes a cambered concentrated light reflecting board and a support for fixing the light reflecting board, a light transmitting board is fixed on the front of the light reflecting board, end boards are arranged at both ends of the light reflecting board, the light reflecting board, the light transmitting board and the end boards jointly form a cavity, a collector pipe is arranged in the cavity along the parallel direction, and the collector pipe is internally provided with a liquid inlet and a liquid outlet.
[0029] As a further improvement of the invention, the collector pipe of the thermal collector is sheathed with a transparent thermal insulation pipe.
[0030] As a further improvement of the invention, the surface of the collector pipe of the thermal collector is black.
[0031] As a further improvement of the invention, the thermal insulation pipe of the thermal collector is a double-layer vacuum glass pipe.
[0032] As a further improvement of the invention, the surface of the collector pipe of the thermal collector is a matte surface.
[0033] As a further improvement of the invention, the support of the thermal collector is provided with a revolving shaft for regulating the light reflecting board to rotate.
[0034] As a further improvement of the invention, the revolving shaft of the thermal collector is provided with an angle gauge.
[0035] As a further improvement of the invention, the high temperature concentrated solar thermal collector in the thermal collector is provided with an actuator for driving the revolving shaft to rotate.
[0036] As a further improvement of the invention, the bottom of the light reflecting board in the thermal collector is provided with a liquid outlet.
[0037] As a further improvement of the invention, the surface of the light transmitting board of the thermal collector is provided with anti-static coating or a conducting layer.
[0038] The invention has the beneficial effects as follows:
[0039] The heat energy utilizing method according to the invention may recycle the heat energy efficiently and has a rapid heat exchange capability and a slow heat exchange capability as well, which meets different requirements of industrial production for heat, may be widely applied in various industrial production processes needing heating up and cooling, and more particularly, applicable to the extraction of mineral salts from salt lakes.
[0040] The heat energy utilizing system according to the invention may take full advantage of abundant sunshine in the plateau areas to efficiently recycle the heat energy, and supplies stable heat for production to meet the demands of production. At the same time, the system according to the invention may produce fresh water in a subsidiary manner, so as to further meet production and living needs.
[0041] The heat energy utilizing system according to the invention is reasonably designed, performs heat energy exchange by using liquid and heat pump to crystallize the bittern only in various kettles, and not to scale a bittern conveying pipeline. The bittern is rapidly, additionally heated by means of the high temperature heat-transfer oil, which may meet the heat quantity required when the water is mostly evaporated under a decompressed state and may achieve the standardization operation. The concentration and crystallization of a batch of bittern may be finished within about 1-2 hours with sunshine. The concentration and crystallization of a batch of bittern may be finished within about 10-30 minutes in a condition that the heat quantity is sufficient at noon, which greatly accelerates the concentration of the bittern, and facilitates the extraction of various mineral salts from the bittern. In this way, the production is more controllable and “living depending on the weather” is avoided.
[0042] Multi-level preheating pools are connected in series, so that the quantity of the bittern in each preheating pool is relatively reduced, which in combination with the heat exchange of countercurrent flow, facilitates the obtaining of the bittern at a higher temperature. At the same time, the heat exchange efficiency is improved and the demand for continuous production is met.
[0043] Compared to the situation that the liquid is heated by a resistance-type heater, the system according to the invention may increase twice to three times of heat quantity at the premise of the same power consumption, and recycles the vast majority of heat energy in the production process at the same time, which realizes the high-efficiency heat energy recycle in the plateau areas, greatly reduces the energy source as required for an industrialized extracting device in the plateau areas, so that the fixed investment quantity is greatly reduced, and it is green and environmentally-friendly.
[0044] The high temperature heat pump used in the heat energy utilizing system has high heat exchange efficiency. The temperature of the hot end of the water tank may be increased by 85° C. in the plateau areas via a first-level heat pump, so the heat exchange efficiency is high. At the same time, the heat pump is not directly contacted with the bittern with strong corrosive substance, so that the service life is long and stable operation may be performed.
[0045] The high temperature solar thermal collector according to the invention is wholly closed and has no air circulation with the outside, so that there is no convection heat loss, the photo-thermal conversion efficiency is high. A heat conducting medium may be heated up to above 200° C., which meets the demands of the special industrial production. It may be better applied to heat the other mediums, such as water, anti-freezing solution, heat-transfer oil and the like.
[0046] The high temperature solar thermal collector according to the invention is simple in structure, is easy to manufacture and is easy to integrally install, does not need to consider the construction effect of seasonally frozen ground, has a strong interchangeability, is convenient to maintain, may effectively withstand the aging of equipment and other harmful natural conditions caused by dust, high wind, rain, snow and ultraviolet ray, and more particularly applicable to the plateau areas.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] FIG. 1 is a structural diagram of a heat recycling system according to the invention;
[0048] FIG. 2 is a structural diagram of a high temperature heat pump of a heat recycling system according to the invention;
[0049] FIG. 3 is a structural diagram of a multipoint thermal balance heat exchanger of a heat recycling system according to the invention; and
[0050] FIG. 4 and FIG. 5 are structural diagrams of a thermal collector according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] A high-efficiency heat energy recycling method includes the following steps.
[0000] 1) a concentrated solar photo-thermal device is utilized to heat heat-transfer oil to more than 120° C. for standby;
2) a liquid heat conducting medium in a water tank hot end and bittern in a preheating pool is heated via the solar photo-thermal device, and the preheated bittern is guided into a temperature rising kettle;
3) heat is absorbed from the cold end of the water tank via a high temperature heat pump, the heat is released to the temperature rising kettle via the hot end of the water tank, and the bittern in the temperature rising kettle is heated up to the temperature required;
4) the bittern in the temperature rising kettle is guided into a reaction kettle, vacuumized for decompressed concentration, the heated heat-transfer oil is guided into a heat exchanger in the reaction kettle to rapidly, additionally heat the reaction kettle, vapor produced by decompressing concentration in the reaction kettle is guided into the heat exchanger in the preheating pool to cool, and distilled water obtained is collected into a distillate tank;
5) high temperature supernatant crystallized in the reaction kettle is guided into a cold end crystallization kettle via a pipeline, heat exchange is performed between the cold end of the water tank and the cold end crystallization kettle via the heat exchanger, the high temperature supernatant is cooled, and the cooled and crystallized normal temperature or low temperature supernatant is guided into a supernatant sedimentation tank;
6) the distilled water is heated with the heat-transfer oil, coarse crystallized salts are scoured in the reaction kettle, and high temperature scouring liquor is guided into a scouring liquor thermal insulation kettle; and
7) the system and the device and the pipeline contacted with the bittern are flushed by using the heated distilled water or sedimentated hot scouring liquor in necessity, and the normal temperature flushing liquor is returned to the lakes after recycling the heat energy in the flushing liquor.
[0052] In order to more rapidly supply heat, the heat-transfer oil is heated up to above 120° C. by using the concentrated solar photo-thermal device, preferably heated up to above 150° C., and more preferably, heated up to above 200° C.
[0053] The hot end of the water tank needs to exchange heat with the temperature rising kettle to heat the bittern in the temperature rising kettle, and the temperature of the liquid heat conducting medium is generally at 70-80° C. In order to obtain a better heating effect, the liquid heat conducting medium in the hot end of the water tank is required to have a higher temperature. The water has a lower cost, higher security and no contamination, but its boiling point is lower, whereas the heat-transfer oil has a higher cost, high boiling point and good security, but its specific heat capacity is lower. According to the specific application requirements, the liquid heat conducting medium may be selected from water or heat-transfer oil, or other liquid heat conducting medium.
[0054] The cold end of the water tank needs to exchange heat with the cold end crystallization kettle, and the medium temperature generally does not exceed 40° C. So selecting the water with high specific heat capacity, low cost and high safety as the heat conducting medium is more economical and practical. Of course, the heat-transfer oil or other liquid heat conducting medium may also be adopted if there are special requirements.
[0055] The heat energy recycling system according to the invention is further described with reference to the drawings hereinafter.
[0056] As shown in FIG. 1 to FIG. 3 , a high-efficiency heat energy recycling system applicable to plateau areas includes a preheating pool 1 , a temperature rising kettle 8 , a reaction kettle 2 , a cold end crystallization kettle 4 , a thermal insulation kettle 3 for scouring liquor and a supernatant sedimentation tank 5 , wherein the preheating pool 1 , the temperature rising kettle 8 , the reaction kettle 2 and the cold end crystallization kettle 4 are all provided with a heat exchanger, the thermal insulation kettle 3 for scouring liquid is internally provided with a thermostat; the preheating pool 1 is provided with a pipeline connecting to the temperature rising kettle 8 , the temperature rising kettle 8 is provided with a pipeline connecting to the reaction kettle 2 , the reaction kettle 2 is provided with a pipeline connecting to the cold end crystallization kettle 4 and the thermal insulation kettle 3 for scouring liquor, the cold end crystallization kettle 4 is provided with a pipeline connecting to the supernatant sedimentation tank 5 .
[0057] The system is further provided with a heat-transfer oil tank 60 , which is connected with a concentrated solar photo-thermal device for heating the heat-transfer oil, and a closed heat-transfer oil pipeline connecting to the heat exchanger in the reaction kettle and the heat exchanger in the distillate tank.
[0058] The hot end of the water tank 61 and the preheating pool 1 are connected with a solar photo-thermal device for supplying heat thereto.
[0059] A high temperature heat pump is arranged between the hot end of the water tank 61 and the cold end of the water tank 62 , the heat exchanger is arranged between the hot end of the water tank 61 and the temperature rising kettle 1 , and the heat exchanger is arranged between the cold end of the water tank 62 and the cold end crystallization kettle 4 .
[0060] The reaction kettle 2 is connected with a vacuum device 21 which is provided with a heat exchanger guiding vapor into the preheating pool 1 and a pipeline extending to the distillate tank 22 . The distillate tank 22 is provided with a pipeline guiding the distilled water into the heater and extending to the reaction kettle 2 and the thermal insulating kettle 3 for scouring liquor.
[0061] As a further improvement of the invention, the preheating pool comprises at least two preheating pools connected in series. Different preheating pools are relatively independent, which may heat the bittern accommodated therein step by step and ensure the bittern at the preheating terminal may more rapidly achieve the temperature required.
[0062] As a further improvement of the invention, the hot end of the water tank is connected with a heating device for supplying heat thereto in an auxiliary manner. The surplus electric power may be converted into the heat energy by using an auxiliary heating device, which steps up the production. At the same time, the scaling of the heating device caused by directly heating the bittern may also be avoided, which affects the heating efficiency.
[0063] As a further improvement of the invention, the high temperature heat pump 7 used in the above-mentioned system is provided with:
[0000] a multipoint thermal balance heat exchanger 71 generating hot water via heat exchange, wherein the multipoint thermal balance heat exchanger is provided with a cold water input end, and hot water output from an output end is accessed to the hot end of the water tank 61 through a water pump 713 and a check valve 714 ;
a heat pump compressor 72 , wherein coolants compressed and output by the heat pump compressor are provided for the multipoint thermal balance heat exchanger 71 through an evaporator 721 and a throttle 722 in sequence, and the coolants are output from the multipoint thermal balance heat exchanger 71 and then are inhaled by the heat pump compressor 72 for circulation; and
the multipoint thermal balance heat exchanger 71 comprises a plurality of groups of heat exchangers 715 connected in series, and a cross runner 716 is arranged among various groups of heat exchangers 715 .
[0064] As a further improvement of the invention, the hot water output end of the multipoint thermal balance heat exchanger 71 is provided with a temperature control valve 717 , and the output of the temperature control valve 717 is connected with the water pump 713 .
[0065] As a further improvement of the invention, a vapor-liquid separator 723 is arranged between the heat pump compressor 72 and the evaporator 721 .
[0066] As a further improvement of the invention, the cold water input end of the multipoint thermal balance heat exchanger 71 is provided with a dirt remover 718 .
[0067] As a further improvement of the invention, the coolants used for the high temperature heat pump are ternary composite coolants with a mass ratio of R124:R245a:R22=3:3:1. The discharge pressure of the composite coolant is 2.3-2.4 MPa, the back pressure is 0.2-0.3 MPa, the condensing temperature is 115-120° C., and the hot water temperature is ensured to be up to 85° C. at the altitude of 3,500-4,500 m, which meets the application of industrial production in plateau.
[0068] The method and the system according to the invention are further described with reference to lithium carbonate extracted from the salt lakes hereinafter.
[0069] A high-efficiency heat energy recycling method for extracting lithium carbonate includes the steps as follows:
[0000] 1) a concentrated solar photo-thermal device is utilized to heat the heat-transfer oil to more than 200° C. for standby;
2) the water in the hot end of the water tank is heated up to above 80° C. via the solar photo-thermal device and the optional auxiliary electric heating device, and the bittern in the preheating pool is preheated, and the preheated bittern is guided into the temperature rising kettle;
3) The hot water in the hot end of the water tank is circulated and guided in a heat exchange coil in the temperature rising kettle, and the bittern in the temperature rising kettle is heated up to above 70° C.;
4) the bittern at the temperature above 70° C. in the temperature rising kettle is guided into the reaction kettle, vacuumized for decompressed concentration, at the same time the heated heat-transfer oil is guided into a heat exchanger in the reaction kettle to rapidly, additionally heat the reaction kettle to ensure the bittern may be continuously and rapidly boiled and rapidly evaporated and concentrated; the vapor produced by decompressing concentration is guided into the heat exchanger in the preheating pool to cool, the released heat firstly heats a second-level preheating pool (high temperature), the condensed hot water is guided into the heat exchanger of a first-level preheating pool (low temperature), in this way, a higher temperature difference remains between the bittern and the vapor (hot water) via heat exchange of countercurrent flow, which may not only effectively preheat the bittern in the second-level preheating temperature, but also may sufficiently recycle the latent heat in the vapor; and distilled water obtained is collected into a distillate tank for standby;
5) high temperature supernatant crystallized in the reaction kettle is guided into a cold end crystallization kettle via a pipeline, a liquid heat conducting medium in the cold end of the water tank is guided into the heat exchange coil in the cold end crystallization kettle, the high temperature supernatant in the cold end crystallization kettle is cooled, the salt in the supernatant is saturated and crystallized to obtain K, Na salts; the cooled and crystallized normal temperature or low temperature supernatant is guided into a supernatant sedimentation tank to perform further recycling or compensate into the salt lakes, which reduces the damage to the salt lake ecology;
6) the distilled water is heated with the heat-transfer oil, coarse crystallized salts of lithium carbonate deposited in the reaction kettle are scoured by using the heated distilled water to dissolve K, Na salts therein, the scouring liquor is collected and guided into a scouring liquor thermal insulation kettle, and kept warm to deposit, which further recycles the lithium carbonate therein; and the lithium carbonate crystals in the reaction kettle are collected and dried;
7) after the device runs for a period of time, the device and the pipeline of the system which are contacted with the bittern are flushed by using the heated distilled water or the supernatant in the scouring liquor thermal insulation kettle to flush salt scales produced by long-term running in the pipeline, the reaction kettle and the scouring liquor thermal insulation kettle, and the flushing liquor is returned to the lakes after recycling the heat energy in the flushing liquor.
[0070] According to the above-mentioned production process, the concentration and crystallization of a batch of bittern may be finished within about 1-2 hours, and the concentration and crystallization of a batch of bittern may be finished within about 10-30 minutes in a condition that the heat quantity is sufficient at noon. By calculating the working hours of 8-10 hours per day, the concentration and crystallization of several batches of bittern may be finished in the same day, the collected and obtained lithium carbonate may be unified and centralized in the scouring liquor thermal insulation kettle to keep warm and stay overnight, and the subsequent treatment is continued after the crystal growth to obtain the lithium carbonate crystals with the purification more than 90%, so that the traditional production process of “living depending on the weather” is totally broken away.
[0071] The heat energy recycling method and system according to the invention, near 60-70% of heat energy may be recycled from the system, and the installed capacity of a matched solar photovoltaic power generating station may be reduced to 25-33% of the original installed capacity, which greatly reduces the fixed investment.
[0072] The test data indicate that a concentrated solar photo-thermal device is adopted in the plateau areas at the altitude of above 3,700 meters to generally achieve a temperature of above 100° C. at about 10:00 AM until at about 18:30 PM, the temperature may still be protected above 120° C., which may totally achieve the industrial production, so that the existing production process in the salt lakes may be completely changed.
[0073] A high temperature concentrated solar thermal collector according to the invention is further described with reference to the drawings hereinafter.
[0074] As shown in FIG. 4 and FIG. 5 , the concentrated solar photo-thermal device includes a cambered concentrated light reflecting board A 1 and a support A 2 for fixing the reflecting board A 1 , a light transmitting board A 3 fixed on the front of the light reflecting board A 1 , end boards A 4 arranged at both ends of the light reflecting board A 1 , the light reflecting board A 1 , the light transmitting board A 3 and the end boards A 4 jointly forming a cavity, a collector pipe A 5 arranged in the cavity along the parallel direction, and the collector pipe A 5 internally provided with a liquid inlet and a liquid outlet.
[0075] The cambered concentrated light reflecting plate is wholly groove-like, and the so-called parallel direction is the axis direction of the light reflecting board. In this way, the sunshine irradiated from different angles may be focused on one line, without frequently regulating the angle of the light reflecting board, which is beneficial for reducing the device maintenance.
[0076] As a further improvement of the invention, the collector pipe A 5 of the thermal collector is sheathed with a transparent thermal insulation pipe A 6 so the light can come through the thermal insulation pipe and the air circulation is obstructed. This may further reduce the heat exchange between the collector pipe and the outside environment, so that the photo-thermal conversion efficiency is improved.
[0077] As a further improvement of the invention, the surface of the collector pipe of the thermal collector is black. The black surface may more sufficiently absorb all kinds of lights, so that the photo-thermal conversion efficiency is improved.
[0078] As a further improvement of the invention, the thermal insulation pipe of the thermal collector is a double-layer vacuum glass pipe. The double-layer vacuum glass pipe has better transparency and thermal insulation performance, which is more beneficial for improving the photo-thermal conversion efficiency.
[0079] As a further improvement of the invention, the surface of the collector pipe of the thermal collector is a matte surface. The matte surface may further reduce the reflection of light, so as to improve the photo-thermal conversion efficiency.
[0080] As a further improvement of the invention, the support A 2 in the thermal collector is provided with a revolving shaft A 21 for regulating the light reflecting board A 1 to rotate, which is convenient to regulate in a condition that the shining angle of the sun is changed greatly.
[0081] As a further improvement of the invention, the revolving shaft of the thermal collector is provided with an angle gauge, thereby facilitating regulation rapidly and accurately.
[0082] As a further improvement of the invention, the high temperature concentrated solar thermal collector in the thermal collector is provided with an actuator for driving the revolving shaft to rotate, so as to be beneficial to automatic regulation and control.
[0083] As a further improvement of the invention, the bottom of the light reflecting board in the thermal collector is provided with a liquid outlet A 11 , which may not only balance the pressure in and out of the cavity, but also may avoid accumulating water in the cavity.
[0084] As a further improvement of the invention, the surface of the light transmitting board of the thermal collector is provided with anti-static coating or an electric conduction layer A 31 , which removes the static electricity on the surface, and prevents the surface from absorbing dust to affect the transparency.
[0085] The heat conducting liquid is guided in via the liquid inlet and guided out via the liquid outlet when used. If necessary, several thermal collectors may be connected in series to obtain a higher temperature, and the temperature of the heat conducting liquid may also be regulated by regulating the liquid feeding speed. It is convenient to obtain the temperature required.
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The invention discloses a high efficiency thermal energy recovery method and system, and a high temperature concentrated solar thermal collector. A concentrated solar photo-thermal device is used to heat heat-transfer oil to a high temperature and the oil is used for rapid heat replenishment for decompressing evaporation. Multiple methods are also used to recover thermal energy so as to recover a large part of thermal energy in a production process, thereby enabling the continuous production in plateau areas, reducing the electricity consumption, lowering the capacity of photovoltaic power stations, and reducing the fixed investment.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
This disclosure pertains to a shock absorbing, damage prevention device for use in separating and restraining loads during transit. More specifically, this disclosure shows a highly portable corrugated void filler which is shipped in a so-called knock down or flat configuration and is assembled in the field to a highly rigid void filler.
(2) Description of the Prior Art
Prior art void fillers such as those disclosed by the Kinnune U.S. Pat. No. 3,854,426 (1974) disclose honeycomb products which are suspended from and adapted to extend the full height of the transported product. These void fillers have met with some limited success but are chronically plagued with problems involved in initially positioning the void filler to insure it deploys the full height of the load and thereafter keeping the void filler in place during transit. Also, costs are prohibitive because of the manufacturing techniques which require not only automatic machinery for applying adhesive but also extensive cutting and forming machines to produce the component parts. Further, it has been observed that at the end of the useful life of the prior art void fillers such as shown in the Kinnune U.S. Pat. No. 3,854,426, there are additional labor costs involved with cleanup and recycling of the corrugated material because metal and wood fasteners and supports must be removed.
Another type of so-called void filler is the dunnage plug shown in the Brucks U.S. Pat. No. 3,421,451 (1969). This structure provides a number of U-shaped, interlocking, corrugated sections. Because the component parts are scored and slotted, they are thus compatible only with correspondingly slotted and scored members. Thus, if it is necessary to vary the width of the dunnage plug to accommodate different spacings between adjacent loads, none of the components of another thickness plug may be used with components of a larger or smaller thickness unit. Thus, because the parts are not interchangeable, there have been problems with providing sufficient component parts in inventory to accommodate spacings between different types of loads.
Another type of void filler or plug is shown in the Carlomagno U.S. Pat. No. 3,534,691 (1970) and the Latter U.S. Pat. No. 3,464,367 (1969). The constructions shown in these patents involve box-type units. U.S. Pat. No. 3,534,691 shows flaps integrally cut therein and extending outwardly for the purpose of fitting between load members to support the box in position. The Latter structure shows open top type box members with flanges extending outwardly therefrom. The top members or caps receive an accordion-shaped member which extends between the adjacent loads. The structures shown in the two patents have not met with widespread acceptance because custom-made dies must be made to cut the required contours in order that the box sections may be folded together. Furthermore, these box-shaped sections do not provide interchangeable parts which can be used when different sized spacings are encountered between loads.
The above difficulties and problems encountered with prior art devices are minimized and/or generally eliminated with the product disclosed herein as will be described.
SUMMARY
Today, cases of canned goods, food products, household items, and other products too numerous to name are transported ported by truck and railroad freight cars. These commodities are generally shipped in cardboard boxes which are stacked on pallets or arranged as so-called unitized loads which are groups of boxes held together with a wrap such as banding or so-called stretch wrap which is a layer of sheet plastic which encircles or otherwise encloses the group of boxes. The void filler of this disclosure if adapted for use in separating virtually any arrangement of boxes during shipment. More specifically, it is particularly designed for use with shrink wrap, stretch wrap, spot glued, and unitized loads.
This disclosure pertains to a so-called void filler which may be mounted in vacant spaces between adjacent loads during transit. The product disclosed is constructed from corrugated cardboard and includes a central body having vertical and diagonal members formed from a continuous member and having a number of slots. Certain slots are adapted to be in horizontal alignment when the body section is folded from a flat or knock down configuration into a configuration in which it is used. In conjunction with the body section, a pair of cap sheets, each having a top flange and a lower, inwardly extending leg, are spaced apart a distance corresponding with the associated slots of the body and are inserted into the body. The top flange of each cap sheet includes reversely bent layers which provide a spring-effect and tend to separate upper and lower layers. This spring-effect is utilized to retain the cap sheets securely in the body slots after insertion. The spring effect not only holds the cap sheets in position but also rigidifies the entire body portion and eliminates the need for using adhesives, fasteners, or any other type of device for maintaining the void filler in the assembled or operative position.
The composite structure effectively provides two I-beams (the cap sheets) interconnected in sandwich fashion by a rigidifying body to form a reinforced beam capable of resisting both compression and torsion loads. The body provides structural members which combine with the top flange and leg of the cap sheet to form rigidifying triangles which provide lightweight strength to the assembled unit.
In use, the void filler may be assembled on-site and positioned at the top portion of a unitized load and adapted to separate the load from an adjacent, load or from the side or end walls of the transporting vehicle. When used to separate adjacent loads, the void filler is suspended by the top flange of each cap sheet and hangs from each load. The unit may be shortened by urging the accordion sections closer together, modifying the lower leg of the cap sheet by making a tab cutout, and then simply cutting off the unwanted end(s).
It is an object of this disclosure to provide a highly portable void filler that is easily transported in a knocked down configuration and does not occupy a large volume and yet can be easily assembled in the field to fill a large volume and maintain a very rigid configuration during transit to maintain a load in position and absorb forces.
It is yet another object of this disclosure to provide a void filler having outwardly extending flanges which are adapted to allow the void filler to be hung between adjacent loads and/or which can be bent upwardly to allow the void filler to be wedged between loads or a wall or be fastened, if necessary, to a side wall of the transporting vehicle.
It is yet another object of this disclosure to provide a void filler having component parts which can be used to fill spacings of a variety of dimensions to thus reduce the number of parts which are to be kept in inventory by a shipper.
Another object of this disclosure is to provide a corrugated void filler which can be easily modified in the field to be customized and fitted into short spaces.
These and other objects of the disclosure will become apparent to those having ordinary skill in the art with reference to the following description, drawings and appended claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial illustration of the void filler;
FIG. 2 is an exploded pictorial illustration of the void filler;
FIG. 3 is an end view of the void filler taken generally along lines 3--3 of FIG. 1;
FIG. 4 is a view showing void fillers in position separating adjacent, loads with portions removed; and
FIG. 5 is another view showing loads in a transporting vehicle and the void filler in position between the load and the vehicle side wall;
FIG. 6 is a cross-section view of the assembled unit with a modification shown by dotted lines; and
FIG. 7 shows a modification of the structures shown in FIGS. 1-5 to permit the void filler to be shortened.
DESCRIPTION
Referring to the drawings, and in particular FIG. 1, there is shown a pictorial illustration of the void filler 10 of this disclosure. Void filler 10 includes a body member 12 having an M-shape. In use, a pair of so-called cap sheets 14 are inserted into the body 12 to form a rigid lightweight void filler 10. As shown in FIG. 2, the body 12 includes downwardly extending sides 16 and a pair of internal or converging diagonals 18 which extend from the top 19 of sides 16 to an apex 20. Body 12 includes a plurality of upper slots 22 and lower slots 23 adapted to receive and hold cap sheets 14 securely in position. As noted from FIG. 2, sides 16 and the diagonals 18 each include four slots 22, 23.
The cap sheets 14 are corrugated as shown in the drawings and, when folded, have essentially the cross sectional shape of a modified I-beam. Lower leg 24 extends inwardly of the void filler 10 and is intended to fit into slots 22 in the lower portion of the body 12. A web 26 extends upwardly from the lower leg 24 and terminates at a top flange 28. Top flange 28 includes a double layer section providing lower layer 30 which extends from the web 26 inwardly of the body 12 into slots 22 and an upper layer 31 which extends outwardly.
The double layer construction is provided by scoring at right angles to the corrugation and folding the cardboard back over itself without cutting or otherwise weakening which would prevent formation of a desired spring effect. With the configuration shown, the upper layer 31 of flange 28 tends to separate from the lower layer 30. Thus, when inserted in the associated slots 22 in the body 12 the tendency to separate between the layers 30, 31 provides a spring effect which locks each cap sheet 14 securely in position.
This construction combines cap sheet 14, which has little resistance to torsion loads (twisting), with body 12, which also has little inherent resistance to torsional loads, to form a composite member or void filler 12 which absorbs torsional and other forces encountered during transit. Cap sheet 14 is provided with a smooth web 26 for positioning adjacent the load. During transit, as a load moves, it slides along the surface of web 26 without binding which could result in high localized stresses and crush the void filler. As the load slides along the web 26, no cutting or damage to the load occurs. Since the load is allowed to move or rub, forces are more evenly distributed into the body 12, and, localized, prohibitive stresses are avoided. Thus, the effectiveness and useful life or void filler 10 in enhanced.
As best shown in FIG. 6, the composite structure of body 12 assembled to cap sheets 14 results in a high strength unit due to the resulting number of triangles formed. FIG. 6 shows three larger and three smaller triangles which rigidify the unit. Specifically, the larger triangles extend between slots 23, 23 and top 19 of side 16. The third larger triangle extends between slot 22 in diagonal 18, to apex 20, to slot 22 in the opposite diagonal. The smaller triangles are formed between upper slots 22, 22 and top 19 and between lower slots 23, 23 and apex 20.
As shown in FIGS. 4 and 5, the void filler 10 is used to separate adjacent, unitized loads. It has been found from testing, that conventional thinking which mandated that any void filler or partition extend the full height of the load is not completely accurate. It has been observed that with the void filler 10 disclosed herein, restraining the top of each unitized or palletized load will generally prevent movement of the entire load under normal conditions. By adding an additional void filler 10 at an intermediate point between the top void filler and the support floor or deck, a greater degree of protection can be obtained. Thus, when used, the void filler 10 of this disclosure need only be positioned and/or at the top of a single level and at the top and middle of a tiered load when deemed necessary. As shown in FIG. 4, void filler 10 may be suspended from the top of the loads and held in position by merely hanging from the top flanges 28 of each cap sheet 14. The void filler 10 immediately below the top void filler 10 shown in FIG. 4 is positioned in the same fashion the top void filler is positioned.
As shown in FIGS. 4 and 5, the void filler 10 of this disclosure is anticipated for, but not restricted to, use in separating unitized loads of cartons. FIGS. 4 and 5 show pairs of loads 40 mounted in a two tier fashion upon a floor 34 of a transporting vehicle. FIG. 5 shows a void between a side wall 36 and the loads 40. Each pallet or unitized load 40 includes a number of boxes 38, generally stacked six high and held in place with straps 42 or a stretch wrap type of sheet plastic covering or banding which encircles the load.
When the void fillers 10 are utilized in spacing loads from a side wall 36, flanges 28 maybe bent upwardly to conform to the flat adjacent side wall and may utilize the inherent spring effect of the bent flange 28 to hold the void filler between the side wall 36 and the load. As shown in the top right portion of FIG. 5, the flange 28 adjacent the load 40 assists in hanging or suspending the void filler 10 in position.
The lower or intermediate void filler 10 shown in FIG. 5 has both flanges 28 bent upwardly and thus produces the same self-restraining spring effect produced by the flanges 28 of FIG. 4 to hold the void filler in position to restrain cartons 38. At times it may be desirable to fasten the upwardly bent flange 28 to an adjacent side wall 36 to positively insure that the volid filler does not move during transit. Alternately, the portion of flange 28 extending outwardly from web 26 may be removed in production or in the field to facilitate positioning.
Modification of the void filler 10 may be made as shown in FIGS. 6 and 7 to shorten its length for fitting into smaller spaces. To shorten the length of the void filler 10, cap sheets 26 are removed and slits are made at the central portion of the lower leg 24 of each cap sheet 26. These slits then provide a flap 44 that is bent downwardly into the same plane with the web 26 of the cap sheet 14. The top flange 28 of the cap sheet 14 is then reinserted into the upper slots 22. With the M-shaped or accordion-shaped configuration of a body 12, as the body 12 is condensed brought together (compare FIGS. 6, 7), the height of the body 12 increases. Essentially, the tops 19 of the sides 16 remain in the same position and the apex 20 moves downwardly. As the body is brought together, the upper slots 22 rotate about point 19. Because slots 22 are close to the point 19, their relative vertical position remains generally unchanged as diagonal section 18 moves closer to sides 16 and thus, regardless how the body 12 is moved together, slots 22 will remain in general horizontal alignment to receive the inwardly extending, sandwiched layers 31, 32 of the flange 28.
On the contrary, the lower slots 23 of the body 12 do not remain in general horizontal alignment as the body 12 sections 16, 18 are brought together. As shown in FIG. 7, the slots 23 of the diagonal sections 18 move downwardly and do not remain in alignment with the slots 23 in the sides 16. Thus, by cutting slits in the lower leg 24 and providing a flap 44, the lower leg 24 may be inserted in the slots 23 of the sides 16 and slots in the converging section are not utilized. As is shown in FIG. 7, ends 46 are removed to thus shorten the overall length of the unit.
Although slots 23 in diagonals 18 are not used for connection, the unit has sufficient, integral strength as provided by the smaller stiffening triangles formed between points 22, 22, 19 in FIG. 7. Further, the large triangle formed by diagonals 18 and the connecting part of top flange 28 insure sufficient strength.
Dimensionally and structurally, it is contemplated that a two-hundred pound (91 Kg.) double wall corrugated cardboard or fibreboard be used for body 12. The distance between sides 16 of body 12 is approximately thirty-two inches (81 cm.) for the units shown in FIGS. 1-5. The sides 22 are nineteen inches high and from eight inches to thirty inches wide. The distance between flange 28 and leg 24 is sixteen inches (162 cm.). The lower layer 30 of flange 28 extends three inches (7.6 cm.) into slots 22. The portion of flange 28 extending from web 26 and away from the body 12 is six inches (15 cm.). In its flat configuration, web 26 is sixteen inches (162 cm.) high and forty inches (101 cm.) in length. The corrugations extend as shown in FIGS. 1, 2. Cap sheet 14 is standardized and one size may be used with any configuration of body 12. Any excess length can be removed in production or in the field.
Certain modifications may be made with the above specifications without departing from the scope of the invention. For example, other types of paper products such as fibreboard and the like could be used in place of corrugated cardboard. Plastic or other non-paper products could be used.
The foregoing description and drawings merely explain and illustrate the invention and the invention is not limited thereto, except insofar as the appended claims are so limited, as those who are skilled in the art and have the disclosure before them will be able to make modifications and variations therein without departing from the scope of the invention.
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A method and product provide a highly portable, corrugated void filler for preventing damage to unitized loads has a body or core formed into an accordian shape to provide a number of aligned slots adapted to receive portions of associated cap sheets which are fitted in place to produce a rigid, lightweight product. Each cap sheet has a top flange with reversely bent layers of cardboard which provide a locking effect urging the layers apart in a spring-like fashion to retain the cap sheets securely in position after each is inserted into slots of the body member. The top flange of each cap sheet has outwardly extending portions adapted for mounting the void filler in position by suspending between loads or by fastening only when necessary to a vehicle sidewall.
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BACKGROUND OF THE INVENTION
The present invention relates to a non-slip type rectilinear wiredrawing machine with tangentially uncoiling capstans incorporating a synchronization device between each two successive capstans.
Conventionally, in a multiple drawing machine for the manufacture of metal wire, where each drawing step reduces the diameter of the wire by a given percentage of its rounded section, the fundamental difficulty encountered is that of synchronizing the rotational speeds of the capstans, which in essence function as collect-and-feed stations intercalated with the successive drawing dies or plates in such a way as to ensure a steady flow of material. Thus, expressing the velocity and section of the wire per drawing step (n) as Vn and Sn, it must be ensured that Sn×Vn=k.
The product of section multiplied by speed, i.e. the volume of the flow of material, must in effect remain constant from one step to the next. Given therefore that the section of the wire is dependent on the diameter of the drawing die or plate located between capstans, and that this same diameter will be subject to an unpredictable and uncontrollable degree of variation through wear during production, a correction can be effected only by varying the velocity of the wire which, in the non-slip type of drawing machine (i.e. where the capstan carries a significant number of single coils of wire, thereby disallowing relative movement between capstan and material), is equivalent to the peripheral surface speed of the capstans.
In multiple machines such as the Morgan and similar types, the wire is wound spirally onto cylindrical capstans and uncoiled in an axial direction from the capstan. Synchronization is achieved in such machines, necessarily, by operating the capstans intermittently, and while the flow of material is rendered steady in this manner, the result is but modestly successful. The main limitations of such machines stem from the need for intermittent type operation on the one hand, and on the other, from the fact that the wire is subjected to undesirable stresses; in effect, the wire is twisted through a full revolution with each coil paid out from the capstan, by reason of the axial uncoiling action. Moreover, these axially uncoiling machines require a device by means of which to transfer the running wire from one capstan to the next (an `uncoiler`, in effect), which comprises pulleys positioned one alongside and another elevated axially from the capstan, serving to direct the wire toward and into the drawing die preceding the next capstan.
In a variation on this type of machine, designed to prevent twisting of the wire (which is undesirable in any event, but absolutely to be avoided when drawing steel with a high carbon content), use is made of two capstans positioned one above the other with a single transfer pulley located in between that enables the wire to run off the second capstan tangentially instead of axially. The drawback of intermittent operation remains in such machines, however, in addition to the considerable structural complications that arise with two capstans to each drawing step.
With the advent of d.c. capstan drive motors, it has been possible to update these machines to newer technological standards; accordingly, the "stop/go" type of intermittent operation can be improved to "slow/fast", and by incorporating further special expedients and transducers, continuous and entirely intermittence-free operation can also be achieved. Also, the use of variable speed converters has led to the embodiment of new rectilinear wiredrawing machines in which the wire passes directly from one capstan to the next. The number of coils passing round each capstan remains fixed, and absolutely no twisting occurs in passage of the wire from step to step.
The capstans themselves are of frustoconical shape, exhibiting a gentle taper that enables and favors an orderly and substantially non-overlapping coil along the winding surface between the pulling face where the wire enters into full contact with the surface, and the run-out face at the very top of the capstan. Accordingly, the wire can be made to uncoil tangentially from such a capstan.
In the rectilinear machine, there is no slippage between the wire and the capstan face, so that the velocity of the wire coincides with the surface speed of the capstan. This automatically dictates the need to govern the tension of the wire between capstan; the necessary control is obtained in most instances by locating a jockey, or dancer, between one capstan and the next, and more exactly, between the exit of each capstan and the drawing die or plate next in sequence, positioned in such a way as to react to any geometrical variation in a loop of wire created between the two capstans for the very purpose in question. The dancer combines with a suitable transducer, of which the response varies with oscillation induced by changes in tension of the wire, to create a control medium of which the corresponding variation in output can be used to correct the speed of the interlocked capstan. In rectilinear machines of the type in question, the wire generally needs to be directed around one or more pulleys before entering the drawing die associated with the following capstan, in order to create a degree of slack sufficient to accommodate the excursion of the dancer; this results in a certain degree of drag on the loop of wire, of which the force will depend on the mechanical load applied to the dancer. Moreover, these pulleys are generally of diameter much smaller than that of the capstan, especially when installed in any number, so that the wire is subjected to a succession of alternate bending stresses; such an effect is not only undesirable, but especially damaging when the wire is still relatively thick during the initial drawing steps, or when operating with particularly large nominal production diameters. Conversely, if the dancer mechanism is reduced to a simple sensor monitoring a single loop of wire located between two capstans, the resulting control becomes so highly sensitive as to produce a critical operating characteristic, and flexibility is lost. Thus, notwithstanding the advantage of affording a speed control facility, even the rectilinear type of wiredrawing machine betrays not inconsiderable drawbacks.
Capstan speed can be governed by monitoring torque rather than speed, however, and this is the method adopted in a further type of machine in which speed is compensated by drag. The advantage of these machines consists in the fact that one has a direct transfer of the wire from one capstan to another, without dancers or other such devices; in practical terms, the wire passes directly from one capstan to the drawing die located between this and the next capstan. Synchronization is achieved automatically inasmuch as the drive of the interlocked capstan will not deliver the total required drawing torque, but a given proportion thereof, insufficient in any event to set the capstan in rotation. The remaining proportion is provided by the capstan next in line by way of the interconnecting wire, which generates the drag necessary to compensate the shortfall. The effect is passed on down to the final capstan in line, which, being speed-controlled, automatically determines the speed of all the preceding capstans. Whilst there are no problems with transfer of the wire from one capstan to the next in such machines, the compensating drag cannot be metered accurately to match the effective requirement, and the risk of the wire breaking is therefore greatly increased in consequence.
Furthermore, the matching of speeds between one capstan and the next is markedly rigid, given the absence of any margin of tolerance, or of any flow compensating means by which to take up the minute variations in velocity between capstans caused by an irregular flow of material.
Finally, optimum torque-metering of the capstan drive motors can indeed be obtained using special transducers (strain gages) placed in contact with the wire at a point prior to its entering each die, which convert the detectable degree of drag into a given output signal. This results in a particularly complex and delicate system, however, and does not ultimately eliminate the risk of wire rupture. The object of the present invention is to overcome the drawbacks mentioned above.
SUMMARY OF THE INVENTION
The stated object is realized in a rectilinear wiredrawing machine with tangentially uncoiling capstans according to the present invention, in which each capstan is composed of two concentric and coaxial parts, the first driven by a motor and comprising the typical capstan pulling face, the second embodied as a freely-revolving tubular ring affording a run-out face from which the wire is drawn through a die by and onto the next capstan; the speed of the single capstans is synchronized by a device capable of monitoring the angular movement both of the power driven first part of each capstan and of the freely-revolving ring, detecting any difference between the two, and adjusting the speed of the motor accordingly. The wire passes direct from one capstan to the next encountering nothing other than a drawing die or plate, eliminating any undesirable stress on the wire, and in addition, eliminating any risk of the wire breaking as occurs typically in a drag compensated machine. Thus, for the first time, the problem of efficient synchronization is properly addressed and resolved by controlling speed, through without exerting any stress on the wire; rather, the coiling action is affected in geometrically controlled conditions, with a margin of tolerance sufficient to safeguard the integrity of the wire at any given moment of the synchronization process.
Among the advantages of the present invention is that it combines the positive features of a dancer speed controlled rectilinear machine and those of a torque controlled drag compensated type.
Another advantage of the machine disclosed is that of its especial simplicity in construction, whereby synchronization is entrusted to an uncomplicated electromechanical control obtainable essentially through appropriate structuring of the capstan.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in detail, by way of example, with the aid of the accompanying drawings, in which:
FIG. 1 is a schematic illustration of the structure of a capstan according to the invention;
FIG. 2 is a detail of the top end of the capstan;
FIG. 3 is a schematic illustration of one capstan, showing the parts essential to the embodiment of a synchronization device characteristic of the wire drawing machine disclosed;
FIG. 4 is a block diagram of the synchronization device;
FIG. 5 is a schematic representation of the machine disclosed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the general illustration of the machine provided by FIG. 5 of the drawings, 9 denotes the wire, which is fed in at 9i and gradually reduced in section to a given production diameter 9u, thereafter being recoiled onto a spool 21 at a speed of rotation which adjusts with the increase in the number of coils, hence in their overall diameter, such that the peripheral recoil velocity remains constant. The capstans 1 adopted in the machine disclosed are essentially frustoconical, favoring an ordered distribution of the coiling wire onto the pulling face 2a and along to the run-out 3a at the top end. More exactly, each capstan 1 is embodied in two distinct concentrically and coaxially disposed parts 2 and 3 (FIGS. 1, 3 and 5), the part denoted 2 being driven by a relative motor 10 of which the shaft 10a is coupled via a power transmission 10b to a basically conventional capstan drive shaft 5 associated axially with the part 2 in question. The part 2 thus driven appears essentially as a cone frustum 22 disposed coaxially in relation to the remaining part 3.
According to the invention, the part of the capstan denoted 3 consists in a freely revolving tubular ring 33 that provides the run-out 3a for the wire 9 and is carried by a relative shaft 4 coaxial with, and, in the case of the example illustrated in the drawings, supported internally of the shaft 5 first mentioned. The ring 33 might be frustoconical, with a taper matched to that of the cone frustum 22, or cylindrical as illustrated. Whichever the case, the ring 33 is embodied with a splayed lip 33a serving to restrain the endmost coils of the outrunning wire 9a. Each such ring 33 is kept continuously in rotation by the next capstan 1 in line, onto which the wire 9 passes by way of a respective drawing die 32 (see FIG. 5), thereby establishing a given angular velocity Na of the relative shaft 4.
The wiredrawing machine according to the invention is controlled by a synchronization device 50 (see FIG. 4) designed to correct the rotational speed of the frustoconical part 2 of the capstan whenever a difference occurs between the angular velocity Nc of the driving shaft 5, integrated mathematically and considered as a degree of angular movement Sc, and the angular velocity Na of the shaft 4 of the freely revolving ring 33, similarly integrated and considered as a degree of angular movement Sa, by way of sensors 7 and 6 fitted to the respective shafts 5 and 4 and serving to monitor the angular velocities in question. Preferably, the device 50 will be electric, such that sensing and subsequent integration of the respective angular velocities, occurring at the block denoted 15 in FIG. 4, can be effected to advantage using conventional encoders 66 and 77 fitted to the relative shafts 4 and 5 (see FIG. 3).
Before proceeding with the description of the synchronization device 50, it should be mentioned that each capstan is associated, conventionally, with a speed control feedback loop 17 serving to pilot control of the rotational speed Nc of the motor 10 through a positive or negative signal amplified by the block denoted 20; this signal reflects the difference detected by a comparator 14 between the output signal of a tacho generator 16, fitted to the shaft of the motor 10, and an electrical reference Vrn selected previously and adopted as the capstan speed control parameter. Thus, in addition to this conventional loop 17 and to the encoders 66 and 67 already mentioned, the synchronization device 50 further comprises a dividing circuit 18 by which the output signals from the encoders are reduced to a ratio, and a comparator 12 by which this ratio is subtracted from a previously selected electrical reference value R funz greater than but effectively close to a nominal synchronization value R syn selected for the capstan 1; the difference signal produced by subtraction, amplified by the block denoted 19, can thus be used to effect a correction of the electrical reference Vrn aforementioned if and when synchronization defects should occur.
In operation, wire 9 about to be drawn toward the capstan next in sequence will first coil a given number of times around the ring 33 which, being mechanically independent of the cone frustum 22, rotates at an angular velocity determined by these final coils of wire 9a, hence by the destination capstan. Any lack of synchronization will therefore result in the coils around the ring 33 becoming slacker or tighter than those enveloping the cone frustum 22. More exactly, this slacker or tighter coiling action will occur at an area denoted 23, which marks the crossover from the cone frustum 22 to the ring 33. Whilst the endmost coils 9a cling tightly to the ring 33 as a result of the pulling force to which they are subject, the preceding coils tend to remain at a substantially constant diameter, given that the flow of material coming onto the pulling face 2a of the capstan must match the flow running off at the opposite end 3a.
In effect, the fact that the section of the wire 9 remains constant along the capstan signifies that its tangential uncoiling velocity must also remain constant, though only if the diameter of the single coils remains constant likewise.
For example, should an increased pulling force be exerted on the endmost coils 9a, as a result of the destination capstan running faster, the freely revolving ring 33 turns faster in response and thus induces a tighter coil at the crossover 23, whereas the speed of the cone frustum 22 remains unchanged (typically slower).
Thus, if Da is the diameter of the ring 33 and Dc the diameter of the wide end of the cone frustum 22 (i.e. the pulling face 2a), then uniform surface speeds and nominal synchronization may be expressed as follows:
Na×Da=Nc×Dc
hence:
Nc/Na=Da/Dc=R.sub.syn <1
It will be seen that the ratio between the speeds of the shafts 5 and 4 compensates the difference in diameters. If, therefore, an electrical association is established between the ring 33 and the cone frustum 22, with a ratio between the value of R syn and 1, one has an effective synchronization medium in the margin of tolerance or flow compensation provided by the facility of the coils to tighten or slacken at the crossover 23. Synchronous conditions are therefore maintained, in general, with a value of R funz between the nominal R syn and 1, not least by reason of the fact that the diameter of the final coil 9a which drives the ring 33 will almost invariably differ from the diameter denoted Da as the coils are likely, in practice, to bunch or overlap (FIG. 2).
Operation is also possible with a value of R funz greater than 1, though the coils would become too slack ultimately, causing the ring 33 to rotate at an angular velocity Na actually less than Nc, with clearly unacceptable results.
To advantage, the coils at the crossover 23 will be kept as tight as possible (i.e. parametrically near to R syn ) in order to increase the stability of the coils 9a running off the capstan in question, which in turn signifies a value of R funz approaching that of R syn though allowing a margin sufficient at any given moment to maintain a diameter of the coils at the crossover 23 such as permits of accommodating any variation in velocity caused by the relative tightening or slackening action. Thus, by adopting a suitable value of R funz , which would be greater in any event than that of R syn and selected preferably with the system in operation, the best possible synchronization will be achieved from a practical standpoint.
A preferred embodiment of the machine will also include a brake 8 associated with the free-running shaft 4, which enables bi-directional reaction and inertia of the ring 33 in response to variations in drag on the wire caused by corresponding variations in the tangential velocity of the capstan 1 next in sequence. This in turn renders the response of the encoders 66 and 67 instantaneous, by virtue of the fact that the endmost coils 9a remain permanently in contact with the surface of the ring 33 whatever the conditions.
An example of the practical application of such a device 50 is illustrated in FIG. 5, where it will be seen that the electrical reference signal Vrn for a given capstan coincides with the input "i" to the speed control feedback loop 17 of the capstan next in sequence (see also FIG. 4), whilst the value Vr.sub.(n-1) of the input "i" to the feedback loop 17 of the capstan first mentioned provides the Vrn reference for the capstan preceding in sequence. In partiuclar, it will be observed that the reference Vr1 serving the first capstan of FIG. 52 is supplied by the following capstan, likewise the signals Vr2 and Vr3 supplied to the next two capstans, whereas the reference Vr4 supplied to the final capstan is dependent on the tangential velocity of the out-running wire 9u and matched to the peripheral velocity of the spool 521.
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In a non-slip rectilinear wiredrawing machine with tangentially uncoiling pstans, each capstan is composed of two concentric and coaxial parts, the first of which driven by a motor and comprising the typical capstan pulling face, the second part a freely-revolving ring affording a run-out from which the wire is drawn through a die by and onto a successive capstan; the speed of the individual capstans is synchronized by a device capable of monitoring both the angular movement of the shaft driving the first part of the capstan and the angular movement of the ring, detecting any difference between the two, and correcting the angular velocity of the shaft accordingly.
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FIELD OF THE INVENTION
[0001] The present invention relates to a novel crystalline form of 5-methoxy-2-[[(4-methoxy-3,5-dimethyl-2-pyridinyl)methyl]sulfinyl]-1H-benzimidazole. 5-methoxy-2-[[(4-methoxy-3,5-dimethyl-2-pyridinyl)methyl]sulfinyl]-1H-benzimidazole is known under the generic name omeprazole and its novel crystalline form is hereinafter referred to as omeprazole form A. Further, the present invention also relates to use of omeprazole form A for the treatment of gastrointestinal disorders, pharmaceutical compositions containing omeprazole form A and processes for the preparation of omeprazole form A.
BACKGROUND OF THE INVENTION AND PRIOR ART
[0002] The compound 5-methoxy-2-[[(4-methoxy-3,5-dimethyl-2-pyridinyl)methyl]sulfinyl]-1H-benzimidazole, having the generic name omeprazole, as well as therapeutically acceptable salts thereof, are described in EP 5129. The single crystal X-ray data and the derived molecular structure of the so far only known crystal form of omeprazole is described by Ohishi et al., Acta Cryst. (1989), C45, 1921-1923. This published crystal form of omeprazole is hereinafter referred to as omeprazole form B.
[0003] Omeprazole is a proton pump inhibitor, i.e. effective in inhibiting gastric acid secretion, and is useful as an antiulcer agent. In a more general sense, omeprazole may be used for treatment of gastric-acid related diseases in mammals and especially in man.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] [0004]FIG. 1 is an X-ray powder diffractogram of omeprazole form A.
[0005] [0005]FIG. 2 is an X-ray powder diffractogram of omeprazole form B.
DESCRIPTION OF THE INVENTION
[0006] It has surprisingly been found that the substance omeprazole can exist in more than one crystal form. It is an object of the present invention to provide omeprazole form A. Another object of the present invention is to provide a process for the preparation of omeprazole form A, substantially free from other forms of omeprazole. X-ray powder diffraction (XRPD) is used as a method of differentiating omeprazole form A from other crystalline and non-crystalline forms of omeprazole. Additionally it is an object of the present invention to provide pharmaceutical formulations comprising omeprazole form A.
[0007] Omeprazole form A is a crystalline form exhibiting advantageous properties, such as being well-defined, being thermodynamically more stable and less hygroscopic than omeprazole form B, especially at room temperature. Omeprazole form A does also show a better chemical stability, such as thermo stability and light stability, than omeprazole form B.
[0008] Omeprazole form B can under certain conditions, completely or partly, be converted into omeprazole form A. Omeprazole form A is thereby characterized in being thermo-dynamically more stable than omeprazole form B.
[0009] Omeprazole form A is further characterized as being essentially non-hygroscopic.
[0010] Omeprazole form A is characterized by the positions and intensities of the peaks in the X-ray powder diffractogram, as well as by the unit cell parameters. The unit cell dimensions have been calculated from accurate Guinier data. The X-ray powder diffractogram data as well as the unit cell parameters for omeprazole form B are different compared to omeprazole form A. Omeprazole form A can thereby be distinguished from omeprazole form B, using X-ray powder diffraction.
[0011] Omeprazole form A, according to the present invention, is characterized in providing an X-ray powder diffraction pattern, as in FIG. 1, exhibiting substantially the following d-values and intensities;
Form A Form A d-value Relative d-value Relative (Å) intensity (Å) intensity 9.5 vs 3.71 s 7.9 s 3.59 m 7.4 w 3.48 m 7.2 vs 3.45 s 6.0 m 3.31 w 5.6 s 3.22 s 5.2 s 3.17 m 5.1 s 3.11 w 4.89 w 3.04 w 4.64 m 3.00 w 4.60 m 2.91 w 4.53 w 2.86 w 4.49 m 2.85 w 4.31 m 2.75 w 4.19 w 2.67 w 4.15 w 2.45 w 3.95 w 2.41 w
[0012] The peaks, identified with d-values calculated from the Bragg formula and intensities, have been extracted from the Guinier diffractogram of omeprazole form A. The relative intensities are less reliable and instead of numerical values the following definitions are used;
% Relative Intensity* Definition 25-100 vs (very strong) 10-25 s (strong) 3-10 m (medium) 1-3 w (weak)
[0013] Omeprazole form A according to the present invention is further characterized by a triclinic unit cell with parameters;
[0014] a=10.410(4) Å
[0015] b=10.468(3) Å
[0016] c=9.729(4) Å
[0017] α=111.51(3)
[0018] β=116.78(3) °
[0019] γ=90.77(3) °
[0020] Omeprazole form A can also be characterized by Raman spectroscopy, where omeprazole form A is characterized by the absence of a band at 1364 cm −1 , which is observed for omeprazole form B, and by the ratio of the relative intensities of the 842 and 836 cm −1 bands. The ratio (intensity of 842 cm-1 band/intensity of 836 cm-1 band) is <1 for omeprazole form A, while the ratio is >1 for omeprazole form B.
[0021] According to the invention there is further provided a process for the preparation of omeprazole form A.
[0022] Omeprazole form A is obtained upon slow crystallization and omeprazole form B is obtained from fast crystallization. Omeprazole form A may be prepared by reaction crystallisation or recrystallizing omeprazole of any form, or mixtures of any forms, in an appropriate solvent, such as for instance methanol, at around room temperature and for a prolonged time period. Examples of prolonged time periods include, but are not limited to, a few hours, such as 2 hours, up to several weeks. Suitable solvents are alkyl alcohols and especially a lower alcohol comprising 1-4 carbon atoms.
[0023] Omeprazole form A may also be prepared by suspending omeprazole of any form, or mixtures of any forms, in an appropriate solvent at around room temperature and for a prolonged time period. Examples of appropriate solvents include, but are not limited to, methanol, ethanol, acetone, ethyl acetate, methyl tert. butyl ether, toluene, or any mixture thereof. Examples of prolonged time periods include, but are not limited to, a few hours, such as 2 hours, up to several weeks.
[0024] The omeprazole form A obtained according to the present invention is substantially free from other crystal and non-crystal forms of omeprazole, such as omeprazole form B. Substantially free from other forms of omeprazole shall be understood to mean that omeprazole form A contains less than 10%, preferably less than 5%, of any other forms of omeprazole, e.g. omeprazole form B.
[0025] Omeprazole form A in mixture with other solid form/forms of omeprazole, e.g. omeprazole form B, also exhibits advantageous properties, such as being chemically more stable than pure omeprazole form B. Mixtures comprising a certain amount of omeprazole form A, by weight, are also chemically more stable than other mixtures comprising a lesser amount of omeprazole form A, by weight. Such mixtures comprising omeprazole form A can be prepared, for example, by mixing omeprazole form A prepared according to the present invention with other solid forms of omeprazole, such as form B, prepared according to prior art.
[0026] The present invention also relates to mixtures comprising omeprazole form A in mixture with other solid forms of omeprazole. Such mixtures comprising omeprazole form A include for instance mixtures containing a detectable amount of omeprazole form A, 1%, 2%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95%, 98% or 99% (by weight), of omeprazole form A.
[0027] Examples of other solid forms of omeprazole include, but are not limited to, omeprazole form B, amorphous forms, and other polymorphs.
[0028] A detectable amount of omeprazole form A is an amount that can be detected using conventional techniques, such as FT-IR, Raman spectroscopy, XRPD and the like.
[0029] The expression chemical stability includes, but is not limited to, thermo stability and light stability.
[0030] The compound of the invention, i.e. omeprazole form A, prepared according to the present invention is analyzed, characterized and differentiated from omeprazole form B by X-ray powder diffraction, a technique which is known per se. Another suitable technique to analyze, characterize and differentiate omeprazole form A from omeprazole form B is by Raman spectroscopy.
[0031] Omeprazole form A is effective as a gastric acid secretion inhibitor, and is useful as an antiulcer agent. In a more general sense, it can be used for treatment of gastric-acid related conditions in mammals and especially in man, including e.g. reflux esophagitis, gastritis, duodenitis, gastric ulcer and duodenal ulcer. Furthermore, it may be used for treatment of other gastrointestinal disorders where gastric acid inhibitory effect is desirable e.g. in patients on NSAID therapy, in patients with Non Ulcer Dyspepsia, in patients with symptomatic gastro-esophageal reflux disease, and in patients with gastrinomas. The compound of the invention may also be used in patients in intensive care situations, in patients with acute upper gastrointestinal bleeding, pre- and postoperatively to prevent aspiration of gastric acid and to treat stress ulceration. Further, the compound of the invention may be useful in the treatment of psoriasis as well as in the treatment of Helicobacter infections and diseases related to these. The compound of the invention may also be used for treatment of inflammatory conditions in mammals, including man.
[0032] Any suitable route of administration may be employed for providing the patient with an effective dosage of omeprazole form A according to the invention. For example, peroral or parenteral formulations and the like may be employed. Dosage forms include capsules, tablets, dispersions, suspensions and the like, e.g. enteric-coated capsules and/or tablets, capsules and/or tablets containing enteric-coated pellets of omeprazole. In all dosage forms omeprazole form A can be admixtured with other suitable constituents.
[0033] According to the invention there is further provided a pharmaceutical composition comprising omeprazole form A, as active ingredient, in association with a pharmaceutically acceptable carrier, diluent or excipient and optionally other therapeutic ingredients. Compositions comprising other therapeutic ingredients are especially of interest in the treatment of Helicobacter infections. The invention also provides the use of omeprazole form A in the manufacture of a medicament for use in the treatment of a gastric-acid related condition and a method of treating a gastric-acid related condition which method comprises administering to a subject suffering from said condition a therapeutically effective amount of omeprazole form A.
[0034] The compositions of the invention include compositions suitable for peroral or parenteral administration. The compositions may be conveniently presented in unit dosage forms, and prepared by any methods known in the art of pharmacy.
[0035] In the practice of the invention, the most suitable route of administration as well as the magnitude of a therapeutic dose of omeprazole form A in any given case will depend on the nature and severity of the disease to be treated. The dose, and dose frequency, may also vary according to the age, body weight, and response of the individual patient. Special requirements may be needed for patients having Zollinger-Ellison syndrome, such as a need for higher doses than the average patient. Children and patients with liver diseases as well as patients under long term treatment will generally benefit from doses that are somewhat lower than the average. Thus, in some conditions it may be necessary to use doses outside the ranges stated below. Such higher and lower doses are within the scope of the present invention.
[0036] In general, a suitable oral dosage form may cover a dose range from 5 mg to 250 mg total daily dose, administered in one single dose or equally divided doses. A preferred dosage range is from 10 mg to 80 mg.
[0037] The compound of the invention may be combined as the active component in intimate admixture with a pharmaceutical carrier according to conventional techniques, such as the oral formulations described in WO 96101623 and EP 247 983, the disclosures of which are hereby incorporated as a whole by reference.
[0038] Combination therapies comprising omeprazole form A and other active ingredients in separate dosage forms, or in one fixed dosage form, may also be used. Examples of such active ingredients include anti-bacterial compounds, non-steroidal anti-inflammatory agents, antacid agents, alginates and prokinetic agents.
[0039] The examples which follow will further illustrate the preparation of the compound of the invention, i.e. omeprazole form A, but are not intended to limit the scope of the invention as defined hereinabove or as claimed below.
EXAMPLES
Example 1
[0040] Preparation of Omeprazole form A
[0041] Omeprazole (55.8 g) is added at room temperature to methanol (348 ml) containing ammonia (1.3 ml; 25%). The suspension is thereafter stirred in darkness for approximately 45 hours and then filtered. The filtrate is dried 18 hours at 30° C. under reduced pressure (<5 mbar). Yield: 43.9 g.
Example 2
[0042] Preparation of Omeprazoleform B
[0043] Omeprazole (50 g) is added to methanol (750 ml) containing ammonia (0.7 ml; 25%) at 50° C. The solution is thereafter filtered and cooled in about 20 minutes to approximately 0° C. The formed crystals are filtered and washed with ice cooled methanol and then dried. The filtrate was dried 24 hours at 40° C. under reduced pressure (<5 mbar). Yield: 39 g.
Example 3
[0044] Characterization of Omeprazole form A and Omeprazole form B Using X-ray Powder Diffraction
[0045] X-ray diffraction analysis was performed according to standard methods which can be found in e.g. Bunn, C. W. (1948), Chemical Crystallography, Clarendon Press, London; or Klug, H. P. & Alexander, L. E. (1974), X-Ray Diffraction Procedures, John Wiley and Sons, New York. The unit cell parameters for omeprazole form A and B have been calculated from the Guinier X-ray powder diffractograms using the program “TREOR” by Wemer, P. -E., Eriksson, L. and Westdahl, M., J. Appl. Crystallogr. 18 (1985) 367-370. The fact that the positions of all peaks in the diffractograms for omeprazole form A and form B may be calculated using the respective unit cell parameters, proves that the unit cells are correct and that the diffractograms are indicative of the pure forms. The diffractogram of omeprazole form A, prepared according to Example 1 in the present application, is shown in FIG. 1 and the diffractogram of omeprazole form B, prepared according to Example 2 in the present application is shown in FIG. 2.
[0046] The peaks, identified with d-values calculated from the Bragg formula and intensities, have been extracted from the diffractograms for omeprazole forms A and form B, and are given in Table 1. In this table the unit cell parameters for omeprazole forms A and B are also given. The relative intensities are less reliable and instead of numerical values the following definitions are used;
% Relative Intensity Definition 25-100 vs (very strong) 10-25 s (strong) 3-10 m (medium) 1-3 w (weak)
[0047] Some additional weak or very weak peaks found in the diffractograms have been omitted from table 1.
[0048] Table 1. X-ray powder diffraction data for omeprazole form A and form B shown in FIGS. 1 and 2. All peaks noted for omeprazole form A and form B can be indexed with the unit cells given below.
Form A Form A d-value Relative d-value Relative (Å) intensity (Å) intensity 9.5 vs 9.6 vs 7.9 s 8.0 m 7.4 w 7.9 m 7.2 vs 7.5 w 6.0 m 7.1 vs 5.6 s 5.9 m 5.2 s 5.6 m 5.1 s 5.3 5 4.89 w 5.1 s 4.64 m 4.54 m 4.60 m 4.48 s 4.53 w 4.41 m 4.49 m 4.14 w 4.31 m 3.75 s 4.19 w 3.57 m 4.15 w 3.47 s 3.95 w 3.40 w 3.71 s 3.28 s 3.59 m 3.22 m 3.48 m 3.02 w 3.45 s 2.97 w 3.31 w 2.87 w 3.22 s 2.37 w 3.17 m 3.11 w 3.04 w 3.00 w 2.91 w 2.86 w 2.85 w 2.75 w 2.67 w 2.45 w 2.41 w
[0049] The triclinic unit cells are:
Unit cell form A Unit cell form B a = 10.410 (4) Å a = 10.257 (10) Å b = 10.468 (3) Å b = 10.717 (6) Å c = 9.729 (4) Å c = 9.694 (10) Å α = 111.51 (3)° α = 112.14 (7)° β = 116.78 (3)° β = 115.56 (5)° γ = 90.77 (3)° γ = 91.76 (7)°
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The present invention relates to a novel crystalline form of 5-methoxy-2-[[(4-methoxy-3,5-dimethyl-2-pyridinyl)methyl]sulfinyl]-1H-benzimidazole, known under the generic name omeprazole. Further, the present invention also relates to the use of the novel crystalline form of 5-methoxy-2-[[(4-methoxy-3,5-dimethyl-2-pyridinyl)methyl]sulfinyl]-1H-benzimidazole for the treatment of gastrointestinal disorders, pharmaceutical compositions containing it as well as processes for the preparation of the novel crystalline form of 5-methoxy-2-[[(4-methoxy-3,5-dimethyl-2-pyridinyl)methyl]sulfinyl]-1H-benzimidazole.
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FIELD OF THE INVENTION
[0001] The present invention relates to an aqueous solution of a polyene fungicide.
BACKGROUND OF THE INVENTION
[0002] Polyene fungicides are used in the prevention of fungal and yeast growth in a wide variety of applications. In particular polyene fungicides, such as natamycin, are used to prevent spoilage of food products such as cheese, sausages, fruit products and beverages. Agricultural, veterinarian and pharmaceutical applications of polyene fungicides are also known.
[0003] For convenient use of preparations comprising a polyene fungicide, the activity of the polyene fungicide in the preparation should be sufficiently stable to allow handling, shipment and/or storage of the preparation. The activity of the polyene fungicide in the preparation depends on a number of different known factors, depending on the kind of polyene fungicide and the specific properties of other components in the preparation. For instance, it has been shown that exclusion of light and high concentrations in combination with moderate temperatures have a positive influence on the stability of natamycin and therefore the efficacy the polyene fungicide. The positive influence of high concentrations on the stability of the polyene fungicide is not surprising because most of the fungicide will be present in the solid state. Protection of natamycin from oxidation and ultraviolet light can be obtained by the use of chlorophyllin and other compounds (Antibiotics and Chemotherapy 9: 327-332).
[0004] The efficacy of a polyene fungicide preparation is in general determined by the concentration of the fungicide and the stability of this polyene fungicide under these conditions. Since only the dissolved fraction has antifungal activity, the fungicidal effect mostly depends on the amount of the dissolved part of the polyene fungicide, which is low in aqueous systems (most food products) and in most organic solvents.
[0005] Further, the stability is also directly linked to the solubility of the polyene fungicide. The dissolved fraction of the polyene fungicide is more susceptible to degradation by factors affecting its stability.
[0006] For many applications the low solubility of natamycin is an advantage rather than a disadvantage because most of the food spoilage fungi are susceptible to very low concentrations of natamycin. The undissolved natamycin thus forms a depot or source by compensating for the dissolved part of the fungicide which has disappeared e.g. by carrying out its activity, decomposition and/or diffusion. This is especially true when surface treatment is employed with the aim of protecting the product, such as cheese or sausages, for a longer period of time.
[0007] For many other applications a higher amount of dissolved natamycin can be advantageous. For instance when a high antifungal activity is required for a short term. This might be the case during some stages of the foodstuff production process; e.g. just before closing the packaging of the product or, in the case of the production of cheese and sausages, shortly after the production when the humidity is high and the product is more susceptible to fungal spoilage.
[0008] A high amount of dissolved natamycin is also advantageous when one has to deal with fungal species with a higher tolerance towards the fungicide. In such cases, a higher amount of the fungicide in the active (dissolved) form is required in combination with a good stability of the active form. For instance, Penicillium discolor is a species with a higher tolerance towards natamycin than the usual spoilage fungi present in cheese warehouses. High contamination levels of such a species may lead to spoilage problems because less than 40 ppm dissolved natamycin in aqueous systems might be too low to prevent the outgrowth of this mould species. The amount of dissolved polyene fungicide can be improved, for instance, by using a low or a high pH. However, the shelf life of such preparations is very limited because of the poor stability of dissolved natamycin especially at low and high pH. Therefore up to now such preparations of dissolved natamycin have to be prepared just before use. An extra disadvantage of such a practice is the need to have specialized equipment and ingredients to hand for making the preparations. A further disadvantage of a solution having a high or a low pH is that its pH is influenced by the pH of the treated subject. For example, the pH of cheese is about 5.0. This means that most of the dissolved natamycin will crystallize shortly after use on the cheese and therefore the protection against the mould will be diminished.
[0009] U.S. Pat. No. 6,369,036 describes the preparation of polyene fungicide compounds, which have an improved release of the fungicide. The enhanced activity of these preparations results from the polyene fungicide being in special crystal forms which have a high potential for dissolving. These compounds can be used in compositions to prevent spoilage of food by fungi species which have a high tolerance towards the fungicide. However these compositions still have to be prepared just before use because the compounds will be transformed to the thermodynamically most stable and thus less soluble form when suspended in an aqueous environment. Therefore, crystal forms of natamycin are known which make a fast release of dissolved natamycin possible. However, in practice, these natamycin crystal forms do not meet the requirement for stable high concentrations of dissolved natamycin especially in aqueous environment.
SUMMARY OF THE INVENTION
[0010] The invention provides an aqueous composition which comprises a dissolved polyene fungicide and a solubilizer, wherein at least 100 ppm of polyene fungicide is present as dissolved polyene fungicide.
[0011] The invention also provides the use of an aqueous composition on or in feed, food or agricultural products.
[0012] The invention further provides a method for preserving the activity of natamycin in an aqueous solution wherein at least 100 ppm of natamycin is dissolved, the method comprising providing said solution with a solubilizer.
DESCRIPTION OF THE INVENTION
[0013] The present invention provides a method of preparing a stable aqueous solution of polyene fungicides, which can be used directly and/or as a stock solution.
[0014] We have found that the solubility of polyene fungicides in aqueous systems can be improved by the addition of a solubilizer, preferably a surfactant. Solubilizers are compounds that can effect a solubilization of an otherwise insoluble material. In general small amounts of solubilizer will be necessary to obtain the desired effect. For example 0.05 to 8 w/w % of solubilizers will give a significant positive effect on the solubility of a polyene fungicide. Surfactants are compounds which reduce interfacial tension at the boundaries between gases, liquids and solid. However because of the expected poor stability of these solutions, combinations of polyene fungicides with solubilizers may have to be used directly or shortly after preparation.
[0015] The present invention also provides a method for preserving the activity of natamycin in an aqueous solution wherein at least 100 ppm of natamycin is dissolved, comprising providing said solution with a solubilizer. The method may further comprise providing said solution with a chelating and/or an antioxidation agent wherein said chelating agent and said antioxidation agent may be the same or a different agent.
[0016] Therefore the present invention also provides an aqueous composition comprising a dissolved polyene fungicide and a solubilizer, preferably a surfactant. At least 100 ppm, typically less than 50000 ppm or preferably from 100 to 10000 ppm of polyene fungicide is present as dissolved polyene fungicide. The polyene fungicide preferably is natamycin.
[0017] Unexpectedly, it has now been found that the solubility of polyene fungicides such as natamycin in aqueous systems can be markedly improved by means of one or more solubilizers and that such a solution is markedly more stable than would have been expected. Moreover, the stability is even better when the pH of the mixture is kept at neutral values, preferably from 5 to 9, more preferably from 6 to 8 while the solubility is maintained. According to the present invention, at least 100 ppm, preferably at least 200 ppm of polyene fungicide, preferably natamycin, is present in the aqueous solution. In general the aqueous composition of the invention comprises less than 50000 ppm, preferably less than 10000 ppm, more preferably less than 1000 ppm of polyene fungicide, which is preferably natamycin.
[0018] Surfactants may be anionic, cationic, non-ionic or amphoteric. Examples of anionic surfactants are sodium lauryl sulfate, sodium dioctyl sulfo succinate and sodium dodecyl sulfate (SDS). Examples of cationic surfactants are dodecyl ammonium chloride and hexadecyl triammonium bromide. Useful nonionic surfactants may be of the hydrophilic or of the hydrophobic type or a combination thereof. Examples of hydrophilic nonionic surfactants are polyethyleneglycol-20 sorbitan monolaurate (also known as PEG -20 sorbitan monolaurate or Tween 20), PEG-20 sorbitan monostearate (also known as Tween 60) and PEG-20 sorbitan monooleate (also known as Tween 80). Examples of hydrophobic non ionic surfactants are sorbitan monolaurate (Span 20) and sorbitan monostearate (Span 60). Examples of amphoteric surfactants are alkyl betaines and alkylsulfobetaines. Preferably SDS is used as surfactant.
[0019] In general 0.1 to 5.0% w/w of surfactant is used in the composition of the invention.
[0020] Other known solubilizers are for example polyvinylpyrrolidone (PVP) or lecithin.
[0021] The stability of the solubilized natamycin can be further improved by adding a chelating agent and/or an anti-oxidation agent. A chelating agent is a compound containing two or more electron donor atoms that is capable of forming coordinate bonds to a single metal atom. Usually these compounds are used to solubilize metal atoms like calcium and other heavy metals. A well known example of a chelating agent is ethylenediaminetetraacetic acid (EDTA). Anti-oxidation agents are substances that are used to slow down the reaction of organic materials with oxygen. Examples of antioxidation agents are butylated hydroxyanisole, riboflavin, ascorbic acid and tocopherol.
[0022] Oxidative inactivation of polyene fungicides is promoted by several metal ions like Fe(III), Ni(II) and Cr(III). This can be prevented by chelating agents like EDTA or polyphosphates. The finding that chelating agents can preserve the stability of soluble natamycin without the presence of any of these harmful heavy metal in the solution is therefore very surprising.
[0023] The chelating agent preferably comprises an aminocarboxylate, for instance ethylenediaminetetraacetic acid and N-dihydroxyethylglycine, a hydroxycarboxylate like citric acid and tartaric acid or a polyphosphate like tripolyphosphoric acid and hexametaphosphoric acid. Preferably a non-acidic chelating agent will be used.
[0024] More preferably said chelating agent comprises ethylenediamine-N,N,N′,N′-tetraacetic acid (EDTA) or a functional equivalent thereof. A functional equivalent of EDTA is a functional part, derivative and/or analogue of EDTA comprising the same fungicide preserving activity in kind not necessarily in amount. The most common functional equivalents of EDTA are the various salts of EDTA such as sodium, potassium, lithium, ammonium, calcium and/or copper salts of EDTA. However, substitution of one or more groups of the molecule with other equivalent groups are also preferred equivalents of EDTA. Non-limiting examples of such equivalents are 1,3-diamino-2-hydroxypropane-N,N,N′,N′-tetraacetic acid and 1,3-diaminopropane-N,N,N′,N′-tetraacetic acid.
[0025] Preferably the amount of chelating agent in said aqueous solution is between 10-10000 ppm. More preferably, between 20-1000 ppm, most preferably between 30-300 ppm.
[0026] For the present invention an anti-oxidation agent may also be added. The anti-oxidation agent is preferably a non-acidic anti-oxidation agent. Preferably, said anti-oxidation agent comprises ascorbic acid, citric acid, Butyl-hydroxy-anisole (BHA), Butyl-hydroxy-toluene (BHT), a gallate, a tocoferol, ascorbyl palmitate and/or calcium ascorbate. More preferably, said anti-oxidation agent comprises BHA, BHT, a tocoferol and/or a gallate.
[0027] Preferably, said anti-oxidation agent is present in said aqueous solution in an amount of 10-10000 ppm.
[0028] In another aspect, the invention provides an aqueous composition comprising a dissolved polyene fungicide, a chelating agent and/or an anti-oxidation agent, wherein said chelating agent and said anti-oxidation agent may be the same agent or a different agent. Preferably between 100 and 10000 ppm polyene fungicide is dissolved in this solution. Preferably no polymers, for example polymer beads, are present in this composition.
[0029] Advantageously the composition of the invention can be stored for at least one week without a loss of more than 10% of the polyene antifungal compound activity. More preferably, the composition may be stored for at least two weeks, more preferably at least one month and most preferably at least 3 months without a loss of more than 10% of the polyene antifungal compound.
[0030] In general the storage temperature will be between 4 and 30° C., preferably between 15 and 25° C.
[0031] In another embodiment the solution of the invention is packed in a container suitable for storage and/or shipment of said solution. Preferably, said solution can be stored for at least one week, preferably at least two weeks, more preferably at least one month and most preferably at least 3 months.
[0032] In one embodiment an aqueous solution according to the invention is obtained by a method according to the invention.
EXAMPLES
Material and Methods
[0000] Materials
[0000]
Di-sodium-EDTA, purchased from Chemolanda bv, 2596 BP Den Haag, The Netherlands.
Ammonia, purchased from Gaches Chimie France, 31750 Escalquens, France.
SDS Solution 20% (w/w), purchased by Bio-Rad Laboratories, Inc 2000 Alfred Nobel Drive Hercules, CA 94547 USA.
Delvocid®, containing 50% (w/w) active natamycin and 50% lactose, DSM Food Specialties, P.O. Box 1, 2600 MA, Delft, The Netherlands.
Amphotericin B code A-4888, lot 122K4013, purchased from Sigma Aldrich Chemie, GmbH, PO Box 1120 Steinheim Germany.
Nystatin code N-6261, lot 120K11351, purchased from Sigma Aldrich Chemie, GmbH, PO Box 1120 Steinheim Germany.
Analytical Method for the Determination of Amount of Natamycin
[0039] This method was used to analyze the amount of active natamycin in a water-based mixture of several components. The method was HPLC based using the International Dairy Federation (Provisional ADF Standard 140, 1987) with a Lichrosorb RP 8 column. Detection was by UV at 303 nm with a range of 0.1- 4 mg/L with an injection volume of 20 μl.
[0040] Sample preparation was carried out by weighing 2 gram prepared formulation with an accuracy of 1 mgram in a measuring flask. 4 ml demineralized water (demiwater) was added and the mixture was stirred for 15 minutes to get a homogeneous suspension.
[0041] Subsequently 80 ml ethanol was added and the mixture was stirred for 10 minutes.
[0042] After ultrasonic treatment the solution was filled up to 100 ml with de-minaralized water and then diluted and/or filtered (0.2 μm) before injecting.
[0043] The amount of active natamycin was calculated as ppm against a series of standards of known natamycin concentrations.
Example 1
[0044] This example describes a method to prepare a formulation suitable for use a high soluble natamycin formulation and which was developed to test the stability in time in relation to the added ingredients and physical parameters.
[0045] The mixtures were made with an electric top stirrer, type RW 20 DZM, from Janke & Kunkel equipped with a Ruston-type stirrer.
[0046] The mixtures were made by adding 2 gram Delvocid (Natamycin) together with 50 gram 20% SDS solution-and eventually additives to a final weight of 1000 gram with demineralised (=demi) water.
[0047] This crude mixture was mixed for 5 minutes to obtain a homogeneous mixture and accordingly adjusted to pH 4-6 with ammonia.
[0048] The obtained formulations with an added amount of active natamycin of 1000 ppm were stored at 18° C. in a closed pot in the dark.
[0049] The prepared mixtures were measured over time for the amount of active natamycin using the analytical method as described hereinabove.
Example 2
[0050] The mixture as described in Example 1 was adjusted to pH=4.0 or pH=6.0 and the natamycin activity was measured over time.
[0051] The results are shown in Table 1.
TABLE 1 Rest activity of completely dissolved natamycin over time (in ppm) Time pH = 4.0 pH = 6.0 1 day 672 988 3 weeks <0.1 444 9 weeks <0.1 57
Example 3
[0052] The mixture as described in Example 1 is combined with 1000 ppm di-sodium-EDTA, adjusted to pH 6.0 and the natamycin activity was measured over time.
[0053] The results are set out in Table 2.
TABLE 2 Rest activity of completely dissolved natamycin over time (in ppm) Time pH = 6.0 pH = 6.0 + Na 2 EDTA 1 day 988 1000 3 weeks 444 805 9 weeks 57 560
Example 4
[0054] Mixtures are made with several polyene fungicides in several concentrations The used polyene fungicides are nystatin, amphotericin and natamycin. The solubility rate is measured visually of the polyene fungicides in demineralized water as such or according to example 1 in combination with SDS to a final SDS concentration of 1% (w/w). It is soluble if a mixture is clear after one minute stirring at room temperature. The results are set out in Table 3
TABLE 3 Solubility of several polyene fungicides in water and water + SDS. Used amount of polyene fungicide Solublized after 1 (ppm) in final minute stirring at Polyene fungicide mixture Solvent room temperature Natamycin 250 Demi- Water No Natamycin 250 1% (w/w) SDS Yes Natamycin 500 1% (w/w) SDS Yes Natamycin 1000 1% (w/w) SDS Yes Nystatin 250 Demi - Water No Nystatin 250 1% (w/w) SDS Yes Nystatin 500 1% (w/w) SDS Almost Nystatin 1000 1% (w/w) SDS No Amphotericin B 250 Demi - Water No Amphotericin B 250 1% (w/w) SDS Yes Amphotericin B 500 1% (w/w) SDS Yes Amphotericin B 1000 1% (w/w) SDS Yes
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The invention provides an aqueous composition comprising a dissolved polyene fungicide and a solubilizer, wherein at least 100 ppm of polyene fungicide is present as dissolved polyene fungicide. The aqueous compositions of the invention may further comprise a chelating and/or antioxidation agent. The compositions of the invention. provide dissolved polyene fungicides in a more stable form. The present invention further provides uses of the compositions of the inventions and methods of making such compositions.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to charge-coupled devices and more particularly to a bipolar dual-channel charge-coupled device for the simultaneous storage of two independent bit streams of charge packets of opposite conductivity types.
2. Description of the Prior Art
Charge-coupled device (CCD) structures for use in data processing system storage and communication signal processing are well known in the art. Referring to the patents and publications listed below under the heading "References Cited By Applicant", Boyle and Smith [Refs. 1, 2, 3] originally disclosed the basic charge-coupled concept in the form of a surface channel device. Krambeck [Ref. 4] then disclosed the buried channel structure wherein the charge packets are within the bulk of the semiconductor rather than at the surface. Modifications of the buried channel arrangement were thereafter disclosed by Carnes and Kosonocky [Ref. 5], Erb [Ref. 6], Tasch [Ref. 7], Esser [Ref. 8] and Walden [Ref. 9].
The charge-coupled structure is a serial device and therefore its access time is much slower than a randomly accessed semiconductor device. However, the charge-coupled device has a higher bit density and simpler structure and therefore lower cost than the random access memory device, and therefore may have utility in mass storage applications where cost rather than speed is of primary importance. However, in these low-cost applications the charge-coupled device must compete on a cost basis with presently available techologies such as disk and tape storage, as well as proposed new technologies such as the bubble magnetic memory.
Therefore, if the charge-coupled device is to succeed in this competition of technolgies, it is vitally important that the cost per bit of information be reduced by every feasible means. Since for a given chip size and technology the cost of manufacture is approximately constant, one of the most effective ways of reducing the cost is to increase the chip density; that is, the number of bits of information stored per chip unit area.
Krambeck [Ref. 4] discloses an arrangement having dual buried channels parallel to and spaced from each other and buried within the semiconductor bulk so as to store two independent bit streams. If feasible, this arrangement would approximately double the bit density. In effect, this proposal appears to be an attempt to fabricate CCD registers on the front as well as the back side of the wafer, and thus obtain two registers in the same area. However, it is believed that the inherent disadvantages of this arrangement render it impractical so that it has not been put into production.
The prior art noted above, as well as all other prior integrated circuit devices of which the present inventor is aware, are divided by a rigid dichotomy of bipolar and MOS technologies. That is, the bipolar devices involve the flow of charge carriers of both conductivity types, whereas the MOS (metal-oxide-semiconductor) devices are unipolar and involve the flow of charge carriers of only one conductivity type. More particularly, all charge-coupled devices of the prior art of which the present inventor is aware embody the unipolar MOS technology.
SUMMARY OF THE INVENTION
The charge-coupled device structure in accordance with the present invention achieves almost double the bit density of the prior art by the heterodoxy of departing from the heretofore rigid separation of bipolar and MOS technologies. That is, the present charge-coupled device is bipolar rather than unipolar in that the current flow comprises the transportation of electrons as well as holes.
More particularly, in the preferred embodiment disclosed for purposes of illustration, a single charge-coupled device stores and transfers two separate independent serial bit streams of information. A first bit stream comprising a series of charge carrier packets of one conductivity type (e.g. electrons) flows along a first channel at the surface of the semiconductor. A second bit stream comprising a series of charge carrier packets of the opposite conductivity type (e.g. holes) flows in a second channel buried within the bulk of the semiconductor and spaced from the first bit stream at the surface of the semiconductor.
In the present invention each gate electrode forms at alternate clock phases two potential wells each trapping charge packets of the opposite conductivity type. More particularly, at one clock phase a first potential well under the gate electrode traps electrons adjacent the surface of the semiconductor, and then at the next clock phase a second potential well under the same gate electrode traps holes in a buried channel spaced inwardly within the interior bulk of the semiconductor. As a result, each gate electrode alternately forms two different charge storage sites for electrons and holes respectively.
Although the resulting bit density is not quite doubled due to the necessity for additional structure and circuitry to accommodate the extra channel, the bit density achieved by the bipolar charge-coupled device of the present invention is substantially increased as compared with unipolar devices of the prior art, and therefore the cost per bit of information is substantially reduced.
IN THE DRAWINGS
FIG. 1 is a sectional plan view, partially broken away, of a charge-coupled device in accordance with the present invention and showing two adjacent serial shift registers or channels.
FIG. 2 is a longitudinal sectional view through the upper channel of FIG. 1 and taken substantially on the line 2--2 in the latter figure.
FIG. 3 is a transverse sectional view through both channels shown in FIG. 1 and is taken substantially on the line 3--3 of the latter figure.
FIG. 4 is a schematic sectional view of the vertical geometry and showing a majority carrier charge packet stored within the buried potential well beneath a first gate electrode and a minority carrier charge packet stored within the surface potential well beneath a second gate electrode, together with plots of the respective electrostatic potentials provided by the two gate electrodes.
DETAILED DESCRIPTION
Referring to FIG. 4, the basic mode of operation of the present invention will first be described. An N-type substrate 9 is shown with a P-type diffusion layer 10 formed adjacent its upper surface. Superimposed over the latter is an insulating layer 11 of silicon dioxide separating the upper surface of the substrate 9 from a series of gate electrodes as indicated schematically at G1 and G2.
The P-type layer 10 is reverse-biased in the conventional manner so as to form a depletion region constituting a buried charge channel along which packets of holes may be stored and transferred in the manner well-known in the art. One such buried charge packet is indicated in FIG. 4 by the dashed lines enclosing the three "plus" symbols designating holes. This buried charge packet is shown as stored within a potential well buried within the interior bulk of the P-type layer 10 and located beneath the first electrode G1.
Located beneath the second electrode G2 and adjacent to the surface of the P-type layer 10 there is shown an electronic charge packet within a potential well indicated by the dashed lines enclosing three "minus" symbols depicting electrons.
The electrostatic potential provided by the φ1 clock voltage applied to gate electrode G1 is shown by a plot beneath that electrode, and similarly, the potential provided by the φ2 clock voltage applied to the gate electrode G2 is shown as a plot beneath the latter electrode. The abscissa of each of these potential plots extends downwardly as shown by the arrow and is marked "DEPTH" so as to indicate the distance from the surface of the substrate. The ordinate of each of these potential plots is shown by the arrow to extend to the right and is the respective electrostatic potential provided by each of the gate electrodes G1 and G2.
By properly time-sequenced clock phase voltages applied to the gates such as G1 and G2, the buried charge potential wells along with the charge packets of holes stored therein may be shifted along the buried charge channel from site to site so as to form a continuous serial stream of data bits flowing from left to right as viewed in the drawings, while simultaneously the surface charge potential wells with the electron charge packets stored therein may be transferred serially from site to site along the surface of the P-type layer 10 so as to provide a second serial data bit stream flowing from right to left. This simultaneous flow of two separate and independent data bit streams enables the bit density of the charge-coupled device of the present invention to be almost doubled as compared with equivalent devices of the prior art. The structural details of a preferred embodiment realizing this novel mode of operation are described below.
Referring now to FIGS. 1 to 3 inclusive, there is shown a preferred embodiment of the invention for the purpose of illustrating one of the many forms which the invention may take in practice. These figures show a portion of an integrated circuit shift register configuration including two adjacent serial channels each constituting a serial shift register section. However, it will be understood that the invention may be readily embodied in parallel sections such as in a serial-parallel-serial memory configuration.
One of the serial shift register sections is shown in the upper portion of FIG. 1 and will be described in detail. The other shift serial register section is an identical mirror image of the first register section and is shown in the lower portion of FIG. 1. The corresponding elements of the two registers have applied thereto the same reference designations with those referring to the second register also having the suffix "a" appended.
Both shift registers are formed in the substrate 9 of N-type semiconductor material which has formed therein adjacent its upper surface the diffusion layer 10 of P-type semiconductor material. Extending over the upper surface of the substrate 9 and layer 10 is the usual dielectric insulating film 11 of silicon dioxide. Superimposed upon the latter and arranged in serial contiguous relation are the gate electrodes G1, G2, G3, G4, Gn.
At the right-hand end of each shift register is a buried charge output port serving as the drain for the hole charge packets. This port comprises a metal contact 12 having a portion 13 projecting downwardly through the insulating silicon dioxide film 11 and in conductive contact with a diffusion region 14 of P + -type and embedded within the P-type layer 10.
At the opposite left-hand end of each shift register is a buried charge input port which serves as a source for the hole charge packets. This port comprises a metal contact 15 having a portion 16 projecting downwardly through the insulating silicon dioxide film 11 so as to conductively contact a P + -type region 17 formed within the P-type layer 10.
At the right-hand end of each shift register there is a surface charge input port serving as the source for the electronic charge packets. This input port comprises a contact 18 having a portion 19 projecting downwardly through the silicon dioxide film 11 in a manner similar to the construction of contact 12 and portion 13. However, the portion 19 of contact 18 extends to a diffusion region 20 which differs from region 14 in that region 20 is N-type and is formed within the P-type layer 10 adjacent the P + -type region 14 as shown in FIG. 3.
The left-hand end of each shift register is provided with a surface charge output port which serves as a drain for the electronic charge packets. This output port is similar in construction to the surface charge input port and comprises a contact 21 having a portion 22 projecting downwardly through the silicon dioxide film 11 so as to make conductive contact with an N-type region 23 diffused within the P-type layer 10 and adjacent to the P + -type region 17.
Referring to FIG. 3, it will be seen that the silicon dioxide film 11 is provided with downwardly extending recessed portions 28, 29, 30 which serve two important functions. First, these portions prevent the electronic charge at the surface of P-type layer 10 from escaping to the N-type substrate 9 which is biased at the most positive voltage. Second, the recessed portions of the silicon dioxide film 11 serve to isolate the adjacent channels which in the preferred embodiment are disclosed as adjacent serial shift register sections. More specifically, the recessed silicon dioxide extension 29 is shown extending between the channel of the first serial shift register section and the adjacent channel of the second serial shift register section so as to isolate the two adjacent channels from each other.
In order to provide a buried channel within P-type layer 10 the latter must be depleted. This is achieved in the conventional manner by the application of a negative bias at 24 to contact 12 of the buried charge output port.
The operation of the structure shown in FIGS. 1 to 3 will be apparent from the above description of the invention with respect to FIG. 4 and therefore will be stated here only summarily. A first serial data bit stream enters a serial shift register section at the surface charge input port 18, 19, 20 and flows as a series of electronic charge packets from right to left, as viewed in the drawings, along the surface of P-type layer 10. These electronic charge packets are transferred from site to site as appropriate clock phase voltages are applied in timed sequence to gate electrodes G1, G2, G3, G4, Gn in the conventional manner well-known in the art. The serial stream of surface electronic charge packets is then output from the shift register section at the surface charge output port 21, 22, 23.
Simultaneously with the flow of the electronic charge packets along the surface of P-type layer 10, a second data bit serial stream flows in the opposite direction from left to right as viewed in the drawing. This second data bit serial stream is in the form of buried hole charge packets. The stream enters the serial shift register section at buried charged input port 15, 16, 17 and the resulting hole charge packets flow serially from site to site along the buried charge depletion region formed within the bulk interior of P-type layer 10. The serial stream of hole charge packets is then output from the serial shift register section at buried charge output port 12, 13, 14.
While the invention has been shown and particularly described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the scope of the invention as delineated in the appended claims.
References Cited By Applicant
1. Boyle, W. S. and Smith, G. E., "Charge Coupled Semiconductor Devices," Bell Sys. Tech. J. (April 1970) pp. 587-593.
2. Boyle, W. S. and Smith, G. E., U.S. Pat. No. 3,858,232; issued Dec. 31, 1974; filed Nov. 9, 1971.
3. Smith, G. E., U.S. Pat. No. 3,761,744; issued Sept. 25, 1973; filed Dec. 2, 1971.
4. Krambeck, R. H., U.S. Pat. No. 3,739,240; issued June 12, 1973; filed Apr. 6, 1971.
5. Carnes, J. E. and Kosonocky, W. F., "Charge-Coupled Devices and Applications," Solid State Technology, (April 1974) pp. 67-77.
6. Erb, D. M., U.S. Pat. No. 3,913,077; issued Oct. 14, 1975; filed Apr. 17, 1974.
7. Tasch, A. F., Jr., U.S. Pat. No. 4,024,563; issued May 17, 1977; filed Sept. 2, 1975.
8. Esser, L. J. M., U.S. Pat. No. 3,965,481; issued June 22, 1976; filed Nov. 22, 1974.
9. Walden, R. H., Krambeck, Strain, R. J., McKenna, J., Schryer, N. L. and Smith, G. E., "The Buried Channel Charge Coupled Device," Bell Sys. Tech. J. (September 1972) pp. 1635-1640.
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A bipolar dual-channel charge-coupled device having a first channel at the surface for storing a first bit stream of minority charge carrier packets and a second channel buried in the bulk for storing a second bit stream of majority charge carrier packets. The two bit streams are transferred along their respective surface and buried channels simultaneously and independently of each other, thereby substantially increasing the bit storage density of the chip.
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TECHNICAL FIELD
The present invention relates to retrieval of submerged weights using a forwardly moving watercraft and a retrieval device attached to a rope connecting the weight and craft.
BACKGROUND OF THE INVENTION
It is a tedious procedure, especially for owners of small watercraft, to retrieve heavy submerged anchor weights. This is especially true in the case of anchors which may have considerable submerged weight. The physical task of raising an anchor, especially in deep water, becomes extremely tiresome.
Mechanical lifts have been known for hoisting anchors. For example the manually operated windlass has been used in ancient times. More recently, power driven winch apparatus have been developed for hoisting submerged weights. However, such apparatus is expensive and bulky, especially for small craft. It therefore becomes desirable to obtain some form of apparatus by which submerged weights may be raised without the tedium, the bulk and expense of independently driven hoisting devices.
Aside from the manual and powered devices mentioned above, flotation hoists also have been devised for raising sunken objects. The prevalent flotation device is an inflatable bladder that is submerged and attached to the sunken weight. The bladder is then inflated to raise the weight to the surface.
The problem with this form of float is that it requires either a diver to set the flotation device, or expensive equipment to set it in place and to effect inflation.
Another flotation device is known that makes use of the power of the associated watercraft. This device includes a float with a depending cord having a ring at one end. The anchor rope is threaded through the ring and is attached to the craft. The float is placed in the water and the craft is moved under power away from the float. Buoyancy of the float and the power of the craft then cooperate to raise the anchor.
This device functions well while the craft is moving. However, once the craft is stopped, the weight will drop back down, with the anchor rope sliding freely through the ring. To retrieve the anchor, then, the operator is forced to pull the rope in while the craft is in motion. The effort required to do this may be as much or more than simply raising the anchor from the bottom with the craft at rest.
Other advancements have included gripping devices that releasably secure the float to the rope once the weight has been lifted. While these devices appear to function well, the rope clamping apparatus is often complex and has a tendency to damage the rope.
An object of the present invention is therefore to provide a simple compact device for lifting submerged weights that have been attached to a watercraft by a rope or similar connector, without requiring significant manual effort.
Another object is to provide such a device that makes use of the motive power source of the watercraft to which the submerged weight is attached for raising the weight.
A still further object is to provide such a device that will raise a submerged weight to the approximate surface of the water, and maintain the weight at the raised position with the rope free to be gathered in without the submerged weight offering resistance.
A yet further object is to provide such a device that may make use of existing flotation devices such as life preservers for providing flotation to lift and buoy the weight.
A still further object is to provide such a device that is very simple in construction and with provisions to avoid damage to the rope when gripped.
These and still further objects and advantages will become apparent upon reading the following description which, taken with the accompanying drawings, describe a preferred form of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the present invention is illustrated in the accompanying drawings, in which:
FIGS. 1-3 are sequential operational views, illustrating the use of the present retrieval device for elevating a weight, such as a boat anchor;
FIG. 4 is an enlarged operational view showing the present device in an unlocked position with the anchor rope sliding forwardly responsive to forward movement of the associated watercraft;
FIG. 5 is a perspective view of the present retrieval device;
FIG. 6 is a side elevation view of the present device with a section of rope in an operative, locked position;
FIG. 7 is a side elevation view showing the lock member in an inoperative, unlocked position;
FIG. 8 is a top plan view of the present retrieval device;
FIG. 9 is an end view of the present device; and
FIG. 10 is an enlarged sectional view showing the beveled gripping edges of the present device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following disclosure of the invention is submitted in furtherance with the constitutional purpose of the Patent Laws "to promote the progress of science and useful arts" (Article 1, Section 8).
A preferred form of the present device is illustrated in the drawings and is designated therein by the reference numeral 10. The present device 10 is intended for use in conjunction with watercraft, such as the small craft at 12 in FIGS. 1-3. The device 10 is useful for elevating a submerged weight 13 that is connected to the watercraft 12 by a rope 14.
It should be understood that the term "rope" as used herein includes other forms of flexible connectors, such as cable, chain, etc.
The weight 13 is shown in FIG. 1-3 as being an anchor. However, it should be understood that any form of submerged weight connectable by a rope 14 to a watercraft 12 may be acted upon by the present invention. It is expected, however, that the most prevalent use will be as shown with an anchor, in conjunction with a rope 14 and a small watercraft 12.
Specifics of the present retrieval device 10 are shown in FIGS. 4-10. In FIG. 4, the device is shown in conjunction with a flotation device 20. The preferred flotation device 20 includes a net bag 21 with a common draw string closure. The net bag 21 may be stuffed with a conventional flotation device such as a life vest or life ring. The net bag 21 is especially useful since it may be adapted to receive nearly any common flotation device that has sufficient buoyancy to lift the submerged weight. The surface area of the flotation device 20 will offer resistance against forward movement in the water as the watercraft 12 moves forwardly (FIG. 4).
Advantageously, the retrieval device 10 includes a rigid frame 26 which is releasably attached by a guide member 27 to rope 14. In the preferred form, the frame 26 is elongated and formed of rigid material, such as stainless steel.
Frame 26 extends between opposed forward and rearward ends 25, 28. An elongated opening 29 (FIGS. 5, 8) is defined by opposite rigid wall surfaces and ends of the frame 26, as shown in FIG. 5.
The guide member 27, preferably in the form of inward spiral bent rods 31 is provided on the frame 26 at the ends 25, 28. The spirals are open at ends of the rods 31, to allow the device to be mounted on the rope 14 at any point between the rope ends, and eliminate any need to thread the device onto a free rope end. The spiral rods 31 define a longitudinal rope receiving axis Y along the length of the frame 26.
An elongated locking member 34 is provided on the present retrieval device 10 between the frame ends 25, 28 for allowing the rope to slide through the guide member 27 in one direction (toward the craft 12) and for selectively preventing the rope from being paid out (away from the craft 12) through the guide member 27 in an opposite direction. The locking member 34 also provides connection to the flotation device 20 (FIG. 4).
The locking member 34 preferably is pivoted on the frame 26 within the opening 29 by a pivot pin 36 (FIGS. 5-7). Pin 36 is situated nearly mid-way along the length of the frame 26, between the forward and rearward ends 25, 28. Pin 36 defines a locking member pivot axis X that is normal to the frame 26 and to the longitudinal rope receiving axis Y.
The locking member 34 and pin 36 are advantageously formed of a strong non-corrosive material such as stainless steel. Common casting or other appropriate conventional forming processes may be used to form both the frame 26, the guide member 27 and the locking member 34.
The locking member 34 extends above and below the frame 26, to opposite sides of the pivot pin 36. Member 34 includes a top end 40 and an opposed bottom end 41. The top end 40 is provided with a flotation connector, preferably in the form of an eyelet 42 (FIGS. 5, 8, 9), adapted to be connected to the drawstring of the flotation receiving net bag 21 (FIG. 4). In operation to retrieve the weight 13, the net and flotation device 20 holds the locking member 34 open, allowing the rope to slip through the retrieval device 10 as the watercraft moves forwardly. The weight and the flotation device then pull the locking member 34 closed when the craft is stopped, and the flotation device 20 and weight are allowed to return to a normal, depending condition (FIGS. 3, 6).
The bottom end 41 of the locking member 34 is bifurcated, with legs 43 converging to form an inverted "V" configuration. The legs 43 converge toward the top end 40 and the longitudinal rope receiving axis Y. Inwardly facing beveled rope engaging edges 44 are provided on the legs 43, as shown in detail by FIG. 10. The edges 44 are smoothly rounded, with flat sides leading tangentially into the otherwise circular periphery of the legs.
The edges 44 are used to firmly grip, but will not damage the rope when the locking member 34 is pivoted toward the rear end of the frame 26 in the operative, rope locking position (FIG. 6). This is a distinct advantage over other known gripping devices that use one moving (usually pivoted) gripping or clamp element that clamps or binds the rope against another clamp element that is stationary relative to the moving element. This places the rope filaments under strain when the clamp is closed.
The legs 43 extend to ends that are spaced apart equally from the longitudinal rope axis Y, such that the distance between the leg ends is approximately equal to half the distance between the forward and rearward frame ends 25, 28. This spacing, and the smooth arcuate curvature of the legs inwardly toward the longitudinal rope receiving axis Y encourages contact between the rope and the converging edges 44 during use.
A stop 50 is provided between the locking member 34 and the frame 26 for preventing pivotal movement of the lock member toward the rearward end of the frame beyond the operative, locking position as shown in FIG. 6. The stop 50, in the preferred form is situated on the frame 26, and is positioned in the rearward swing path of the locking member 34. The location of the stop 50 is selected so the approximate rope contact points along the edges 44 are stopped in their arcuate movement toward the rearward frame end 28 on a line 51 (FIG. 6) between the contact points and the pivot axis X that approaches a perpendicular relation to the rope receiving axis Y. Of course this angle will vary somewhat with the diameter of the rope. However, for the device to be most effective, the angle should be within a tolerance of approximately plus or minus 10° (between the line 51 and the rope receiving axis Y).
The locking member 34 swings between the operative locking position discussed above, where the rope is firmly gripped between the opposed gripping edges 44, and a forwardly pivoted inoperative position (FIGS. 4, 7), where the gripping surfaces are situated closer to the forward frame end 25. With the locking member 34 in the inoperative, open position, the rope 14 is allowed to slide in a forward direction through the device responsive to forward motion of the watercraft, as shown in FIGS. 2 and 4.
Operation of the present invention is best understood with reference to FIGS. 1-3. These figures diagrammatically illustrate use of the invention in conjunction with a submerged weight 13 in the form of an anchor. However, it is again emphasized that other weights may be used. For example, the weight could very well be a submerged fishing apparatus, such as a crab pot. In such situations, the flotation device and rope would temporarily be disconnected from the boat. The flotation device 20 would then function as a typical buoy, marking the location of the submerged weight. The steps followed to raise the weight would then be similar to those described herein for raising the anchor shown in FIGS. 1-3, except that a first step would be to pull the free end of the rope upwardly from the flotation device 20 and secure it to the watercraft.
FIG. 1 thus illustrates a beginning position for operation of the present retrieval device 10. Here, the weight 13 (anchor) has been submerged and is in contact with the bottom surface. The rope 14 leads upwardly from the anchor to the watercraft 12, where it is fastened to secure the watercraft in position.
At this time, the present device 10 may simply be loose and stored conveniently on the craft 12. To initiate use, the device 10 is mounted to the rope simply by laterally fitting the open spiral rods 31 over the rope in such a manner that the rope slides freely along the length of the frame 26 along the rope receiving axis Y. The frame 26 is fitted to the rope in such an orientation that the forward frame end 25 will face the watercraft when the device is overboard and operating,
A life preserver or other flotation device 20 is stuffed into the net bag 21 and the drawstring is attached to the flotation connector eyelet 42. In order to retrieve the weight, the user simply drops the assembly overboard, (assuming the free end of the rope is attached to the watercraft) and the watercraft is started in forward motion. The craft's speed need not be excessive to produce the desired effect. In fact, it is desirable to use lower speeds as high speeds could damage the craft 12, the weight 13, or the rope 14.
As the craft progresses (FIG. 2), the flotation device will remain on or very near the surface due to its buoyancy. Its shape and mass inherently resists the forward motion of the craft 12. This resistance to motion and the buoyancy of the flotation device overcomes the tendency for the rope to pull to a straight line between the craft 12 and the submerged weight 13. A resultant upward force is produced along the rope 14 that has the effect of lifting the weight 13 from the bottom surface toward the float as the craft continues to move along. The same resistance to forward motion causes the drawstring of the net to hold the locking member 34 in the inoperative, open position (FIG. 4), thereby allowing the rope to slide freely through the guide member 27 in the forward direction.
The locking member 34 will allow free motion of the rope in this direction, but will swing back against the stop 50, gripping the rope securely between the rope engaging edges 44 when forward motion is stopped. In fact, the more rearward tension delivered along the rope from the anchor weight, the harder the rope is pulled into the converging legs of the locking member. The rope is thereby secured to the device. Thus, when the weight reaches a point where it is directly below the flotation device 20 (FIG. 3), the craft 12 may be stopped and the rope, which is now slack between the craft 12 and the retrieval device 10, may be easily pulled in.
Buoyancy of the flotation device and the locking member 34 will hold the weight in its lifted position during this time. Thus, the only exertion required on the part of the user in retracting the rope, is in pulling the flotation device toward the watercraft. This may be done with relative ease. Then, once the retrieval device 10 and weight 13 are adjacent the watercraft, the user may simply lift the flotation device 10 and weight 13 into the craft.
It can be seen that the present retrieval device affords a simple yet very effective device that facilitates raising a submerged weight by action of the associated watercraft. Thus, there is no need for additional motors or drive mechanisms, nor is there need for the operator to labor at lifting the weight completely from the bottom surface to the craft. The only physical exertion required is lifting the retrieved weight and flotation device into the craft, if desired.
In compliance with the statute, the invention has been described in language more or less specific as to structural features. It is to be understood, however, that the invention is not limited to the specific features shown, since the means and construction herein disclosed comprise a preferred form of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.
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A retrieval device is described that facilitates lifting of a submerged weight by action of the forward motion of an associated watercraft connected to the weight by a rope. The rope is releasably attached to the device by a guide member on an elongated rigid frame. A locking member is also provided, to enable sliding movement of the rope in a forward direction, and to grip and hold the rope against rearward motion. Powered motion of the watercraft through the water provides sufficient force to pull the rope forwardly through the device. A top end of the locking member is attached to a net supported flotation device. The flotation device also serves to hold the locking member in an inoperative, open condition during forward motion of the watercraft and forward sliding motion of the rope therethrough. Once the weight is pulled to the vicinity of the device, forward motion of the watercraft is halted. The locking member then functions to prevent the weight from pulling the rope back downwardly. The user is then free to retrieve the free expanse of rope between the watercraft and flotation device without lifting the weight.
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FIELD OF INVENTION
The present invention relates to the processing of crude oil in a petroleum refining operation. Particular attention is focused on the removal of corrosive contaminants from the oil.
BACKGROUND OF THE INVENTION
Crude oil is processed through petroleum refineries in order to separate the various hydrocarbon products from each other in the crude. Much of this processing takes place at elevated temperatures which reach as high as 700 F. in the distillation columns.
Raw crude oil contains corrosive elements which cannot be removed in the field. Of primary importance is brine which characteristically makes up from about 0.2 to 2.0 percent of the incoming raw crude. Brine contains chloride salts, primarily the magnesium, calcium and sodium varieties thereof.
The desalting operation removes a significant amount of these impurities. However, small amounts of the chloride salts remain with the desalted crude as it is charged into the distillation unit.
During the elevated temperature processing of the crude charge in the distillation unit, the chloride salts, primariy MgCl 2 , are hydrolyzed via the following reaction: ##STR1## HCl is then carried overhead in the fractionation towers. Since it is a highly corrosive acid, the HCl will attack and corrode the metallic surfaces throughout the fractionation unit and the upper regions of the distillation columns. The HCl can also combine with volatile basic materials, such as NH 3 , to form corrosive salt deposits on tower internals.
Corrosive destruction of and deposition onto these metallic components require corrective action in the form of costly and time consuming repairs. This is detrimental to the cost effective operation of the entire refinery.
A commonly used method to control the evolution of HCl involves the addition of NaOH. This is generally done by injecting an aqueous solution of NaOH into the desalted crude oil charge line. The function of the NaOH is to react with the readily hydrolyzable salts to form NaCl and the corresponding hydroxide. NaCl is much more resistant to hydrothermal decomposition than, for example, MgCl 2 . This results in the generation of less HCl.
NaOH is an effective inhibitor of HCl evolution, but its use is accompanied by various negative factors. The choice of this treatment program to reduce chloride concentrations requires the use of large excesses of NaOH. There are two primary reasons for this. First, NaOH is a strong base which will react with acidic species present in all crude oils to various degrees. These acidic species include carboxylic acids, including naphthenic acids, and H 2 S. The second reason for the requirement of large quantities of NaOH is due to its poor dispersibility in crude oil which renders it functionally less efficient.
Excessive amounts of NaOH cause further problems for the refinery operator. NaOH results in caustic cracking and embrittlement near the feed point and causes increased deposition of excess caustic, Mg (OH) 2 , CaCO 3 , etc. in the crude preheat section. Additionally, the practice, described above, produces an increased concentration of Na + in the bottoms products which necessitates further processing or results in the production of a lower grade end product. Furthermore, higher Na + content of bottoms products causes an increased rate of poisoning of downstream catalytic units. These negative factors are significant economic disincentives militating against the use of NaOH. If NaOH were not used, however, increased corrosion and deposition would result.
PRIOR ART
Beyond the traditional, well-known approach of inhibiting the evolution of HCl by use of NaOH, other methods have been developed.
These primarily require the addition of specific amine or ammonia compounds.
U.S. Pat. Nos. 2,913,406 and 3,033,781, both to Hoover, disclose corrosion inhibiting compounds blended from copper compounds such as copper carbonate, ammonia and sodium or ammonium bicarbonate. These complex compounds are intended to react with and neutralize the acidic species present in the crude oil.
Petro et al., U.S. Pat. No. 3,272,736, combine the teachings of Hoover with a modification of conventional treatment programs. They disclose a process in which ammonium carbonate and either sodium hydroxide or potassium hydroxide, or mixtures thereof, are added to the crude oil prior to elevated temperature processing.
Japanese patent No. 49-38902 discloses the use of amine compounds, including morpholine, pyperidine, piperazine, and ethylene diamine. These amines are vaporized upon heating in the distillation column. They then condense on the upper portions of the condenser and distillation column where much of the corrosive damage occurs.
In a refinement of the above process, U.S. Pat. No. 3,819,328, Go, adds the requirement of pH regulation. Under this process, pH control is achieved by use of alkylene polyamines, preferably ethylene diamine. By this method, the pH is adjusted to between 5.5 and 7.0 resulting in a minimization of corrosion on the acid side and fouling on the basic side.
DETAILED DESCRIPTION OF THE INVENTION
The present invention consists of a way to reduce the amount of Na + needed to effect a given reduction in HCl evolution without causing precipitation of Mg(OH) 2 or CaCO 3 . It has been discovered that an effective chelating agent can prevent the generation of HCl. The chelant must be thermally stable at flash zone temperatures and of low oil solubility but high water solubility.
The chelant of the present invention, such as the commercially available Na 3 NTA (trisodium nitrilotriacetic acid), may be added to the hydrocarbon at any point in a petroleum refinery prior to the preheat unit. Ideally, however, addition would be between the desalter and the preheat unit. The chelant may be contained within a suitable carrier, such as an aqueous medium. It may be added continuously or shot fed into the hydrocarbon stream. All the above process parameters may be varied to provide for optimum usefulness under any given processing conditions.
Experiments have been conducted which prove that hydrolysis of MgCl 2 can be prevented or substantially reduced by the use of a chelant, trisodium nitrilotriacetic acid, Na3 NTA. The data shown in Table I were collected by steam distilling MgCl 2 alone or with either Na 3 , NTA or NaOH. All runs were conducted at 245° C. in a USP mineral oil; steam is passed through for not more than 30 minutes. Aqueous condensates were analyzed for Cl - by ion chromatography. The % hydrolysis was calculated from the Cl - concentration, the volume of aqueous condensate and the amount of MgCl 2 . The less hydrolysis occurring, the more efficient the treatment.
TABLE I______________________________________Test Molar Ratio RelativeNo. Neutralizer (Neut:Mg.sup.+ 2) % Hydrolysis Moles Na.sup.+______________________________________1 None -- 57.4 (15 mins) --2 None -- 56.9 --3 None -- 66.3 --4 None -- 65.2 --5 NaOH 1:1 25.5 16 NaOH 2:1 0.33 27 Na.sub.3 NTA* 0.25:1 11.7 0.758 Na.sub.3 NTA* 0.37:1 5.3 1.19 Na.sub.3 NTA* 0.75:1 6.9 2.310 Na3NTA* 0.8:1 7.6 2.411 Na3NTA* 1.6:1 0.04 4.8______________________________________ *nitrilotriacetic acid, trisodium salt
Table I illustrates that the chelant is more efficient than caustic at suppressing hydrolysis (compare test numbers 5 and 7). Remarkably, this is achieved with less overall addition of free Na + to the system.
Field studies were conducted at two different full scale petroleum refineries. In Table II, the results of analyses at one refinery are shown. Only the conditions affecting the concentration of Cl - in the overhead condensing system are monitored.
TABLE II______________________________________REFINERY TRIAL I Over- Over- head head ppm Cl.sup.- Moles Charge Cl.sup.- Reduc- Na/ Rate PTB Base- tion MolesNeutralizer MGPD as Na line ppm % Cl.sup.-______________________________________NaOH 140 1.6 85 78 90 6.2NaOH 140 0.85 85 61 72 3.6NaOH 140 0.60 85 49 58 3.7Na.sub.3 NTA 140 1.6 84 42 50 12.0Na.sub.3 NTA 140 0.68 84 15 18 14.3______________________________________
At the second refinery, overhead cl - concentrations are monitored in addition to pH, organic acid levels and HSO 3 - levels. Results are shown in Table III.
TABLE III__________________________________________________________________________REFINERY TRIAL II Overhead Overhead Over- OverheadNeutralizer Cl.sup.- Reduction Moles Na/ head Organic Overhead(PTB as Na) Day Baseline Cl.sup.- ppm Mole Cl.sup.- pH Acids.sup.1 HSO.sub.3.sup.-__________________________________________________________________________None 1 151 -- -- 7.2 12 16NaOH(0.15) 1 120 31 1.47 7.4 24 16Na.sub.3 NTA(0.35) 1 91 60 1.79 7.3 8 10None 2 114 -- -- 8.0 11 16Na.sub.3 NTA(0.77) 2 73 41 5.47 7.8 34 26Na.sub.3 NTA(0.34) 2 102 12 8.14 8.0 22 24__________________________________________________________________________ .sup.1 Numbers are chart units at an IC sensitivity of 10 μs
The above data clearly indicates the sensitivity of the treatment program to varying system conditions. For example, the different efficiencies (mole Na + /mole Cl - ) between Tables II and III may be due to the fact that more hydrolytically stable metals, were present in the crude being processed through the refinery used to provide the data for Table II. These metals may compete for the reaction sites on the chelant thereby allowing for fewer chelant/Mg +2 reactions.
The chelant treatment program variations between the two days of analysis covered in Table III may be due to the varying quantities of different crude slates processed during that period of time. On day 1, the chelant was as efficient as caustic. On day 2, the efficiency of the chelant was greatly reduced. This is thought to have resulted from the addition of "condensate" to the crude slate. It is well known that each crude contains different concentrations of numerous constituents, such as hydrocarbon makeup and the concentrations of various salts, metals and other contaminants. The following shows the varying crude percentages both on the day before and then during the two day analysis at the refinery of Table III.
______________________________________ Day Day 1 Day 1Crude Slates Before A.M. P.M. Day 2______________________________________Brent 46% 44% 39% 39%Malango 40% 38% 39% 39%ANS + Condensate.sup.1 12% 12% 17% 17%CAT Feed 2% 6% 6% 6%______________________________________ .sup.1 Alaskan North Slope + Algerian Condensate; however, no condensate charged until Day 1P.M.
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 method of neutralizing chloride ions present in a hydrocarbon medium during processing in a petroleum refinery. Nitrilotriacetic acid or its salt form is injected into the crude charge upstream of the preheat unit. Chloride levels are reduced in this way without the deleterious effects which result from treatment with the conventionally used NaOH.
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This is a continuation-in-part of U.S. Pat. application Ser. No. 08/880,049 filed Jun. 20, 1997 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a system for cleaning debris from roof gutters. More particularly, the invention relates to a remotely-controllable self-cleaning gutter system which can be operated from ground level quickly and with negligible effort.
Cleaning debris, such as leaves, twigs, evergreen needles, etc. from roof gutters normally requires climbing a ladder to the elevation of the gutter and performing the cleaning by hand. Such a task is dangerous, difficult and time-consuming, with the result that the task is often neglected causing gutter drains and their downspouts to become obstructed by debris. This in turn causes the gutters to overflow, resulting in water damage to buildings and landscaping.
Because of the dangerous and difficult nature of gutter cleaning by such conventional methods, many different pole-type gutter cleaning implements have been proposed to enable the user to remain on the ground while cleaning a gutter. However these devices are laborious and time-consuming to use, and are of questionable effectiveness particularly if a gutter contains a large amount of debris. Moreover, they are difficult or impossible to use for gutters located at relatively high elevations above the ground.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to a remotely-controllable self-cleaning roof gutter system which is operable from ground level and requires no laborious or time-consuming effort on the part of the user.
According to one aspect of the invention, a gutter is provided with at least one inflatable bladder. A fluid infusion conduit is connected to an interior chamber within the bladder to selectively inflate the normally deflated bladder by the infusion of pressurized fluid from a remote source when it is desired to clean the gutter. The inflation of the bladder lifts debris deposited within the gutter to a location at or near the top of the gutter where the debris is readily removable. Preferably, the fluid is supplied from an ordinary domestic water source, although other water or air sources could be used if desired.
Removal of the lifted debris can, within the scope of the invention, be accomplished in any of several ways while the bladder is inflated. These could, for example, include the ordinary forces of nature such as gravity, or the use of handheld water-spraying or air-blowing hoses or other conduits which the user could direct toward the lifted debris while standing at or near ground level. Preferably, the debris is removed merely by gravity so that it falls to the ground beneath the gutter without any effort by the user.
According to a separate aspect of the invention, the removal of the lifted debris is facilitated by an upwardly-movable debris-collecting and debris-lifting element within the gutter which could, alternatively, be a part of the bladder, an element mounted on the bladder, a separately mounted element liftable by the bladder, or an element liftable by a mechanism other than a bladder which would enable the bladder to be eliminated.
The foregoing and other objectives, features, and advantages of the invention will be more readily understood upon consideration of the following detailed description, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an extended top view of an exemplary embodiment of the invention.
FIG. 2 is an enlarged cross-sectional view taken along line 2--2 of FIG. 1.
FIG. 3 is an enlarged partial sectional view taken along line 3--3 of FIG. 1, also showing attached fluid supply components.
FIG. 4 is an enlarged partial sectional view taken along line 4--4 of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIGS. 1 and 2, an elongate roof gutter 10 having a channel-shaped cross-section defining an interior bottom surface 12 and a top 14 is mounted on a building 16 below the overhanging edge 18 of a roof 20. The gutter 10 may be mounted to the building 16 by any suitable means, preferably by respective longitudinally-spaced snap-on bottom supports such as 22. The inside lip of the gutter includes an elongate jaw 24 for gripping the edge of the lower shingle layer along the length of the gutter. Any water entering the interior of the jaw 24 is drained into the gutter through apertures 25 spaced along the length of the gutter. The supports such as 22 can be provided in different lengths or with length-varying shims to accommodate different roof overhang dimensions.
The interior bottom surface 12 of the gutter has a drain 26 at one end which connects to a downspout 28 for conducting water from the gutter downwardly toward ground level.
A selectively inflatable/deflatable bladder 30 is installed on the interior bottom surface 12 in a deflated condition so as to extend longitudinally along the gutter. As shown in FIG. 2, the bladder preferably has inwardly-folding pleated sidewalls which collapse when the bladder is deflated. The interior chamber 32 of the bladder is selectively inflatable in response to infusion of a fluid into the chamber, thereby inflating the bladder toward the top of the gutter so that it assumes a configuration, such as that shown in dotted lines in FIG. 2, protruding from the top 14 of the gutter. The bladder 30 can be constructed of any flexible fluid-impervious material such as plastic, rubber, or fabric, or a composite of two or more such materials.
The material of the bladder 30 is preferably originally furnished in long tubular lengths which exceed the expected lengths of the gutters in which the material is to be installed. This enables the installer to cut the bladder material to a length, such as shown in FIG. 1, which extends longitudinally along the entire length of a gutter except for the area of the drain 26, so that the drain remains unobstructed by the bladder. Resilient elongate metal or plastic clamps 37, spanning the width of the collapsed bladder material, can be used to seal the previously-cut ends of the bladder by folding the ends double and applying the clamps to the folded ends as shown in FIG. 4.
As an alternative to the single continuous elongate bladder 30 shown in FIG. 1, multiple bladders could, in accordance with the present invention, be distributed discontinuously along the gutter with respective interior chambers interconnected in series or in parallel by fluid conduits. Such multiple, shorter bladders could be employed in variable numbers in each gutter depending upon the gutter's length.
In order to selectively inflate or deflate the bladder 30, a flexible fluid conduit such as a plastic tube 38 is connected to the interior chamber 32 of the bladder adjacent one end as shown in FIG. 3. A metal or plastic fluid coupling 40 having a fluid passageway therethrough has a lower threaded nipple 40a. Prior to clamping the adjacent end of the bladder, the installer forms aligned holes through the bottom of the bladder 30 and the bottom of the gutter 10 and inserts the threaded nipple 40a downwardly from the interior chamber 32 of the bladder through a washer 41 and through the aligned holes. The installer then slips a mating washer 43 over the bottom of the nipple 40a and applies a threaded nut 42 tightly to the nipple 40a, thereby sealing the hole in the bottom of the bladder by clamping its surrounding material tightly beneath the top of the coupling 40. The adjacent end of the bladder 30 is then clamped by a clamp 37. The conduit 38 is pushed tightly onto the nipple 40a and clamped to it, thereby completing the connection between the conduit 38 and the interior chamber 32.
The fluid conduit 38 extends downwardly from the gutter 10 to a location remote from the gutter where an actuating valve assembly, consisting of a selectively openable and closable fluid valve 46 and pressure reducer valve 47, are interposed in the conduit 38 near ground level. The valve assembly has a garden hose swivel coupling 48 for accepting the threaded insertion of a standard garden hose 50. The pressure reducer valve 47 preferably reduces the normal domestic water pressure to between 5 and 15 psi. A standard anti-siphon valve (not shown) can be connected at the opposite end of the garden hose 50 if desired.
Although it is within the scope of the invention to rely solely on the bladder 30 to collect and lift debris out of the top of the gutter, such process is performed more effectively by the inclusion of a separate debris-collecting and -lifting element, preferably in the form of an elongate plate 44 of concave cross-section. The plate 44 extends along the length of the gutter except for the area of the drain 26, and is pivotally attached by an elongate hinge 45 to the outside lip of the gutter.
An inverted, cup-shaped, fluid-permeable plastic screening member 44a is tightly attached by a slotted jaw 44b to one end of the plate 44 in a location above the drain 26 so as to permit normal drainage from the gutter into the drain through the screening member 44a while preventing the passage of larger particles of debris into the drain 26 and downspout 28. When the bladder 30 is inflated toward the top of the gutter as described previously, the bladder lifts the entire plate 44 and debris-screening member 44a pivotally upward to a substantially inverted position such as shown in dotted lines in FIG. 2, so that the debris on the plate and screening member is lifted and dumped over the outside wall of the gutter along its entire length. The inside wall 10a of the gutter has a radius of curvature matching the hinged pivoting radius of the plate 44, thereby guiding the plate 44 and bladder away from interference with the roof edge 18 during inflation, while also preventing any debris from being trapped beneath the roof overhang.
If the drain 26 is located at the opposite end of the gutter, the opposite jaw 44b (FIG. 1) of the screening member 44a is used to attach the screening member to the opposite end of the plate 44.
In use, a self-cleaning roof gutter system of the type just described is preferably installed as a complete new gutter installation. Alternatively, an existing gutter could be retrofitted to perform the self-cleaning function by inserting a liner, shaped like the gutter 10, into the existing gutter, removing any existing gutter mounting hardware traversing the top of the gutter which would interfere with the operation of the cleaning system and substituting bottom mounting hardware similar to support 22 shown in FIG. 2.
Debris collects above the deflated bladder in the gutter's normal course of operation. Debris also can be expected to collect in especially heavy concentrations on the debris-screening member 44a. When it is desired to clean the gutter, a garden hose such as 50 is attached to the coupling 48 at the bottom of the conduit 38. The actuating valve 46 is moved to its open position as shown in FIG. 3 and water is infused from the garden hose 50 through the conduit 38 into the bladder's interior chamber 32. When the bladder is fully inflated, all of the debris above the bladder will have been lifted and dumped from the top of the gutter, together with the debris on the screening member 44a. When the debris has been dumped, the valve 46 is rotated 90° counterclockwise (as seen in FIG. 3) to its closed position which prevents the further infusion of water from the garden hose 50 while permitting drainage of the conduit 38 by gravity through a drain port 46a. The resultant loss of pressure in the conduit 38 creates a siphoning effect so that the water in the chamber 32 is quickly drained and the bladder is deflated completely by atmospheric pressure to its normal collapsed condition. If the outward extremity of pivoted movement of the plate 44 is limited by the hinge 45 so that the plate's center of gravity remains inboard of the hinge pivot axis, the plate 44 will return to its normal downward position by gravity when the bladder deflates. Preferably, however, the pivoting movement is not so limited in order to maximize the outward dumping motion of the plate 44 by enabling the plate to be inverted as shown in FIG. 2. In such case, longitudinally spaced snap-in connectors such as 52 (FIG. 2), between the top of the bladder 30 and apertures 54 formed in the plate 44, force the downward return of the plate 44 when the bladder is deflated, while also positively maintaining the bladder in its proper position in the gutter despite repeated inflations and deflations. Alternatively, return springs could force the downward return of the plate 44, and the bottom of the bladder could be adhered or otherwise connected to the gutter to maintain it in its proper position if necessary.
All of the components of the system are preferably constructed of an opaque, corrosion-resistant material, preferably flexible plastic of low elasticity in the case of the bladder material and conduit 38, and relatively rigid metal or plastic for the other components. Although the control valve 46 is shown as being manually operated, it could instead be solenoid-operated with multiple such valves all connected to a common electrical controller so that all of the gutter-cleaning units on a particular building can be operated remotely from a single location, either manually or by automatic timed operation.
Instead of a curved inside wall 10a, the inside wall could be straight and inclined parallel to the outside wall, in which case a bladder could be used without the pivotal plate 44, or with an upwardly slidable plate mounted atop the bladder.
Instead of a bladder, other means could be used for pivoting the plate 44, such as a simple fluid piston or motor in which case the bladder 30 could be eliminated.
The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow.
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A remotely-controllable self-cleaning roof gutter preferably has a selectively inflatable and deflatable bladder extending longitudinally along the interior of the roof gutter. The bladder has an interior chamber connected to a fluid conduit which extends downwardly from the gutter so that the inflation or deflation of the bladder can be controlled manually by a person standing on the ground. When the gutter is to be cleaned, the normally deflated bladder is inflated by introducing pressurized fluid into the conduit which causes the bladder to lift debris toward the top of the gutter and dump it over the top of the gutter onto the ground by gravity. Thereafter, the bladder is deflated and the gutter is restored to normal usage. Preferably, a fluid-permeable screening member is mounted immediately above the gutter drain and is liftable by the inflated bladder in unison with the debris so that debris surrounding the screening member is likewise removed by gravity.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is entitled to the benefit of and incorporates by reference essential subject matter disclosed in German Patent Application No. 103 23 767.4 filed on May 22, 2003 and German Patent Application No. 103 30 760.5 filed on Jul. 7, 2003.
FIELD OF THE INVENTION
[0002] The invention concerns a piston compressor, particularly a hermetic refrigerant compressor, with a compression chamber, which is limited by a valve plate arrangement having a valve plate with a suction gas opening and a pressure gas opening, a suction valve plate with a suction valve element, and a pressure valve plate with a pressure valve element.
BACKGROUND OF THE INVENTION
[0003] Such a refrigerant compressor is known from, for example, DE 199 15 918 C2. A suction valve is fixed on the valve plate bottom side facing the compression chamber. A pressure valve is fixed on the opposite valve plate upper side, where it is located in a recess. A sealing is located between the cylinder adopting the compression chamber and the valve plate, and an additional sealing is located between the valve plate and the cylinder head cover. Together with a partition wall formed in the cover, this additional sealing ensures that the suction side and the pressure side are separated from each other. For this purpose, it is required that the complete cylinder head arrangement be assembled by means of screw bolts and fixed on the cylinder. In order to achieve a sufficient tightness, high tightening forces are required. Further, only narrow manufacturing tolerances are permitted. When the separation between the suction side and the pressure side is not realised satisfactorily, compressed, and thus hot, gas from the pressure side can reach the suction side, which reduces the efficiency of the compressor.
[0004] The tightening forces, which can be achieved with screws, are limited. Also, the forces, with which the parts forming the cylinder head are assembled, cannot in other ways be increased to a value exceeding a predetermined value, as this would cause a too high material strain.
SUMMARY OF THE INVENTION
[0005] The invention is based on the task of achieving a good efficiency, also with simple mounting.
[0006] With a piston compressor as mentioned in the introduction, this task is solved in that the pressure valve plate and the suction valve plate are located on the side of the valve plate facing the compression chamber.
[0007] Thus, the pressure valve plate and the suction valve plate are no longer located on different sides of the valve plate, on the contrary, they are located on the same side of the valve plate, namely on the side facing the compression chamber. In this connection, the fact is utilised that the suction valve plate and the pressure valve plate are usually substantially thinner than the valve plate. This means that the suction valve plate and the pressure valve plate are more flexible than the valve plate, that is, they can bear more closely on each other, when the forces used for tightening are smaller. Further, an additional advantage occurs. The fact that the compressed gas no longer has to pass through the valve plate before reaching the pressure valve causes that the dead space is reduced. This improves the efficiency of the compressor. A projection, often formed on the front side of a piston reducing the compression chamber, which projects into the pressure gas opening of the valve plate in the upper dead point position, thus reducing the damaging dead volume, is no longer required. Locating not only the suction valve plate but also the pressure valve plate on the side of the valve plate facing the compression chamber simplifies the manufacturing. Usually, it is no longer required to fit sealings between the valve plate, the suction valve plate and the pressure valve plate.
[0008] Preferably, the suction valve plate forms a pressure valve seat for the pressure valve element and the pressure valve plate forms a suction valve seat for the suction valve element. Thus, the working required for manufacturing the valve seat could be limited to the suction valve plate and the pressure valve plate. This working, if required at all, then takes place on the sides of the suction valve plate and the pressure valve plate, which bear on each other in the mounted state. This further improves the tightness.
[0009] It is particularly preferred that, with intermediate mounting of a reinforcement plate, the pressure valve plate and the suction valve plate are located on the side of the valve plate, which exists in the form of a stiffening element, facing the compression chamber. However, the valve plate, which exists in the form of a stiffening element, is not limited to a substantially plane embodiment. It can also perform other functions, for example be part of a muffling arrangement or other parts of the cylinder head. However, still the valve plate ensures that the limiting wall of the compression chamber adopting the valves is rigid and mechanically stable. However, it is an advantage that the suction valve plate and the pressure valve plate are usually substantially thinner than the traditional valve plate. Thus, the suction valve plate and the pressure valve plate are more flexible than the valve plate. The flexibility of the suction valve plate and the pressure valve plate makes it possible for both plates to bear more closely on bearing surfaces, also when the forces used for tightening are smaller. In principle, an improved tightness will thus occur. However, the flexible embodiment of the suction valve plate involves the risk that, during a suction stroke, when suction pressure rules in the compression volume, the suction valve plate sags in the area of the environment of the pressure valve. During a suction stroke, the previously generated pressure namely rules here. In many cases, a flexible suction valve plate is not stable enough to adopt the forces occurring through the pressure difference without significant bending. Under certain circumstances, a repeated deformation will cause a fatigue fracture of the suction valve plate. The deformation is now effectively prevented or at least substantially reduced by the reinforcement plate. The reinforcement plate does not have to be substantially more stable than the suction valve plate. Also with a relatively weakly dimensioned reinforcement plate, the sag of the suction valve plate can be reduced to a harmless extent.
[0010] Preferably, the suction valve plate, the reinforcement plate and the pressure valve plate have substantially the same thickness. However, their thicknesses do not have to be exactly the same. Deviations from 50% downward and 100% upwards are permissible. The thickness of the reinforcement plate will be chosen in dependence of the magnitude of the pressure ruling on the pressure side in such a manner that fatigue fractures of the suction valve plate are avoided. This means that the thickness of the reinforcement plate will be chosen so that it provides a sufficient support. On the other hand, the thickness of the reinforcement plate will be kept as small as possible to avoid an excessive increase of the harmful volume in the pressure opening.
[0011] Preferably, the reinforcement plate forms a pressure valve seat for the pressure valve element and a suction valve seat for the suction valve element. Thus, the workings, which are required for the manufacturing of the valve seats, can be limited to the reinforcement plate. If required at all, this working then occurs on the two sides of the reinforcement plate, which bear on the suction valve plate or the pressure valve plate, respectively, in the mounted state. This further improves the tightness.
[0012] Preferably, the suction valve plate, in relevant cases the reinforcement plate and the pressure valve plate are made of spring steel. In this case, spring steel has several advantages. Firstly, the suction valve element and the pressure valve element can be made in one piece with the suction valve plate and the pressure valve plate, respectively, for example as a flexible tongue. Secondly, spring steels can be formed relatively plane, so that a safe closing of the suction opening and the pressure opening in the suction valve plate and the pressure valve plate can be ensured in a simple manner.
[0013] Preferably, the valve plate, the pressure valve plate and the suction valve plate, or the valve plate, the pressure valve plate and the reinforcement plate and, in some cases, the suction valve plate are undetachably connected with each other. In this case, undetachably means that the three or four plates cannot be detached from each other by removing an auxiliary assembling part, for example a screw. Of course, if required, it is possible to use auxiliary assembling parts to connect the plates additionally to the undetachable connection.
[0014] In this connection, preferably a connection is provided, which connects the valve plate, the pressure valve plate and the suction valve plate, or the valve plate, the pressure valve plate and the reinforcement plate and, in relevant cases, the suction valve plate, at a common position. For example, the suction valve plate and the valve plate are connected through the pressure valve plate. When a reinforcement plate is available, it may be ensured that the suction valve plate and the valve plate in the form of a stiffening element are connected through the reinforcement plate and the pressure valve plate.
[0015] Advantageously, the connection is made in the form of a line, which surrounds an area around a pressure valve. Then, the connection is not used to provide a mechanical cohesion between the suction valve plate, in relevant cases the reinforcement plate, the pressure valve plate and the valve plate. At the same time, the connection forms a sealing line, which surrounds the area around the pressure valve, so that pressure gas, which passes the pressure valve, may reach this line, but cannot penetrate the connection along this line. In this connection, the term “line” must be understood functionally. Of course, the connection along this line may have a certain width.
[0016] Preferably, the connection is made as a welded connection. Such a welded connection is easily manufactured. A welded connection has the advantage that with the welding several elements can be fixed to each other at the same time, that is, the suction valve plate, in relevant cases the reinforcement plate, the pressure valve plate and the valve plate can be connected with each other. In some cases it can be avoided to weld the suction valve plate onto the other elements of the stack, when the tightness between the suction valve plate and the reinforcement plate can be ensured otherwise. Such a welding can preferably be made without adding electrode material, for example by means of a laser beam. After alignment of the valve plate, the suction valve plate, in relevant cases the reinforcement plate and the pressure valve plate in relation to each other, such a laser beam is directed onto the surface of the suction valve plate and then moved along the line. Thus, not only the suction valve plate, in relevant cases the reinforcement plate, the pressure valve plate and the valve plate are connected with each other, but at the same time, a sealing around the pressure valve is produced. Such a method is not only possible with a welding process, but can also be used with an electron beam process.
[0017] It is preferred that the suction valve plate has at least one slot-like opening, which follows the course of the line. Of course also more than one slot-like opening can be provided. Particularly, when the connection between the three or four plates is realised by means of a welding, the slot-like opening(s) has/have advantages. A possibly occurring welding bead will be adopted by the opening, that is, it does not project into the compression chamber. Thus, the dead volume of the compressor can be further minimised. In its upper dead point, the piston can namely be set to a smaller distance to the suction valve plate, as it would be possible, when a welding bead existed. These considerations also apply, when the connection is not made as a welded connection, but as a soldered or glued connection. Also in this case, the slot-like openings can adopt possibly occurring projecting. Also the reinforcement plate may have corresponding slot-like openings, so that also inside the plate package comprising the four plates interfering welding or gluing beads cannot occur.
[0018] Preferably, the side of the valve plate facing the compression chamber has a bearing surface for the pressure valve element located in the pressure gas opening. Thus, the bearing surface serves as retainer bridge. A separate retainer bridge for the pressure valve element is no longer required. In principle, the element called valve plate could also be regarded as “retainer bridge”, so that with the present embodiment the valve plate in its traditional form is practically omitted.
[0019] Preferably, the valve plate, the pressure valve plate, in relevant cases the reinforcement plate and the suction valve plate has corresponding recesses in the area of their circumferences, in which projections of a cylinder element surrounding the compression chamber engage. Together with the recesses, the projections serve the purpose of aligning the suction valve plate, in relevant cases the reinforcement plate, the pressure valve plate and the valve plate in relation to each other in the correct angular positions. This further simplifies the mounting.
[0020] Preferably, the valve plate arrangement bears with intermediate mounting of a sealing on a bearing surface of the cylinder element, which is formed by a diameter extension of the cylinder element. This sealing ensures that during a compression process, that is, during a reduction of the compression chamber, gas cannot leak from the compression chamber at an undesired spot. The discharge of the gas from the compression chamber is thus limited to its way through the pressure valve. The sealing can equalise possibly occurring unevennesses. It is, for example, made of an elastomer.
[0021] Preferably, the valve plate arrangement is connected with a flange surrounding the bearing surface, and compresses the sealing. Such a connection can, for example, be made by means of welding. However, the connection can also be made by bordering the flange. Before the welding or bordering, a pressure is exerted on the valve plate arrangement, which causes a compression of the sealing. In this compressed state, a welding is then made. Such a welding can, for example in the circumferential direction, lead to a closed welding seam, which further improves the tightness.
[0022] Preferably, the recesses in the valve plate only penetrate partly through the thickness of the valve plate. This involves the advantage that the “upper side” of the valve plate, that is, the side facing the compression chamber, is plane. Thus, the recesses do not have to be additionally closed or taken into consideration in other ways.
[0023] Preferably, a recess surrounds the suction gas opening and/or the pressure gas opening in the valve plate. A connector of a suction muffler or a pressure muffler, respectively, can be inserted in such a recess, so that also on the side of the valve plate facing away from the compression chamber an excellent separation of the suction side from the pressure side can be realised.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] In the following, the invention is described on the basis of preferred embodiments in connection with the drawings showing:
[0025] FIG. 1 is a schematic sectional view of a piston compressor
[0026] FIG. 2 a is an enlarged section from FIG. 1 of a valve plate arrangement with three plates
[0027] FIG. 2 b is an enlarged section from FIG. 1 of a valve plate arrangement with four plates
[0028] FIG. 3 is a view of a valve plate arrangement seen from the piston
[0029] FIG. 4 is a view of a cylinder element in the longitudinal section
[0030] FIG. 5 is a suction valve plate
[0031] FIG. 6 is a pressure valve plate
[0032] FIG. 7 is a modified embodiment of a suction valve plate
[0033] FIG. 8 is a valve plate from the side facing away from a compression chamber.
[0034] FIG. 9 is a sectional view IX-IX according to FIG. 8
[0035] FIG. 10 is a sectional view X-X according to FIG. 8
[0036] FIG. 11 is a view of the valve plate from the side of the compression chamber
[0037] FIG. 12 is a view of a reinforcement plate
[0038] FIG. 13 is a perspective exploded view of the valve plate arrangement.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] A piston compressor 1 , shown schematically in FIG. 1 , has a cylinder element 2 , which surrounds a compression chamber 3 in the circumferential direction. On a front side, the compression chamber 3 is bordered by a merely schematically shown piston 4 , which is movable in the direction of a double arrow 5 . On the side facing the piston 4 , the compression chamber 3 is bordered by a valve plate arrangement 6 , which will be described in detail in the following. For reasons of clarity, other elements, like suction muffler, pressure muffler, cylinder head cover or the like are not shown, can, however, be fitted accordingly by the person skilled in the art according to needs. 40 The valve plate arrangement 6 with three plates in FIG. 2 a shows a valve plate 7 , which is penetrated by a suction gas opening 8 and a pressure gas opening 9 . The valve plate arrangement 6 with four plates in FIG. 2 b has a valve plate 7 in the form of a stiffening element, which is also penetrated by the suction gas opening 8 and the pressure gas opening 9 . The valve plate 7 in the form of a stiffening element is here made as a plate. However, with this valve plate 7 in the form of a stiffening element, the plane or plate-like shape is not absolutely required. As can also be seen from FIG. 10 , a recess 10 surrounds the suction gas opening 8 . A recess 11 surrounds the pressure gas opening 9 . In both recesses, connection pipes, not shown in detail, from suction mufflers or pressure mufflers, respectively, can be inserted. It is also possible to connect these connection pipes fixedly with the valve plate 7 , for example by means of gluing or welding. In this case, a cylinder head cover may, under certain circumstances, be avoided.
[0040] On the side of the valve plate 7 facing the compression chamber 3 , firstly a pressure valve plate 12 bears, which has ( FIG. 6 ) a pressure valve element 13 in the form of a flexible tongue. Further, the pressure valve plate has a suction opening 14 , which is merely formed by a hole in the pressure valve plate 12 .
[0041] On the side of the pressure valve plate 12 facing the compression chamber 3 bears, according to FIG. 2 a , a suction valve plate 15 . On the side of the pressure valve plate 12 facing the compression chamber 3 bears, according to FIG. 2 b , a reinforcement plate 40 ( FIG. 12 ), which also has a pressure gas opening 41 and a suction gas opening 42 , which are formed by holes in the reinforcement plate 40 .
[0042] On the side of the reinforcement plate 40 facing the compression chamber 3 bears a suction valve plate 15 . The suction valve plate has ( FIG. 5 ) a suction valve element 16 and a pressure opening 17 . The suction valve element 16 is also made as a flexible element. The pressure opening 17 is merely a circular hole.
[0043] Both the pressure valve plate 12 and the suction valve plate 15 are made of spring steel. Also the reinforcement plate 40 is made of spring steel. In the present embodiment, spring steel has the advantage that both the pressure valve element 13 and the suction valve element 16 can be made in one piece with the pressure valve plate 12 or the suction valve plate 15 , respectively. However, the valve elements 13 , 16 can be made separately from the valve plates 12 , 15 , and then be fitted together with the valve plates 12 , 15 . Further, spring steel is relatively thin and can be provided with a surface, which ensures that the pressure valve plate 12 , in relevant cases the reinforcement plate and the suction valve plate 15 bear sealingly on each other.
[0044] With a valve plate arrangement with three plates according to FIG. 2 a , the suction valve plate 15 forms, together with the pressure opening 17 , a valve seat 29 for the pressure valve element 13 . The pressure valve plate 12 forms, together with the suction opening 14 , a valve seat 30 for the suction valve element 16 . In the valve plate arrangement with four plates according to FIG. 2 b , the reinforcement plate 40 forms, together with the pressure opening 41 a valve seat 29 for the pressure valve element 13 . The reinforcement plate 40 forms, together with the suction opening 42 , a valve seat 30 for the suction valve element 16 ( FIG. 3 ). According to the views in FIGS. 5 and 6 , the pressure valve plate 12 is folded onto the suction valve plate 15 .
[0045] FIG. 12 shows a top view of the reinforcement plate 40 .
[0046] FIG. 13 shows a perspective exploded view of the valve package or the valve arrangement 6 , which is formed by the valve plate 7 , the pressure valve plate 12 , the reinforcement plate 40 and the suction valve plate 15 . From this figure, the relative allocations of the individual suction openings 8 , 14 , 42 and the individual pressure openings 9 , 41 , 17 can be seen.
[0047] As appears from FIG. 2 a , the pressure valve plate 12 , the suction valve plate 15 and the valve plate 7 are connected with each other by means of a welded seam 18 . In this connection, the welded seam penetrates the pressure valve plate 12 .
[0048] As appears from FIG. 2 b , the pressure valve plate 12 , the reinforcement plate 40 , the suction valve plate 15 and the plate 7 are connected with each other by means of a welded seam 18 . In this connection, the welded seam 18 penetrates the pressure valve plate 12 and the reinforcement plate 40 .
[0049] As appears particularly from FIG. 3 , the welded seam 18 surrounds an area around the pressure valve. Thus, it surrounds the pressure valve element 13 and the pressure opening 17 , according to FIG. 2 b also the pressure opening 41 at a certain distance. The welded seam 18 is made to be gas tight, that is, it surrounds a pressure gas area, from which the compressed gas cannot escape during the upward movement of the piston 4 .
[0050] For the welding, for example, a laser can be used, which is directed to the surface of the suction valve plate 15 , after aligning of the valve plate 7 , the pressure valve plate 12 , in relevant cases the reinforcement plate 40 and the suction valve plate 15 in relation to each other. The beam intensity of the laser is controlled so that the material of the parts mentioned is only molten in a relatively narrow area. This keeps the risk small that the valve plates mentioned, 7 , 12 , 15 and in relevant cases 40 , are distorted. This is not only possible with a laser welding process; also an electron beam process can be used.
[0051] With the welded seam 18 , an undetachable connection is made between the valve plate 7 , the pressure valve plate 12 , in relevant cases the reinforcement plate 40 and the suction valve plate 15 . On the one hand, this connection keeps the valve plates 7 , 12 , 15 , and in relevant cases the reinforcement plate 40 , firmly together, and on the other hand, it ensures that gas passing the pressure valve cannot leak to other areas.
[0052] Of course, also other connection methods can be used, for example, soldering or gluing processes. In certain cases, also auxiliary assembling parts, like rivets or the like, can be used, the auxiliary assembling parts, however, not taking over the only connection, when they cannot take over the additional task of sealing around the pressure gas area.
[0053] For adopting the valve plate arrangement 6 , the cylinder element 2 has a diameter extension 19 . This diameter extension 19 forms a support face 20 , that is, a sort of offset front side of the cylinder element 2 , on which the valve plate arrangement 6 is supported under insertion of a sealing 21 . The valve plate arrangement 6 is then loaded in the direction of the cylinder element 2 in such a way that the sealing 21 is compressed. Then the valve plate arrangement 6 , or rather the valve plate 7 , is connected, by means of a welded connection 22 , with a circumferential flange 23 of the cylinder element 2 , so that the sealing 21 remains compressed. The welded connection 22 can also be replaced by another connection kind, for example a bordering connection. In this connection, it is expedient, when the flange 23 projects over the valve plate arrangement 6 or the valve plate arrangement 6 has a circumferential groove, in which a corresponding bordering edge can engage.
[0054] The sealing 21 seals the compression chamber 3 in the area of the end facing the valve plate arrangement 6 , thus preventing that compressed refrigerant gas escapes to the outside here. The only way for the refrigerant gas to leave the compression chamber 3 remains the pressure opening 17 , when it is released by the pressure valve element 13 .
[0055] FIG. 7 shows an embodiment of a suction valve plate 15 , which is somewhat modified in relation to the embodiment shown in FIG. 5 . The same parts have the same reference numbers.
[0056] Slits 24 have been added, which extend along the welded seam 18 shown. The slits are meant for preventing that during welding of the valve plate 7 with the suction valve plate 15 , in relevant cases the reinforcement plate 40 , and the pressure valve plate 12 , molten metal leaves a welding bead to project from the surface of the suction valve plate 15 . This would require a larger safety distance to the piston and thus cause an increased dead volume. When the slits 24 are provided, the unavoidable welding bead is located in the slit. Accordingly, this also applies, when a soldering seam or a gluing seam replaces the welding seam 18 . Alternatively to the slit, stamps may be provided in the valve plate 7 , in relevant cases in the reinforcement plate 40 and in the suction and pressure valve plates 12 , 15 , said stamps pointing away from the compression chamber 3 .
[0057] The slits 24 have interruptions 25 . These interruptions are located where the sealing 21 is supported on the side of the suction valve plate 15 facing the compression chamber 3 . Here, a bead can still project from the surface of the suction valve plate 15 . However, this area is outside the cross-section of the compression chamber 3 and is adopted by the sealing ring 21 .
[0058] Both the pressure valve plate 12 and the suction valve plate 15 , and in relevant cases the reinforcement plate 40 , have several recesses 26 , 26 ′ distributed in the circumferential direction, which correspond to projections 26 a on the cylinder element 2 ( FIG. 4 ). Also the valve 7 has corresponding recesses 26 , 26 ′. As shown, the recesses 26 , 26 ′ can be distributed evenly in the circumferential direction. However, one of the recesses is broader than the others, so that it is ensured that the valve plates 7 , 12 , 15 , and in relevant cases 40 , can only be assembled in one predetermined angular orientation.
[0059] The valve plate 7 can be seen in the FIGS. 8 to 11 . From a comparison of the FIGS. 8 and 11 it appears that the recesses 26 , 26 ′ in the valve plate 7 do not penetrate through the whole thickness. Thus, the recesses 26 , 26 ′, do not interfere with the topside of the valve plate 7 shown in FIG. 8 , which is facing away from the compression chamber. The same applies for the upper area of the circumference of the valve plate 7 . This makes it easier to make the welded connection 22 tight.
[0060] FIG. 9 shows that a projection 27 projects laterally into the pressure gas opening 9 , which projection 27 forms a bearing surface 28 for the pressure valve element 13 . The bearing surface 28 limits the movement of the pressure valve element 13 , when compressed refrigerant gas is discharged from the compression chamber 3 . Thus, the bearing surface 28 replaces a separate retainer bridge, which is otherwise usually provided to protect the pressure valve element 13 from damages during opening.
[0061] FIG. 3 now shows the design of a valve plate arrangement 6 with the individual valve elements. The pressure valve element 13 bears on the pressure valve seat 29 , which, according to FIG. 2 a , is formed on the side of the suction valve plate 15 facing away from the compression chamber 3 , and according to FIG. 2 b on the side of the reinforcement plate 40 facing away from the compression chamber 3 . The suction valve element 16 bears on the suction valve seat 30 , which is formed on the side of the pressure valve plate 12 facing the compression chamber 3 . The fact that merely the suction valve plate 15 , and in relevant cases the reinforcement plate 40 , is located between the compression chamber and the pressure valve plate 12 , makes it possible to keep the undesired dead volume between the pressure valve element 13 and the compression chamber 3 relatively small. It is practically limited to the thickness of the suction valve plate 15 , when the valve plate arrangement comprises three plates, and to the sum of the thicknesses of the suction valve plate 15 and the reinforcement plate 40 , when the valve plate arrangement comprises four plates. This thickness is in the area of some tenths of a mm. Additional measures for keeping the dead volume small are not required. Also without additional measures an excellent efficiency of the compressor can be achieved.
[0062] The reinforcement plate 40 prevents that the area of the suction valve plate 15 , which is inside the welding seam 18 , and acted upon by a pressure difference during a suction stroke, said pressure difference resulting from the reduced pressure in the compression chamber and the increased pressure on the pressure side of the compressor, sags. Without the reinforcement plate 40 , a sagging in the magnitude of 150 μm could be observed. With the reinforcement plate 40 , this sagging was reduced to a harmless magnitude of about 10 μm. Such a reduction can also be achieved with a relatively thin reinforcement plate 40 . The thickness of the reinforcement plate 40 is, for example, in the magnitude of 0.2 mm, that is, approximately in the magnitude of the thickness of the suction valve plate 15 and the pressure valve plate 12 .
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The invention concerns a piston compressor, particularly a hermetic refrigerant compressor, with a compression chamber, which is limited by a valve plate arrangement having a valve plate with a suction gas opening and a pressure gas opening, a suction valve plate with a suction valve element, and a pressure valve plate with a pressure valve element. It is endeavoured to achieve a good efficiency combined with a simple assembly. For this purpose, it is ensured that the pressure valve plate and the suction valve plate are located on the side of the valve plate facing the compression chamber.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent application Ser. No. 12/642,026, filed Dec. 18, 2009, now U.S. Pat. No. 8,343,973, entitled “Phenoxymethyl Heterocyclic Compounds,” which claims the benefit of priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 61/176,413, filed May 7, 2009, entitled “Vicinal Substituted Heterocyclic Compounds.” The entire contents of these priority applications are incorporated herein by reference.
BACKGROUND
[0002] Cyclic phosphodiesterases are intracellular enzymes which, through the hydrolysis of cyclic nucleotides cAMP and cGMP, regulate the levels of these mono phosphate nucleotides which serve as second messengers in the signaling cascade of G-protein coupled receptors. In neurons, PDEs also play a role in the regulation of downstream cGMP and cAMP dependent kinases which phosphorylate proteins involved in the regulation of synaptic transmission and homeostasis. To date, eleven different PDE families have been identified which are encoded by 21 genes. The PDEs contain a variable N-terminal regulatory domain and a highly conserved C-terminal catalytic domain and differ in their substrate specificity, expression and localization in cellular and tissue compartments, including the CNS.
[0003] The discovery of a new PDE family, PDE10, was reported simultaneously by three groups in 1999 (Soderling et al. “Isolation and characterization of a dual-substrate phosphodiesterase gene family: PDE10A” Proc. Natl. Sci. 1999, 96, 7071-7076; Loughney et al. “Isolation and characterization of PDE10A, a novel human 3′,5′-cyclic nucleotide phosphodiesterase” Gene 1999, 234, 109-117; Fujishige et al. “Cloning and characterization of a novel human phosphodiesterase that hydrolyzes both cAMP and cGMP (PDE10A)” J. Biol. Chem. 1999, 274, 18438-18445). The human PDE10 sequence is highly homologous to both the rat and mouse variants with 95% amino acid identity overall, and 98% identity conserved in the catalytic region.
[0004] PDE10 is primarily expressed in the brain (caudate nucleus and putamen) and is highly localized in the medium spiny neurons of the striatum, which is one of the principal inputs to the basal ganglia. This localization of PDE10 has led to speculation that it may influence the dopaminergic and glutamatergic pathways both which play roles in the pathology of various psychotic and neurodegenerative disorders.
[0005] PDE10 hydrolyzes both cAMP (K m =0.05 uM) and cGMP (K m =3 uM) (Soderling et al. “Isolation and Characterization of a dual-substrate phosphodiesterase gene family: PDE10 .” Proc. Natl. Sci. USA 1999, 96(12), 7071-7076). In addition, PDE10 has a five-fold greater V max for cGMP than for cAMP and these in vitro kinetic data have lead to the speculation that PDE10 may act as a cAMP-inhibited cGMP phosphodiesterase in vivo (Soderling and Beavo “Regulation of cAMP and cGMP signaling: New phosphodiesterases and new functions,” Curr. Opin. Cell Biol., 2000, 12, 174-179).
[0006] PDE10 is also one of five phosphodiesterase members to contain a tandem GAF domain at their N-terminus. It is differentiated by the fact that the other GAF containing PDEs (PDE2, 5, 6, and 11) bind cGMP while recent data points to the tight binding of cAMP to the GAF domain of PDE10 (Handa et al. “Crystal structure of the GAF-B domain from human phosphodiesterase 10A complexed with its ligand, cAMP” J. Biol. Chem. 2008, May 13 th , ePub).
[0007] PDE10 inhibitors have been disclosed for the treatment of a variety of neurological and psychiatric disorders including Parkinson's disease, schizophrenia, Huntington's disease, delusional disorders, drug-induced psychoses, obsessive compulsive and panic disorders (US Patent Application 2003/0032579). Studies in rats (Kostowski et. al “Papaverine drug induced stereotypy and catalepsy and biogenic amines in the brain of the rat” Pharmacol. Biochem. Behav. 1976, 5, 15-17) have showed that papaverine, a selective PDE10 inhibitor, reduces apomorphine induced stereotypies and rat brain dopamine levels and increases haloperidol induced catalepsy. This experiment lends support to the use of a PDE10 inhibitor as an antipsychotic since similar trends are seen with known, marketed antipsychotics.
[0008] Antipsychotic medications are the mainstay of current treatment for schizophrenia. Conventional or classic antipsychotics, typified by haloperidol, were introduced in the mid-1950s and have a proven track record over the last half century in the treatment of schizophrenia. While these drugs are effective against the positive, psychotic symptoms of schizophrenia, they show little benefit in alleviating negative symptoms or the cognitive impairment associated with the disease. In addition, drugs such as haloperidol have extreme side effects such as extrapyramidal symptoms (EPS) due to their specific dopamine D2 receptor interaction. An even more severe condition characterized by significant, prolonged, abnormal motor movements known as tardive dyskinesia also may emerge with prolonged classic antipsychotic treatment.
[0009] The 1990s saw the development of several new drugs for schizophrenia, referred to as atypical antipsychotics, typified by risperidone and olanzapine and most effectively, clozapine. These atypical antipsychotics are generally characterized by effectiveness against both the positive and negative symptoms associated with schizophrenia, but have little effectiveness against cognitive deficiencies and persisting cognitive impairment remain a serious public health concern (Davis, J. M et al. “Dose response and dose equivalence of antipsychotics.” Journal of Clinical Psychopharmacology, 2004, 24 (2), 192-208; Friedman, J. H. et al “Treatment of psychosis in Parkinson's disease: Safety considerations.” Drug Safety, 2003, 26 (9), 643-659). In addition, the atypical antipsychotic agents, while effective in treating the positive and, to some degree, negative symptoms of schizophrenia, have significant side effects. For example, clozapine which is one of the most clinically effective antipsychotic drugs shows agranulocytosis in approximately 1.5% of patients with fatalities due to this side effect being observed. Other atypical antipsychotic drugs have significant side effects including metabolic side effects (type 2 diabetes, significant weight gain, and dyslipidemia), sexual dysfunction, sedation, and potential cardiovascular side effects that compromise their clinically effectiveness. In the large, recently published NIH sponsored CATIE study, (Lieberman et al “The Clinical Antipsychotic Trials Of Intervention Effectiveness (CATIE) Schizophrenia Trial: clinical comparison of subgroups with and without the metabolic syndrome.” Schizophrenia Research, 2005, 80 (1), 9-43) 74% of patients discontinued use of their antipsychotic medication within 18 months due to a number of factors including poor tolerability or incomplete efficacy. Therefore, a substantial clinical need still exists for more effective and better tolerated antipsychotic mediations possibly through the use of PDE10 inhibitors.
BRIEF SUMMARY
[0010] The disclosure relates compounds which are inhibitors of phosphodiesterase 10. The disclosure further relates to processes, pharmaceutical compositions, pharmaceutical preparations and pharmaceutical use of the compounds in the treatment of mammals, including human(s) for central nervous system (CNS) disorders and other disorders which may affect CNS function. The disclosure also relates to methods for treating neurological, neurodegenerative and psychiatric disorders including but not limited to those comprising cognitive deficits or schizophrenic symptoms.
[0011] Described herein are compounds of Formula (I) that are inhibitors of at least one phosphodiesterase 10:
[0000]
[0000] wherein:
HET is a heterocyclic ring selected from Formulas A29, A31 and A39 below
[0000]
[0000] and the left most radical is connected to the X group;
X is selected from optionally substituted aryl and optionally substituted heteroaryl;
Z is optionally substituted heteroaryl;
each R 2 is independently selected from C 1 -C 4 alkyl, or two R 2 groups taken together with the carbon to which they are attached form a 3 membered cycloalkyl ring.
[0012] In one embodiment, alkyl groups are fully saturated whether present on their own or as part of another group (e.g. alkylamino or alkoxy).
[0013] In certain embodiments, substituent groups are not further substituted.
[0014] In various embodiments, any group that is defined as being optionally substituted can be singly or independently multiply optionally substituted.
[0015] In one embodiment, HET is selected from Formulas A29 and A31.
[0016] In another embodiment, HET is Formula A29.
[0017] In another embodiment, HET is Formula A31.
[0018] In one embodiment, X is selected from a monocyclic heteroaryl having 5 ring atoms selected from C, O, S and N provided the total number of ring heteroatoms is less than or equal to four and where no more than one of the total number of heteroatoms is oxygen or sulfur, and a monocyclic aromatic ring having 6 atoms selected from C and N provided that not more than 3 ring atoms are N, and where said ring may be optionally and independently substituted with up to two groups selected from C 1 -C 4 alkyl, cycloalkyl, cycloalkyloxy, C 1 -C 4 alkoxy, CF 3 , carboxy, alkoxyalkyl, C 1 -C 4 cycloalkylalkoxy, amino, alkylamino, dialkylamino, amido, alkylamido, dialkylamido, thioalkyl, halogen, cyano, alkylsulfonyl and nitro. Examples include but are not limited to 1H-pyrrolyl, furanyl, thiophenyl, imidazolyl, pyrazolyl, isothiazolyl, isoxazolyl, oxazolyl, thiazolyl, 1,2,3-triazolyl, 1,2,4-triazolyl, 1,2,3-oxadiazolyl, 1,2,4-oxadiazolyl, 1,2,5-oxadiazolyl, 1,3,4-oxadiazolyl, 1,2,3-thiadiazolyl, 1,2,4-thiadiazolyl, 1,2,5-thiadiazolyl, 1,3,4-thiadiazolyl, tetrazolyl, 1,2,3,4-oxatriazolyl, 1,2,3,5-oxatriazolyl, 1,2,3,4-thiatriazolyl, 1,2,3,5-thiatriazolyl, 1,2,3-triazinyl, 1,2,4-triazinyl, 1,3,5-triazinyl, pyridinyl, pyrazinyl, pyridazinyl and pyrimidinyl.
[0019] In a further embodiment, X is a monocyclic heteroaryl having 6 ring atoms selected from C and N provided that not more than 3 ring atoms are N, and where said ring may be optionally and independently substituted with up to two groups selected from C 1 -C 4 alkyl, cycloalkyl, cycloalkyloxy, C 1 -C 4 alkoxy, CF 3 , carboxy, alkoxyalkyl, C 1 -C 4 cycloalkylalkoxy, amino, alkylamino, dialkylamino, amido, alkylamido, dialkylamido, thioalkyl, halogen, cyano, alkylsulfonyl and nitro. Examples include but are not limited to 1,2,3-triazinyl, 1,2,4-triazinyl, 1,3,5-triazinyl, pyridinyl, pyrazinyl, pyridazinyl and pyrimidinyl.
[0020] In a further embodiment, X is a monocyclic heteroaryl having 5 ring atoms selected from C, O, S, and N, provided the total number of ring heteroatoms is less than or equal to four and where no more than one of the total number of heteroatoms is oxygen or sulfur and where said ring may be optionally and independently substituted with up to two groups selected from C 1 -C 4 alkyl, cycloalkyl, cycloalkyloxy, C 1 -C 4 alkoxy, CF 3 , carboxy, alkoxyalkyl, C 1 -C 4 cycloalkylalkoxy, amino, alkylamino, dialkylamino, amido, alkylamido, dialkylamido, thioalkyl, halogen, cyano, alkylsulfonyl and nitro. Examples include but are not limited to 1H-pyrrolyl, furanyl, thiophenyl, imidazolyl, pyrazolyl, isothiazolyl, isoxazolyl, oxazolyl, thiazolyl, 1,2,3-triazolyl, 1,2,4-triazolyl, 1,2,3-oxadiazolyl, 1,2,4-oxadiazolyl, 1,2,5-oxadiazolyl, 1,3,4-oxadiazolyl, 1,2,3-thiadiazolyl, 1,2,4-thiadiazolyl, 1,2,5-thiadiazolyl, 1,3,4-thiadiazolyl, tetrazolyl, 1,2,3,4-oxatriazolyl, 1,2,3,5-oxatriazolyl, 1,2,3,4-thiatriazolyl, 1,2,3,5-thiatriazolyl.
[0021] In a further embodiment, X is 4-pyridinyl optionally substituted with one group selected from C 1 -C 4 alkyl, cyclopropyl, cyclopropyloxy, cyclopropylmethyl, C 1 -C 4 alkoxy, CF 3 , amino, alkylamino, dialkylamino, thioalkyl, halogen, alkylsulfonyl and cyano.
[0022] In a further embodiment, X is 4-pyridinyl.
[0023] In another embodiment X is selected from restricted phenyl.
[0024] In a further embodiment, X is selected from a 3,4-disubstituted phenyl, 4-substituted phenyl. and 4-pyridinyl.
[0025] In a further embodiment, X is selected from a 3,4-disubstituted phenyl and 4-substituted phenyl.
[0026] In another embodiment, X is selected from 4-pyridinyl and 4-substituted phenyl.
[0027] In an additional embodiment, X is 4-substituted phenyl.
[0028] In a further embodiment, X is 4-methoxyphenyl.
[0029] In another embodiment, X is 4-chlorophenyl.
[0030] In another embodiment, X is 4-cyanophenyl.
[0031] In one embodiment, Z is heteroaryl but is not quinolinyl or pyridyl.
[0032] In one embodiment, Z is heteroaryl but is not quinolinyl.
[0033] In one embodiment, Z is heteroaryl but is not pyridyl.
[0034] In one embodiment, Z is not pyridin-2-yl.
[0035] In one embodiment, Z is not pyridinyl.
[0036] In another embodiment, Z is selected from pyridin-2-yl, imidazo[1,2-a]pyridin-2-yl, imidazo[1,2-b]pyridazin-2-yl, and imidazo[1,2-b]pyridazin-6-yl all of which may be optionally substituted with up to 2 substituents independently selected from C 1 -C 4 alkyl, cycloalkyl, cycloalkyloxy, C 1 -C 4 alkoxy, CF 3 , carboxy, alkoxyalkyl, C 1 -C 4 cycloalkylalkoxy, amino, alkylamino, dialkylamino, amido, alkylamido, dialkylamido, thioalkyl, halogen, cyano, alkylsulfonyl and nitro.
[0037] In a further embodiment, Z is selected from imidazo[1,2-a]pyridin-2-yl, imidazo[1,2-b]pyridazin-2-yl, and imidazo[1,2-b]pyridazin-6-yl all of which may be optionally substituted with up to 2 substituents independently selected from C 1 -C 4 alkyl, C 1 -C 4 alkoxy, C 3 -C 6 cycloalkyl, C 3 -C 6 cycloalkyloxy, cycloalkylalkyl, cycloalkylalkoxy, halogen, alkylsulfonyl and cyano.
[0038] In a further embodiment, Z is a 3,5-disubstituted-pyridin-2-yl with each substituent being independently selected from C 1 -C 4 alkyl, C 1 -C 4 alkoxy, C 3 -C 6 cycloalkyl, C 3 -C 6 cycloalkyloxy, cycloalkylalkyl, cycloalkylalkoxy, halogen, alkylsulfonyl and cyano.
[0000]
[0039] In a further embodiment, Z is 5-substituted-pyridin-2-yl with the substituent being independently selected from C 1 -C 4 alkyl, C 1 -C 4 alkoxy, C 3 -C 6 cycloalkyl, C 3 -C 6 cycloalkyloxy, cycloalkylalkyl, cycloalkylalkoxy, halogen, alkylsulfonyl and cyano.
[0000]
[0040] In an additional embodiment, Z is imidazo[1,2-a]pyridin-2-yl substituted with up to 2 substituents independently selected from C 1 -C 4 alkyl, C 1 -C 4 alkoxy, C 3 -C 6 cycloalkyl, C 3 -C 6 cycloalkyloxy, cycloalkylalkyl, cycloalkylalkoxy, halogen, alkylsulfonyl and cyano.
[0041] In an additional embodiment, Z is imidazo[1,2-b]pyridazin-2-yl substituted with up to 2 substituents independently selected from C 1 -C 4 alkyl, C 1 -C 4 alkoxy, C 3 -C 6 cycloalkyl, C 3 -C 6 cycloalkyloxy, cycloalkylalkyl, cycloalkylalkoxy, halogen, alkylsulfonyl and cyano.
[0042] In an additional embodiment, Z is imidazo[1,2-b]pyridazin-6-yl substituted with up to 2 substituents independently selected from C 1 -C 4 alkyl, C 1 -C 4 alkoxy, C 3 -C 6 cycloalkyl, C 3 -C 6 cycloalkyloxy, cycloalkylalkyl, cycloalkylalkoxy, halogen, alkylsulfonyl and cyano.
[0043] In a further embodiment, any Z substituent may be unsubstituted.
[0044] In one embodiment, R 2 is C 1 -C 4 alkyl.
[0045] In another embodiment, R 2 is methyl.
[0046] In another embodiment, two R 2 groups taken together form a 3 membered cycloalkyl ring.
[0047] Compounds of the disclosure may contain asymmetric centers and exist as different enantiomers or diastereomers or a combination of these therein. All enantiomeric, diastereomeric forms of Formula (I) are embodied herein.
[0048] Compounds in the disclosure may be in the form of pharmaceutically acceptable salts. The phrase “pharmaceutically acceptable” refers to salts prepared from pharmaceutically acceptable non-toxic bases and acids, including inorganic and organic bases and inorganic and organic acids. Salts derived from inorganic bases include lithium, sodium, potassium, magnesium, calcium and zinc. Salts derived from organic bases include ammonia, primary, secondary and tertiary amines, and amino acids. Salts derived from inorganic acids include sulfuric, hydrochloric, phosphoric, hydrobromic. Salts derived from organic acids include C 1-6 alkyl carboxylic acids, di-carboxylic acids and tricarboxylic acids such as acetic acid, proprionic acid, fumaric acid, maleic acid, succinic acid, tartaric acid, adipic acid and citric acid, and alkylsulfonic acids such as methanesulphonic, and aryl sulfonic acids such as para-tolouene sulfonic acid and benzene sulfonic acid.
[0049] Compounds in the disclosure may be in the form of a solvate. This occurs when a compound of Formula (I) has an energetically favorable interaction with a solvent, crystallizes in a manner that it incorporates solvent molecules into the crystal lattice or a complex is formed with solvent molecules in the solid or liquid state. Examples of solvents forming solvates are water (hydrates), MeOH, EtOH, iPrOH, and acetone.
[0050] Compounds in the disclosure may exist in different crystal forms known as polymorphs. Polymorphism is the ability of a substance to exist in two or more crystalline phases that have different arrangements and/or conformations of the molecule in the crystal lattice.
[0051] Compounds in the disclosure may exist as isotopically labeled compounds of Formula (I) where one or more atoms are replaced by atoms having the same atomic number but a different atomic mass from the atomic mass which is predominantly seen in nature. Examples of isotopes include, but are not limited to hydrogen isotopes (deuterium, tritium), carbon isotopes ( 11 C, 13 C, 14 C) and nitrogen isotopes ( 13 N, 15 N). For example, substitution with heavier isotopes such as deuterium ( 2 H) may offer certain therapeutic advantages resulting from greater metabolic stability which could be preferable and lead to longer in vivo half-life or dose reduction in a mammal or human.
[0052] Prodrugs of compounds embodied by Formula (I) are also within the scope of this disclosure. Particular derivatives of compounds of Formula (I) which may have little to negligible pharmacological activity themselves, can, when administered to a mammal or human, be converted into compounds of Formula (I) having the desired biological activity.
[0053] Compounds in the disclosure and their pharmaceutically acceptable salts, prodrugs, as well as metabolites of the compounds, may also be used to treat certain eating disorders, obesity, compulsive gambling, sexual disorders, narcolepsy, sleep disorders, diabetes, metabolic syndrome, neurodegenerative disorders and CNS disorders/conditions as well as in smoking cessation treatment.
[0054] In one embodiment the treatment of CNS disorders and conditions by the compounds of the disclosure can include Huntington's disease, schizophrenia and schizo-affective conditions, delusional disorders, drug-induced psychoses, panic and obsessive compulsive disorders, post-traumatic stress disorders, age-related cognitive decline, attention deficit/hyperactivity disorder, bipolar disorders, personality disorders of the paranoid type, personality disorders of the schizoid type, psychosis induced by alcohol, amphetamines, phencyclidine, opioids hallucinogens or other drug-induced psychosis, dyskinesia or choreiform conditions including dyskinesia induced by dopamine agonists, dopaminergic therapies, psychosis associated with Parkinson's disease, psychotic symptoms associated with other neurodegenerative disorders including Alzheimer's disease, dystonic conditions such as idiopathic dystonia, drug-induced dystonia, torsion dystonia, and tardive dyskinesia, mood disorders including major depressive episodes, post-stroke depression, minor depressive disorder, premenstrual dysphoric disorder, dementia including but not limited to multi-infarct dementia, AIDS-related dementia, and neurodegenerative dementia.
[0055] In another embodiment, compounds of the disclosure may be used for the treatment of eating disorders, obesity, compulsive gambling, sexual disorders, narcolepsy, sleep disorders as well as in smoking cessation treatment.
[0056] In a further embodiment, compounds of the disclosure may be used for the treatment of obesity, schizophrenia, schizo-affective conditions, Huntington's disease, dystonic conditions and tardive dyskinesia.
[0057] In another embodiment, compounds of the disclosure may be used for the treatment of schizophrenia, schizo-affective conditions, Huntington's disease and obesity.
[0058] In a further embodiment, compounds of the disclosure may be used for the treatment of schizophrenia and schizo-affective conditions.
[0059] In an additional embodiment, compounds of the disclosure may be used for the treatment of Huntington's disease.
[0060] In another embodiment, compounds of the disclosure may be used for the treatment of obesity and metabolic syndrome.
[0061] Compounds of the disclosure may also be used in mammals and humans in conjuction with conventional antipsychotic medications including but not limited to Clozapine, Olanzapine, Risperidone, Ziprasidone, Haloperidol, Aripiprazole, Sertindole and Quetiapine. The combination of a compound of Formula (I) with a subtherapeutic dose of an aforementioned conventional antipsychotic medication may afford certain treatment advantages including improved side effect profiles and lower dosing requirements.
DEFINITIONS
[0062] Alkyl is meant to denote a linear or branched saturated or unsaturated aliphatic C 1 -C 8 hydrocarbon which can be optionally substituted with up to 3 fluorine atoms and, if specified, substituted with other groups. Unsaturation in the form of a double or triple carbon-carbon bond may be internal or terminally located and in the case of a double bond both cis and trans isomers are included. Examples of alkyl groups include but are not limited to methyl, trifluoromethyl, ethyl, trifluoroethyl, isobutyl, neopentyl, cis- and trans-2-butenyl, isobutenyl, propargyl. C 1 -C 4 alkyl is the subset of alkyl limited to a total of up to 4 carbon atoms.
[0063] In each case in which a size range for the number of atoms in a ring or chain is disclosed, all subsets are disclosed. Thus, C x -C y includes all subsets, e.g., C 1 -C 4 includes C 1 -C 2 , C 2 -C 4 , C 1 -C 3 etc.
[0064] Acyl is an alkyl-C(O)— group wherein alkyl is as defined above. Examples of acyl groups include acetyl and proprionyl.
[0065] Alkoxy is an alkyl-O— group wherein alkyl is as defined above. C 1 -C 4 alkoxy is the subset of alkyl-O— where the subset of alkyl is limited to a total of up to 4 carbon atoms. Examples of alkoxy groups include methoxy, trifluoromethoxy, ethoxy, trifluoroethoxy, and propoxy.
[0066] Alkoxyalkyl is an alkyl-O—(C 1 -C 4 alkyl)- group wherein alkyl is as defined above. Examples of alkoxyalkyl groups include methoxymethyl and ethoxymethyl.
[0067] Alkoxyalkyloxy is an alkoxy-alkyl-O— group wherein alkoxy and alkyl are as defined above. Examples of alkoxyalkyloxy groups include methoxymethyloxy (CH 3 OCH 2 O—) and methoxyethyloxy (CH 3 OCH 2 CH 2 O—) groups.
[0068] Alkylthio is alkyl-S— group wherein alkyl is as defined above. Alkylthio includes C 1 -C 4 alkylathio.
[0069] Alkylsulfonyl is alkyl-SO 2 — wherein alkyl is as defined above. Alkylsulfonyl includes C 1 -C 4 alkylsulfonyl.
[0070] Alkylamino is alkyl-NH— wherein alkyl is as defined above. Alkylamino includes C 1 -C 4 alkylamino.
[0071] Dialkylamino is (alkyl) 2 -N— wherein alkyl is as defined above.
[0072] Amido is H 2 NC(O)—.
[0073] Alkylamido is alkyl-NHC(O)— wherein alkyl is as defined above.
[0074] Dialkylamido is (alkyl) 2 -NC(O)— wherein alkyl is as defined above.
[0075] Aromatic is heteroaryl or aryl wherein heteroaryl and aryl are as defined below.
[0076] Aryl is a phenyl or napthyl group. Aryl groups may be optionally and independently substituted with up to three groups selected from halogen, CF 3 , CN, NO 2 , OH, alkyl, cycloalkyl, cycloalkylalkyl, alkoxy, alkoxyalkyl, aryloxy, alkoxyalkyloxy, heterocycloalkyl, heterocycloalkylalkyl, heterocycloalkyloxy, heteroaryl, heteroaryloxy, —OCH 2 CH 2 OCH 3 , —OC(O)R a , —OC(O)OR a , —OC(O)NHR a , —OC(O)N(R a ), —SR a , —S(O)R a , —NH 2 , —NHR a , —N(R a )(R b ), —NHC(O)R a , —N(R a )C(O)R b , —NHC(O)OR a , —N(R a )C(O)OR b , —N(R a )C(O)NH(R b ), —N(R a )C(O)NH(R b ) 2 , —C(O)NH 2 , —C(O)NHR a , —C(O)N(R a )(R b ), —CO 2 H, —CO 2 R a , —COR a wherein R a and R b are independently chosen from alkyl, alkoxyalkyl, —CH 2 CH 2 OH, —CH 2 CH 2 OMe, cycloalkyl, cycloalkylalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocycloalkyl, and heterocycloalkylalkyl, each of which is optionally and independently substituted with up to three groups selected from only halogen, Me, Et, i Pr, t Bu, unsubstituted cyclopropyl, unsubstituted cyclobutyl, CN, NO 2 , NH 2 , CF 3 , NHMe, NMe 2 , OMe, OCF 3 , each of which are attached via carbon-carbon or carbon-nitrogen or carbon-oxygen single bonds; or R a and R b taken together with the atom(s) to which they are attached form a 5-6 membered ring.
[0077] Arylalkyl is an aryl-alkyl- group wherein aryl and alkyl are as defined above.
[0078] Aryloxy is an aryl-O— group wherein aryl is as defined above.
[0079] Arylalkoxy is an aryl-(C 1 -C 4 alkyl)-O— group wherein aryl is as defined above.
[0080] Carboxy is a CO 2 H or CO 2 R c group wherein R c is independently chosen from, alkyl, C 1 -C 4 alkyl, cycloalkyl, arylalkyl, cycloalkylalkyl, CF 3 , and alkoxyalkyl, wherein alkyl is as defined above.
[0081] Cycloalkyl is a C 3 -C 7 cyclic non-aromatic hydrocarbon which may contain a single double bond and is optionally and independently substituted with up to three groups selected from alkyl, alkoxy, hydroxyl and oxo. Examples of cycloalkyl groups include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cyclopentenyl and cyclohexanonyl.
[0082] Cycloalkyloxy is a cycloalkyl-O— group wherein cycloalkyl is as defined above. Examples include cyclopropyloxy, cyclobutyloxy and cyclopentyloxy. C 3 -C 6 cycloalkyloxy is the subset of cycloalkyl-O— where cycloalkyl contains 3-6 carbon atoms.
[0083] Cycloalkylalkyl is a cycloalkyl-(C 1 -C 4 alkyl)- group. Examples include cyclopropylmethyl, cyclopropylethyl, cyclohexylmethyl and cyclohexylethyl.
[0084] Cycloalkylalkoxy is a cycloalkyl-(C 1 -C 4 alkyl)-O— group wherein cycloalkyl and alkyl are as defined above. Examples of cycloalkylalkoxy groups include cyclopropylmethoxy, cyclopentylmethoxy and cyclohexylmethoxy.
[0085] Halogen is F, Cl, Br or I.
[0086] Heteroaryl is a tetrazole, 1,2,3,4-oxatriazole, 1,2,3,5-oxatriazole, a mono or bicyclic aromatic ring system, or a heterobicyclic ring system with one aromatic ring having 5 to 10 ring atoms independently selected from C, N, O and S, provided that not more than 3 ring atoms in any single ring are other than C. Examples of heteroaryl groups include but are not limited to thiophenyl, furanyl, thiazolyl, isothiazolyl, oxazolyl, isoxazolyl, 1,2,4-oxadiazolyl, 1,3,4-oxadiazolyl, pyrrazolyl, imidazolyl, 1,2,3-triazolyl, 1,3,4-triazolyl, pyrimidinyl, pyrazinyl, indolyl, quinolyl, tetrahydroquinolyl, isoquinolyl, tetrahydroisoquinolyl, indazolyl, benzthiadiazololyl, benzoxadiazolyl and benzimidazolyl. Heteroaryl groups may be optionally and independently substituted with up to 3 substituents independently selected from halogen, CF 3 , CN, NO 2 , OH, alkyl, cycloalkyl, cycloalkylalkyl, alkoxy, alkoxyalkyl, aryloxy, alkoxyalkyloxy, heterocycloalkyl, heterocycloalkylalkyl, heterocycloalkyloxy, heteroaryl, heteroaryloxy, —OCH 2 CH 2 OCH 3 , —OC(O)R a , —OC(O)OR a , —OC(O)NHR a , —OC(O)N(R a ), —SR a , —S(O)R a , —NH 2 , —NHR a , —N(R a )(R b ), —NHC(O)R a , —N(R a )C(O)R b , —NHC(O)OR a , —N(R a )C(O)OR b , —N(R a )C(O)NH(R b ), —N(R a )C(O)NH(R b ) 2 , —C(O)NH 2 , —C(O)NHR a , —C(O)N(R a )(R b ), —CO 2 H, —CO 2 R a , —COR a wherein R a and R b are independently chosen from alkyl, alkoxyalkyl, —CH 2 CH 2 OH, —CH 2 CH 2 OMe, cycloalkyl, cycloalkylalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocycloalkyl, and heterocycloalkylalkyl, each of which is optionally and independently substituted with up to three groups selected from only halogen, Me, Et, i Pr, t Bu, unsubstituted cyclopropyl, unsubstituted cyclobutyl, CN, NO 2 , NH 2 , CF 3 , NHMe, NMe 2 , OMe, OCF 3 , each of which are attached via carbon-carbon or carbon-nitrogen or carbon-oxygen single bonds; or R a and R b taken together with the atom(s) to which they are attached form a 5-6 membered ring.
[0087] Heteroarylalkyl is a heteroaryl-(C 1 -C 4 alkyl)- group wherein heteroaryl and alkyl are as defined above. Examples of heteroarylalkyl groups include 4-pyridinylmethyl and 4-pyridinylethyl.
[0088] Heteroaryloxy is a heteroaryl-O group wherein heteroaryl is as defined above.
[0089] Heteroarylalkoxy is a heteroaryl-(C 1 -C 4 alkyl)-O— group wherein heteroaryl and alkoxy are as defined above. Examples of heteroarylalkyl groups include 4-pyridinylmethoxy and 4-pyridinylethoxy.
[0090] Heterobicyclic ring system is a ring system having 8-10 atoms independently selected from C, N, O and S, provided that not more than 3 ring atoms in any single ring are other than carbon and provided that at least one of the rings is aromatic; said bicyclic ring may be optionally and independently substituted with up to 3 substituents independently selected from alkyl, alkoxy, cycloalkyl, C 3 -C 6 cycloalkyloxy, cycloalkylalkyl, halogen, nitro, alkylsulfonyl and cyano. Examples of 8-10 membered heterobicyclic ring systems include but are not limited to 1,5-naphthyridyl, 1,2,3,4-tetrahydro-1,5-naphthyridyl 1,6-naphthyridyl, 1,2,3,4-tetrahydro-1,6-naphthyridyl 1,7-naphthyridyl, 1,2,3,4-tetrahydro-1,7-naphthyridinyl 1,8-naphthyridyl, 1,2,3,4-tetrahydro-1,8-naphthyridyl, 2,6-naphthyridyl, 2,7-naphthyridyl, cinnolyl, isoquinolyl, tetrahydroisoquinolinyl, phthalazyl, quinazolyl, 1,2,3,4-tetrahydroquinazolinyl, quinolyl, tetrahydroquinolinyl, quinoxalyl, tetrahydroquinoxalinyl, benzo[d][1,2,3]triazyl, benzo[e][1,2,4]triazyl, pyrido[2,3-b]pyrazyl, pyrido[2,3-c]pyridazyl, pyrido[2,3-d]pyrimidyl, pyrido[3,2-b]pyrazyl, pyrido[3,2-c]pyridazyl, pyrido[3,2-c]pyrimidyl, pyrido[3,4-b]pyrazyl, pyrido[3,4-c]pyridazyl, pyrido[3,4-d]pyrimidyl, pyrido[4,3-b]pyrazyl, pyrido[4,3-c]pyridazyl, pyrido[4,3-c]pyrimidyl, quinazolyl, 1H-benzo[d][1,2,3]triazoyl, 1H-benzo[d]imidazoyl, 1H-indazoyl, 1H-indoyl, 2H-benzo[d][1,2,3]triazoyl, 2H-pyrazolo[3,4-b]pyridinyl, 2H-pyrazolo[4,3-b]pyridinyl, [1,2,3]triazolo[1,5-a]pyridinyl, [1,2,4]triazolo[1,5-a]pyridinyl, [1,2,4]triazolo[4,3-a]pyridinyl, benzo[b]thienyl, benzo[c][1,2,5]oxadiazyl, benzo[c][1,2,5]thiadiazolyl, benzo[d]isothiazoyl, benzo[d]isoxazoyl, benzo[d]oxazoyl, benzo[d]thiazoyl, benzofuryl, imidazo[1,2-a]pyrazyl, imidazo[1,2-a]pyridinyl, imidazo[1,2-a]pyrimidyl, imidazo[1,2-b]pyridazyl, imidazo[1,2-c]pyrimidyl, imidazo[1,5-a]pyrazyl, imidazo[1,5-a]pyridinyl, imidazo[1,5-a]pyrimidyl, imidazo[1,5-b]pyridazyl, imidazo[1,5-c]pyrimidyl, indolizyl, pyrazolo[1,5-a]pyrazyl, pyrazolo[1,5-a]pyridinyl, pyrazolo[1,5-a]pyrimidyl, pyrazolo[1,5-b]pyridazine, pyrazolo[1,5-c]pyrimidine, pyrrolo[1,2-a]pyrazine, pyrrolo[1,2-a]pyrimidyl, pyrrolo[1,2-b]pyridazyl, pyrrolo[1,2-c]pyrimidyl, 1H-imidazo[4,5-b]pyridinyl, 1H-imidazo[4,5-c]pyridinyl, 1H-pyrazolo[3,4-b]pyridinyl, 1H-pyrazolo[3,4-c]pyridinyl, 1H-pyrazolo[4,3-b]pyridinyl, 1H-pyrazolo[4,3-c]pyridinyl, 1H-pyrrolo[2,3-b]pyridinyl, 1H-pyrrolo[2,3-c]pyridinyl, 1H-pyrrolo[3,2-b]pyridinyl, 1H-pyrrolo[3,2-c]pyridinyl, 2H-indazoyl, 3H-imidazo[4,5-b]pyridinyl, 3H-imidazo[4,5-c]pyridinyl, benzo[c]isothiazyl, benzo[c]isoxazyl, furo[2,3-b]pyridinyl, furo[2,3-c]pyridinyl, furo[3,2-b]pyridinyl, furo[3,2-c]pyridinyl, isothiazolo[4,5-b]pyridinyl, isothiazolo[4,5-c]pyridinyl, isothiazolo[5,4-b]pyridinyl, isothiazolo[5,4-c]pyridinyl, isoxazolo[4,5-b]pyridinyl, isoxazolo[4,5-c]pyridinyl, isoxazolo[5,4-b]pyridinyl, isoxazolo[5,4-c]pyridinyl, oxazolo[4,5-b]pyridinyl, oxazolo[4,5-c]pyridinyl, oxazolo[5,4-b]pyridinyl, oxazolo[5,4-c]pyridinyl, thiazolo[4,5-b]pyridiyl, thiazolo[4,5-c]pyridinyl, thiazolo[5,4-b]pyridinyl, thiazolo[5,4-c]pyridinyl, thieno[2,3-b]pyridinyl, thieno[2,3-c]pyridinyl, thieno[3,2-b]pyridinyl and thieno[3,2-c]pyridinyl.
[0091] Heterocycloalkyl is a non-aromatic, monocyclic or bicyclic saturated or partially unsaturated ring system comprising 5-10 ring atoms selected from C, N, O and S, provided that not more than 2 ring atoms in any single ring are other than C. In the case where the heterocycloalkyl group contains a nitrogen atom the nitrogen may be substituted with an alkyl, acyl, —C(O)O-alkyl, —C(O)NH(alkyl) or a —C(O)N(alkyl) 2 group. Heterocycloalkyl groups may be optionally and independently substituted with hydroxy, alkyl and alkoxy groups and may contain up to two oxo groups. Heterocycloalkyl groups may be linked to the rest of the molecule via either carbon or nitrogen ring atoms. Examples of heterocycloalkyl groups include tetrahydrofuranyl, tetrahydrothienyl, tetrahydro-2H-pyran, tetrahydro-2H-thiopyranyl, pyrrolidinyl, pyrrolidonyl, succinimidyl, piperidinyl, piperazinyl, N-methylpiperazinyl, morpholinyl, morpholin-3-one, thiomorpholinyl, thiomorpholin-3-one, 2,5-diazabicyclo[2.2.2]octanyl, 2,5-diazabicyclo[2.2.1]heptanyl, octahydro-1H-pyrido[1,2-a]pyrazine, 3-thia-6-azabicyclo[3.1.1]heptane and 3-oxa-6-azabicyclo[3.1.1]heptanyl.
[0092] Heterocycloalkylalkyl is a heterocycloalkyl-(C 1 -C 4 alkyl)- group wherein heterocycloalkyl is as defined above.
[0093] Heterocycloalkyloxy is a heterocycloalkyl-O— group wherein heterocycloalkyl is as defined above.
[0094] Heterocycloalkylalkoxy is a heterocycloalkyl-(C 1 -C 4 alkyl)-O— group wherein heterocycloalkyl is as defined above.
[0095] Oxo is a —C(O)— group.
[0096] Phenyl is a benzene ring which may be optionally and independently substituted with up to three groups selected from halogen, CF 3 , CN, NO 2 , OH, alkyl, cycloalkyl, cycloalkylalkyl, alkoxy, alkoxyalkyl, aryloxy, alkoxyalkyloxy, heterocycloalkyl, heterocycloalkylalkyl, heterocycloalkyloxy, heteroaryl, heteroaryloxy, —OCH 2 CH 2 OCH 3 , —OC(O)R a , —OC(O)OR a , —OC(O)NHR a , —OC(O)N(R a ), —SR a , —S(O)R a , —NH 2 , —NHR a , —N(R a )(R b ), —NHC(O)R a , —N(R a )C(O)R b , —NHC(O)OR a , —N(R a )C(O)OR b , —N(R a )C(O)NH(R b ), —N(R a )C(O)NH(R b ) 2 , —C(O)NH 2 , —C(O)NHR a , —C(O)N(R a )(R b ), —CO 2 H, —CO 2 R a , —COR a wherein R a and R b are independently chosen from alkyl, alkoxyalkyl, —CH 2 CH 2 OH, —CH 2 CH 2 OMe, cycloalkyl, cycloalkylalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocycloalkyl, and heterocycloalkylalkyl, each of which is optionally and independently substituted with up to three groups selected from only halogen, Me, Et, i Pr, t Bu, unsubstituted cyclopropyl, unsubstituted cyclobutyl, CN, NO 2 , NH 2 , CF 3 , NHMe, NMe 2 , OMe, OCF 3 , each of which are attached via carbon-carbon or carbon-nitrogen or carbon-oxygen single bonds; or R a and R b taken together with the atom(s) to which they are attached form a 5-6 membered ring.
[0097] Restricted phenyl is a benzene ring which may be optionally and independently substituted with up to three groups selected from halogen, CF 3 , CN, alkoxy, alkoxyalkyl, aryloxy, alkoxyalkyloxy, heterocycloalkyl, heterocycloalkyloxy, heteroaryl, heteroaryloxy, —OCH 2 CH 2 OCH 3 , —OC(O)R a , —OC(O)OR a , —OC(O)N(R a ), —N(R a )(R b ), —NHC(O)R a , —N(R a )C(O)R b , —NHC(O)OR a , —N(R a )C(O)OR b , —C(O)N(R a )(R b ), —COR a wherein R a and R b are independently chosen from alkyl, alkoxyalkyl, —CH 2 CH 2 OH, —CH 2 CH 2 OMe, cycloalkyl, cycloalkylalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocycloalkyl, and heterocycloalkylalkyl, each of which is optionally and independently substituted with up to three groups selected from only halogen, Me, Et, i Pr, t Bu, unsubstituted cyclopropyl, unsubstituted cyclobutyl, CN, NO 2 , NH 2 , CF 3 , NHMe, NMe 2 , OMe, OCF 3 , each of which are attached via carbon-carbon or carbon-nitrogen or carbon-oxygen single bonds; or R a and R b taken together with the atom(s) to which they are attached form a 5-6 membered ring.
[0098] Abbreviations used in the following examples and preparations include:
Ac Acyl (Me-C(O)—) AcN Acetonitrile BINAP 2,2′-bis(diphenylphosphino)-1,1′-binaphthyl Bn Benzyl Celite® Diatomaceous earth DBU 1,8-Diazabicyclo[5.4.0]undec-7-ene DCC N,N′, Dicyclohexylcarbodiimide DCM Dichloromethane DIEA Di-isopropylethyl amine DIPEA Di-isopropylethyl amine DMAP 4-Dimethylaminopyridine DMF Dimethylformamide DMP Dess Martin Periodinane DMSO Dimethyl sulfoxide Dppf 1,4-Bis(diphenylphosphino) ferrocene EDC 1-(3-Dimethylaminopropyl)-3-ethylcarbodiimide Hydrochloride Et 3 N Triethylamine g gram(s) h Hour(s) hr Hour(s) HATU 2-(7-Aza-1H-benzotriazole-1-yl)-1,1,3,3-tetramethyluronium hexafluorophosphate HMDS Hexamethyldisilazide HOBt 1-Hydroxybenzotriazole HPLC High Pressure Liquid Chromatography HRMS High resolution mass spectrometry i.v. Intravenous KHMDS Potassium Hexamethydisilazide LDA Lithium Di-isopropylamide m Multiplet m- meta MEM Methoxyethoxymethyl MeOH Methyl Alcohol or Methanol min Minute(s) mmol millimoles mmole millimoles Ms Mesylate MS Mass Spectrometry MW Molecular Weight NBS N-Bromosuccinamide NIS N-Iodosuccinamide NMR Nuclear Magnetic Resonance NMM N-Methyl Morpholine NMP N-Methyl-2-pyrrolidone o ortho o/n overnight p para PCC Pyridinium Chlorochromate PEPPSI 1,3-Bis(2,6-diisopropylphenyl)imidazolidene)(3-chloropyridinyl) palladium(II)dichloride PhNTf 2 1,1,1-trifluoro-N-phenyl-N-(trifluoromethylsulfonyl)methanesulfonamide POPd Dihydrogen dichlorobis(di-tert-butylphosphinito-kp) palladate (2-) p.s.i. Pounds per square inch PPA Polyphosphoric acid PPAA 1-Propanephosphonic Acid Cyclic Anhydride PTSA p-Toluenesulfonic acid PyBOP® Benzotriazol-1-yl-oxytripyrrolidinophosphonium hexafluorophosphate RT (or rt) room temperature (about 20-25° C.) s Singlet sat. Saturated t Triplet TBAF Tetra-butyl ammonium fluoride TEA Triethylamine TFA Trifluoroacetic Acid THF Tetrahydrofuran TLC Thin layer chromatography TMS Trimethylsilyl Tf Triflate Tof-MS Time of Flight Mass Spectrometry Ts Tosylate v/v volume/volume wt/v weight/volume
DETAILED DESCRIPTION
[0169] The 1,2 disubstituted heterocyclic compounds of Formula I may be prepared from multi-step organic synthesis routes from commercially available starting materials by one skilled in the art of organic synthesis using established organic synthetic procedures. Non-commercially available phenyl acetic acids can be made from commercially available starting materials via methods known by one skilled in the art of organic synthesis. Such methods include synthesis from the corresponding aryl acids via. the Wolff rearrangement using diazomethane.
[0170] Compounds of the disclosure where HET is A29 and A31 may be prepared generally as depicted in Schemes 1-8 below.
[0171] Compounds of the disclosure of Formula (I) wherein HET is A29 and X=phenyl or heteroaryl (each respectively optionally substituted) thus having general Formula LIV may be prepared generally as depicted in Scheme 1:
[0000]
[0172] Alternatively, compounds of the disclosure of Formula (I) wherein HET is A29 and X=phenyl or heteroaryl (each respectively optionally substituted) and thus having general Formula LIV may also be prepared generally as depicted in Scheme 2:
[0000]
[0173] Intermediate compounds of Formula LXIII may alternatively be synthesized as depicted in Scheme 3.
[0000]
[0174] Compounds of the disclosure of Formula (I) wherein HET is A31 and X=phenyl or heteroaryl (each optionally substituted) are as described previously and thus having general Formula LXXIV may be prepared generally as depicted in Scheme 4:
[0000]
[0175] The general synthesis of heterocyclic chloride intermediates (Z—CH 2 —Cl) where Z corresponds to an imidazo[1,2-a]pyrid-2-yl is depicted in Scheme 5.
[0000]
[0176] The general synthesis of heterocyclic chloride intermediates (Z—CH 2 —Cl) where Z corresponds to an imidazo[1,2-b]pyridazin-6-yl is depicted in Scheme 6.
[0000]
[0177] The general synthesis of heterocyclic chloride intermediates (Z—CH 2 —Cl) where Z corresponds to an imidazo[1,2-b]pyridazin-2-yl is depicted in Scheme 7.
[0000]
[0178] The general synthesis of heterocyclic chloride intermediates (Z—CH 2 —Cl) where Z corresponds to either a 5-substituted-pyridin-2-yl or a 3,5-disubstituted-1pyridin-2-yl is depicted in Scheme 8.
[0000]
[0179] Reactive groups not involved in the above processes can be protected with standard protecting groups during the reactions and removed by standard procedures (T. W. Greene & P. G. M. Wuts, Protecting Groups in Organic Synthesis, Third Edition, Wiley-Interscience) known to those of ordinary skill in the art. Presently preferred protecting groups include methyl, benzyl, MEM, acetate and tetrahydropyranyl for the hydroxyl moiety, and BOC, Cbz, trifluoroacetamide and benzyl for the amino moiety, methyl, ethyl, tert-butyl and benzyl esters for the carboxylic acid moiety. Practitoners in the art will also recognize that the order of certain chemical reactions can be changed. Practitioners of the art will also note that alternative reagents and conditions exist for various chemical steps.
Experimental Procedures
[0180] The synthesis of N-methoxy-N-methylcarboxamides from their corresponding carboxylic acids is known by those of ordinary skill in the art. A representative procedure is described below, where is selected from
[0000]
[0181] To a stirred solution of carboxylic acid (1 eq., 3 mmol) in DCM (50 mL) was added HATU (1.5 eq, 4.5 mmol), N-methoxy methylamine (1.5 eq, 4.5 mmol) and TEA (3 eq., 9 mmol) at RT under nitrogen atmosphere. The reaction mixture was then stirred at RT for 3 h. The reaction mixture was diluted with water and the aqueous layer was extracted with DCM (3×50 mL). The combined organic extracts were washed with water (50 mL), brine (20 mL), dried over anhydrous Na 2 SO 4 , filtered and evaporated under reduced pressure to afford the corresponding N-methoxy-N-methylcarboxamide.
HPLC Conditions
[0182] Condition-A:
[0183] Column: Acquity BEH C-18 (50×2.1 mm, 1.7μ,)
[0184] Column Temp: 25° C.
[0185] Mobile Phase A/B: Acetonitrile (0.025% TFA) and water
[0186] Flow Rate: 0.50 mL/Min
4-(5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile
[0187]
[0188] To a suspension of NaH (0.9 g) in THF at RT was added 3-hydroxy-3-methyl-2-butanone (1 g) and ethyl methyl 4-cyanobenzoate (1.58 g). The resultant mixture was refluxed overnight, upon which the reaction was quenched with 12N HCl (6 mL). MgSO4 (excess) was added until the organic phase became clear. The solids were removed by filtration and the filtrate was concentrated under reduced pressure. The residue was purified by column chromatography to give 4-(5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile (0.63 g).
Synthesis of 4-(4-Hydroxyphenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one
4-Methoxy-N-methoxy-N-methylbenzamide
[0189]
[0190] To a stirred solution of 4-methoxybenzoic acid (10.0 g, 65.70 mmol) in DCM (50 mL) were added EDCI (18.90 g, 98.60 mmol), HOBT (10.0 g, 65.70 mmol), N-methoxy methylamine (13.0 g, 131.40 mmol) and DIPEA (34.3 mL, 197.20 mmol) at RT under a nitrogen atmosphere. The reaction mixture was stirred at RT for 12 h. The reaction mixture was diluted with water and the aqueous layer was extracted with DCM (3×100 mL). The combined organic extracts were washed with water (2×100 mL), brine (2×50 mL), dried over anhydrous Na 2 SO 4 , filtered and evaporated under reduced pressure to afford crude product. The crude material was purified by flash column chromatography using 20% ethyl acetate in hexane and silica gel (230-400 Mesh) to afford N,4-dimethoxy-N-methylbenzamide (11.0 g, 86%) as a colorless liquid.
4-Hydroxy-1-(4-methoxyphenyl)-4-methylpent-2-yn-1-one
[0191]
[0192] To a stirred solution of 2-methylbut-3-yn-2-ol (2.15 g, 25.6 mmol) in dry THF (80 mL) was added n-BuLi (24.0 mL, 38.7 mmol, 1.6 M in hexane) drop wise at −20° C. under an inert atmosphere for a period of 10 min. After being stirred for 30 min at −20° C., a solution of N,4-dimethoxy-N-methylbenzamide (2.5 g, 12.8 mmol) in dry THF (10 mL) was added to reaction mixture and stirring was continued for an additional 3 h at −20° C. The reaction mixture was quenched with a saturated NH 4 Cl solution and extracted with EtOAc (2×100 mL). The combined organic layer was washed with water (100 mL), brine (40 mL), dried over Na 2 SO 4 , filtered and concentrated in vacuo to afford 4-hydroxy-1-(4-methoxyphenyl)-4-methylpent-2-yn-1-one (2.25 g, 81%) as a colorless liquid.
5-(4-Methoxyphenyl)-2,2-dimethylfuran-3(2H)-one
[0193]
[0194] To 4-hydroxy-1-(4-methoxyphenyl)-4-methylpent-2-yn-1-one (10 g, 45.8 mmol) was added methanolic ammonia (50 mL) at room temperature and the reaction mixture was stirred overnight. The mixture was concentrated under reduced pressure and 50% aqueous acetic acid was added. The resultant mixture was heated at reflux for 4 hours. The pH was adjusted to 8 with saturated ammonium chloride solution and extracted with DCM. The combined organics were washed with water and brine solution, dried over sodium sulphate, filtered, concentrated under reduced pressure and washed with heptane to afford 5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (8.6 g, 86%) as white solid. 1 H NMR (500 MHz, d 6 -DMSO): δ 7.99 (d, 2H), 7.15 (d, 2H), 6.20 (s, 1H), 3.89 (s, 3H). 1.42 (s, 6H). MS: [M+H]+: m/z=218.1.
4-Bromo-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one
[0195]
[0196] To a stirred solution of 5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (5.5 g, 0.025 mol) in CHCl 3 (100 mL) was added NBS (6.733 g, 0.038 mol) portion wise at RT. The reaction mixture was stirred for 2 h at RT. The reaction mixture was diluted with DCM (100 mL), washed with water (50 mL), brine (50 mL), dried over Na 2 SO 4 , filtered and then concentrated in vacuo to obtain the crude product. The crude material was purified via by flash column chromatography using 25% ethyl acetate in hexane and silica gel (230-400 Mesh) to afford 4-bromo-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (4.6 g, 65%) as a solid.
4-(4-(Benzyloxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one
[0197]
[0198] 4-Bromo-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (2 g, 6.7 mol), 2-(4-(benzyloxy)phenyl)-4,4,5,5-tetramethyl-1,3,2-dioxaborolane (2.43 g, 0.0067 mol), and Cs 2 CO 3 (11 g, 0.034 mol) in toluene (25 mL) and water (8 mL) was degassed, Pd (dppf) Cl 2 (1.1 g, 0.0013 mol) was added under an inert atmosphere and the mixture degassed once again. The reaction was heated at reflux for 3 h, upon which the reaction mixture was filtered through a pad of Celite® and the filtrate was diluted with EtOAc (100 mL), washed with water (50 mL), brine (50 mL), dried over Na 2 SO 4 , filtered and concentrated in vacuo to obtain the crude product. The crude material was purified by flash column chromatography using 30% ethyl acetate in hexane and silica gel (230-400 Mesh), Rf=0.30 to afford 4-(4-(benzyloxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (2.3 g, 73%) as solid. 1 H NMR (500 MHz, d 6 -DMSO): δ 8.42 (d, J=7.6 Hz, 1H), 8.06-7.99 (m, 2H), 7.95 (t, J=7.2 Hz, 1H), 7.72 (t, J=7.2 Hz, 1H), 7.63 (t, J=7.8 Hz, 1H), 7.56 (d, J=7.2 Hz, 2H); 7.18 (d, J=7.4 Hz, 2H), 7.12 (d, J=7.2 Hz, 2H), 6.89 (d, J=7.2 Hz, 2H), 5.38 (s, 2H), 3.79 (s, 3H). 1.42 (s, 6H). MS: [M+H]+: m/z=452.1; [M+Na]+: m/z=474.2.
4-(4-Hydroxyphenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one
[0199]
[0200] 5% Palladium on carbon (7.0 g) was added to a solution 4-(4-(benzyloxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (19 g, 42.1 mmol) in methanol (25 ml) at RT under an atmosphere of nitrogen. The nitrogen atmosphere was changed to an atmosphere of hydrogen. The reaction mixture was stirred under an atmosphere of hydrogen at RT for 4 h (the reaction was monitored by TLC). The reaction mixtures was filtered over through a pad of Celite®, washed with methanol, concentrated in vacuo and the resultant residue was slurried with heptane. The solid was filtered & dried under vacuum to afford 4-(4-hydroxyphenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (14.0 g, 95%,) as light yellow solid. 1 H NMR, 500 MHz, DMSO-d 6 : δ 9.5 (bs, 1H), 7.55 (d, 2H), 7.05 (d, 2H), 7.0 (d, 2H), 6.75 (d, 2H), 3.8 (s, 3H), 1.4 (s, 6H). MS: [M+H]: m/z=311.2. HPLC: (98.8%, Eclipse XDB-C18, 150×4.6 mm, 5 um. Mobile Phase: 0.1% TFA in Water. (A). ACN (B), Flow rate: 1.5 ml/min).
Synthesis of 5-(4-Hydroxyphenyl)-2,2-dimethyl-4-(pyridin-4-yl)furan-3(2H)-one
Trimethyl (2-methylbut-3-yn-2-yloxy) silane
[0201]
[0202] To a stirred solution of 2-methylbut-3-yn-2-ol (20 g, 0.23 mol) in HMDS (42.3 g, 0.261 mol) was added LiClO 4 (38.03 g, 0.35 mol) at RT. The reaction mixture was then stirred for additional 30 minutes, diluted with water (100 mL) and then extracted with ether (3×200 mL). The combined ether layers were washed with water (100 mL) and brine (100 mL), dried over Na 2 SO and filtered. The ether was distilled off at 80° C. to afford trimethyl (2-methylbut-3-yn-2-yloxy) silane (25 g) as an oil.
4-Methyl-1-(pyridin-4-yl)-4-(trimethylsilyloxy)pent-2-yn-1-one
[0203]
[0204] To a pre-cooled −78° C. stirred solution of trimethyl (2-methylbut-3-yn-2-yloxy) silane (5.0 g, 0.03 mol) in dry THF (150 mL), n-BuLi (23.82 mL, 0.03 mol, 1.6 M in hexane) was added dropwise over a period of 10 minutes under an inert atmosphere. The reactions was stirred for 30 minutes at −78° C. and then a solution of N-methoxy-N-methylisonicotinamide (6.34 g, 0.03 mol) in dry THF (30 mL) was added to the reaction mixture and stirring was continued for an additional 40 min at −78° C. The reaction mixture was quenched with a saturated NH 4 Cl solution and extracted with EtOAc (2×100 mL). The combined organic layers were washed with water (100 mL) and brine (100 mL), dried over Na 2 SO 4 , filtered and finally concentrated in vacuo to obtain a residue. The residue was purified via silica gel column chromatography eluting with 5% EtOAc in hexanes to afford 4-methyl-1-(pyridin-4-yl)-4-(trimethylsilyloxy)pent-2-yn-1-one (2.2 g, 27%) as oil.
4-Hydroxy-4-methyl-1-(pyridin-4-yl) pent-2-yn-1-one
[0205]
[0206] To a stirred solution of 4-methyl-1-(pyridin-4-yl)-4-(trimethylsilyloxy) pent-2-yn-1-one (0.5 g, 1.915 mmol) in DCM (10 mL) was added PTSA (0.47 g, 2.49 mmol) at RT and the reaction mixture was stirred for 2 h. The reaction mixture was diluted with DCM (50 mL). The organic layers were washed with a saturated NaHCO 3 solution and water, dried over Na 2 SO 4 , filtered and then concentrated in vacuo to afford 4-hydroxy-4-methyl-1-(pyridin-4-yl) pent-2-yn-1-one (0.35 g, 96%) as an oil.
2,2-Dimethyl-5-(pyridin-4-yl)furan-3(2H)-one
[0207]
[0208] To a stirred solution of 4-hydroxy-4-methyl-1-(pyridin-4-yl) pent-2-yn-1-one (1.49 g, 0.007 mol) in ethanol (15 mL), diethylamine (0.511 g, 0.007 mol) in EtOH (15 mL) was added dropwise at RT. The mixture was then stirred for additional 40 min. The EtOH was evaporated and the mixture was diluted with EtOAc (100 mL). The organic layers were washed with water (50 mL) and brine (20 mL), dried over Na 2 SO 4 , filtered and concentrated in vacuo to afford 2,2-dimethyl-5-(pyridin-4-yl)furan-3(2H)-one (1.4 g).
4-Bromo-2,2-dimethyl-5-(pyridin-4-yl)furan-3(2H)-one
[0209]
[0210] To a stirred solution of 2,2-dimethyl-5-(pyridin-4-yl)furan-3(2H)-one (0.81 g, 4.28 mmol) in CHCl 3 (20 mL), NBS (1.3 g, 7.28 mmol) was added portionwise at RT. The reaction mixture was then stirred for 2 h and diluted with DCM (100 mL). The organic layers were washed with water (50 mL) and brine (50 mL), dried over Na 2 SO 4 , filtered, and then concentrated in vacuo to obtain the crude product. The crude material was purified via silica gel column chromatography to afford 4-bromo-2,2-dimethyl-5-(pyridin-4-yl)furan-3(2H)-one (0.25 g, 21%) as a solid.
4-(4-(Benzyloxy)phenyl)-2,2-dimethyl-5-(pyridin-4-yl)furan-3(2H)-one
[0211]
[0212] A solution of 4-bromo-2,2-dimethyl-5-(pyridin-4-yl)furan-3(2H)-one (10.0 g, 37.2 mmol), 2-(4-(benzyloxy)phenyl)-4,4,5,5-tetramethyl-1,3,2-dioxaborolane (13.8 g, 44.7 mmol), and Cs 2 CO 3 (36.27 g, 111.6 mmol) in toluene (100 mL) and water (50 mL) was degassed. Dichloro[1,1′-bis(diphenylphosphino)ferrocene]palladium(ll) (2.7 g, 3.7 mmol) was added under an inert atmosphere and again degassed. Then the reaction was refluxed for 3 h and monitored by TLC. Upon complete consumption of the starting material, the reaction mixture was filtered through a bed of Celite® washing with ethyl acetate. The organic layer was then washed with water, brine, dried over Na 2 SO 4 , filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 20% ethyl acetate in n-hexanes on 230-400 mesh silica gel to afford 4-(4-(benzyloxy)phenyl)-2,2-dimethyl-5-(pyridin-4-yl)furan-3(2H)-one (8.3 g, 60.2%) as a light orange color solid. 1 H NMR, 500 MHz, DMSO-d 6 : δ 8.2 (d, 2H), 7.85 (d, 2H), 7.6 (d, 4H), 7.4 (t, 1H), 7.15 (d, 2H), 7.05 (d, 2H), 5.1 (s, 2H), 1.45 (s, 6H). MS: [M+H]+: m/z=396.0. HPLC: (97.5%, Column: Eclipse XDB-C18, 150×4.6 mm, 5 um. Mobile Phase: 0.1% TFA in Water. (A). ACN (B), Flow rate: 1.5 ml/min).
5-(4-Hydroxyphenyl)-2,2-dimethyl-4-(pyridin-4-yl)furan-3(2H)-one
[0213]
[0214] To a stirred solution of 5-(4-(benzyloxy)phenyl)-2,2-dimethyl-4-(pyridin-4-yl)furan-3(2H)-one (620 mg, 0.001 mmol) in MeOH (15 mL) was added Pd (OH) 2 (120 mg, 0.85 mmol) at RT under an inert atmosphere. The reaction mixture was stirred under a hydrogen atmosphere for 1 h. The reaction mixture was then filtered through a pad of Celite® and the filtrate was concentrated in vacuo to obtain the crude product. The crude material was purified via silica gel column chromatography to afford 544-hydroxyphenyl)-2,2-dimethyl-4-(pyridin-4-yl)furan-3(2H)-one (280 mg, 60%) as a solid.
Synthesis of 4-(3-(4-Hydroxyphenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile
4-Cyano-N-methoxy-N-methylbenzamide
[0215]
[0216] To a stirred solution of 4-cyanobenzoic acid (5.0 g, 34.0 mmol) in DCM (75 mL) were added HATU (19.40 g, 51.0 mmol), N-methoxy, N-methylamine (4.90 g, 51.0 mmol) and TEA (14.30 mL, 102.0 mmol) at RT under a nitrogen atmosphere. The reaction mixture was then stirred at RT for 3 h, diluted with water and the aqueous layer was extracted with DCM (3×100 mL). The combined organic extracts were washed with water (60 mL) and brine (30 mL), dried over anhydrous Na 2 SO 4 , filtered and evaporated under reduced pressure to afford 4-cyano-N-methoxy-N-methylbenzamide (6.2 g, 96%) as a yellow color oil.
4-(4-Methyl-4-(trimethylsilyloxy)pent-2-ynoyl)benzonitrile
[0217]
[0218] To a −78° C. stirred solution of trimethyl (2-methylbut-3-yn-2-yloxy) silane (3.3 g, 20.00 mmol) in dry THF (45 mL), n-BuLi (4.1 mL, 9.00 mmol, 1.6 M in hexane) was added dropwise over 10 minutes under an inert atmosphere. The reaction mixture was stirred for 30 min at −78° C., and then a solution of 4-cyano-N-methoxy-N-methylbenzamide (2.0 g, 10.00 mmol) in dry THF (15 mL) was added to the reaction mixture and stirring was continued for an additional 1 h at −78° C. The reaction mixture was quenched with a saturated NH 4 Cl solution and extracted with EtOAc (2×100 mL). The combined organic layers were washed with water (50 mL) and brine (50 mL), dried over Na 2 SO 4 , filtered, and concentrated in vacuo to obtain the crude product. The crude material was purified via silica gel column chromatography eluting with 15% EtOAc in hexanes to afford 4-(4-methyl-4-(trimethylsilyloxy)pent-2-ynoyl)benzonitrile (3.8 g, 68%) as a yellow oil.
4-(4-Hydroxy-4-methylpent-2-ynoyl)benzonitrile
[0219]
[0220] To a stirred solution of 4-(4-methyl-4-(trimethylsilyloxy)pent-2-ynoyl)benzonitrile (1.7 g, 5.00 mmol) in DCM (15 mL) was added PTSA (1.70 g, 8.90 mmol) at RT and the reaction mixture was stirred for 30 min. The reaction mixture was diluted with water (10 mL) and extracted with DCM (2×50 mL). The combined organic layers were washed with a saturated NaHCO 3 solution and water, dried over Na 2 SO 4 , filtered, and then concentrated in vacuo to afford 4-(4-hydroxy-4-methylpent-2-ynoyl)benzonitrile (1.20 g) as a yellow oil.
4-(5,5-Dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile
[0221]
[0222] To a stirred solution of crude 4-(4-hydroxy-4-methylpent-2-ynoyl)benzonitrile (1.2 g, 5.60 mmol) in ethanol (12 mL), a solution of diethyl amine (0.58 mL, 5.60 mmol) in EtOH (5 mL) was added dropwise at RT. The reaction mixture was then stirred for additional 1 h. The ethanol was removed and the mixture then diluted with EtOAc (50 mL). The combined organic layers were washed with water (10 mL), brine (10 mL), dried over Na 2 SO 4 , filtered, and concentrated in vacuo to afford crude 4-(5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile (1.2 g) as a light green semi solid which was taken on to the next step without further purification.
4-(3-Bromo-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile
[0223]
[0224] To a stirred solution of 4-(5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile (1.2 g, 5.60 mmol) in CHCl 3 (12 mL), NBS (1.1 g, 6.00 mmol) was added portionwise at RT. The reaction mixture was then stirred for 3 h and diluted with DCM (100 mL). The combined organic layers were washed with water (30 mL) and brine (30 mL), dried over Na 2 SO 4 , filtered, and then concentrated in vacuo to obtain the crude product. The crude material was purified via silica gel column chromatography to afford 4-(3-bromo-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile (0.50 g, 31%) as an off white solid.
4-(3-(4-(benzyloxy)phenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile
[0225]
[0226] A solution of 4-(3-bromo-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile (29.0 g, 107.4 mmol), 2-(4-(benzyloxy)phenyl)-4,4,5,5-tetramethyl-1,3,2-dioxaborolane (34.7 g, 118.8 mmol), and Cs 2 CO 3 (104.7 g, 322.2 mmol) in toluene (200 mL) and water (50 mL) was degassed. Dichloro[1,1′-bis(diphenylphosphino)ferrocene]palladium(II) (8.5 g, 10 mmol) was added under an inert atmosphere and the solution was again degassed. The reaction was then refluxed for 3 h and monitored for completion by TLC. Upon complete consumption of the starting material, the reaction mixture was filtered through a bed of Celite® washing with ethyl acetate. The organic layer was then washed with water, brine, dried over Na 2 SO 4 , filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 20% ethyl acetate in n-hexane on 230-400 mesh silica gel (Rf=0.3) to afford 4-(3-(4-(benzyloxy)phenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile (31.5 g, 74.25%) as solid. 1 H NMR: 500 MHz, DMSO-d 6 : δ 7.95 (d, 2H), 7.75 (d, 2H), 7.5 (d, 4H), 7.35 (t, 1H), 7.15 (d, 2H), 7.05 (d, 2H), 5.1 (s, 2H), 1.45 (s, 6H). MS: [M+H]+: m/z=396.0. HPLC: (99.5%, Eclipse XDB-C18, 150×4.6 mm, 5 um. Mobile Phase: 0.1% TFA in Water. (A). ACN (B), Flow rate: 1.5 ml/min).
4-(3-(4-Hydroxyphenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile
[0227]
[0228] Boron tribromide (3.4 g, 15.8 mmol) was added to a solution of 4-(3-(4-(benzyloxy)phenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile (2.5 g, 6.3 mmol) in DCM at 0° C. & the mixture was stirred for 1 h (reaction was monitored by TLC). Upon complete consumption of the starting material, the mixture was quenched with chilled water and extracted with DCM, The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by column chromatography to afford 4-(3-(4-hydroxyphenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile (1.8 g, 93.2%,) as yellow solid. 1 H NMR: 500 MHz, CDCl 3 : δ 9.6 (s, 1H), 7.95 (d, 2H), 7.75 (d, 2H), 7.0 (d, 2H), 6.75 (d, 2H), 1.5 (s, 6H).
2,3,5-Trimethylpyridine 1-oxide
[0229]
[0230] 3-Chloro per benzoic acid (10 g, 164.2 mmol) was added to a solution of 2,3,5-trimethylpyridine (10 g, 82.1 mmol) in DCM at 0° C. and the mixture was stirred at RT for 8 h (the reaction was monitored by TLC). The reaction was quenched with sodium bicarbonate solution and stirred for 1 h at RT. The organic layer was separated, dried over sodium sulfate, filtered and concentrated under reduced pressure to afford 2,3,5-trimethylpyridine 1-oxide (6.5 g, 58.0%,) as a brown solid. 1 H NMR: 200 MHz, CDCl 3 : δ 8.15 (s, 1H), 7.15 (s, 1H), 2.55 (s, 3H), 2.35 (s, 3H), 2.25 (s, 3H). MS: [M+H]+: m/z=311.2.
2-(Chloromethyl)-3,5-dimethylpyridine
[0231]
[0232] Tosyl chloride (12.5 g, 65.6 mmol) was added to a solution of 2,3,5-trimethylpyridine 1-oxide (6.0 g, 43.7 mmol), and triethylamine (6.6 g, 65.6 mmol) in DCM (60 ml) at RT under an atmosphere of nitrogen. The reaction mixture was heated to reflux and reflux was maintained 4 h (reaction was monitored by TLC). The reaction was quenched with water and extracted with DCM. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 10% ethyl acetate in n-hexanes and silica gel (230-400 Mesh) to afford 2-(chloromethyl)-3,5-dimethylpyridine (4.5 g, 66.1%,) as a brown thick syrup. 1 H NMR: 200 MHz, CDCl 3 : δ 8.15 (s, 1H), 7.45 (s, 1H), 4.75 (s, 2H), 2.35 (s, 3H), 2.25 (s, 3H). MS: [M+H]+: m/z=156.3.
4-(4-((3,5-dimethylpyridin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one
[0233]
[0234] 4-(4-Hydroxyphenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (3.0 g, 9.6 mmol) was added to a mixture of cesium carbonate (12.6 g, 38.6 mmol) and DMF (1000 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred at RT for 30 min upon which 2-(chloromethyl)-3,5-dimethylpyridine (2.25 g, 14.5 mmol) was added. The reaction mixture was heated for 4 h at 80° C. (the reaction was monitored by TLC). The reaction mixture was diluted with water and extracted with EtOAc. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 15% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford 4-(4-((3,5-dimethylpyridin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (3.2 g, 65.3%,) as an off-white solid. 1 H NMR: 500 MHz, DMSO-d 6 : δ 8.2 (s, 1H), 7.65 (d, 2H), 7.45 (s, 1H), 7.15 (d, 2H), 7.1 (d, 2H), 7.0 (d, 2H), 5.2 (s, 2H), 3.8 (s, 3H), 2.35 (s, 3H), 2.3 (s, 3H), 1.45 (s, 6H). MS: [M+H]+: m/z=430.4. HPLC (96.3%, Condition-A).
4-(4-((3,5-dimethylpyridin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one methanesulfonate
[0235]
[0236] Methanesulfonic acid (445.0 mg, 4.6 mmol) was added to a solution of 4-(4-((3,5-dimethylpyridin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (2.01 g, 4.6 mmol) in DCM (3 ml) and diethyl ether (150 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred at RT for 4 h and the solids were removed by filtration. The solid was washed with 20% DCM in diethyl ether and dried under vacuo to afford 4-(4-((3,5-dimethylpyridin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one methanesulfonate (2.1 g, 87%) as a white solid. 1 H NMR: 500 MHz, DMSO-d 6 : δ 8.2 (s, 1H), 7.65 (d, 2H), 7.45 (s, 1H), 7.15 (d, 2H), 7.1 (d, 2H), 7.0 (d, 2H), 5.2 (s, 2H), 3.8 (s, 3H), 2.35 (s, 3H), 2.3 (s, 3H), 1.45 (s, 6H), HPLC: (98.9%, Condition-A).
2-(Chloromethyl)imidazo[1,2-a]pyridine
[0237]
[0238] 1,3-Dichloroacetone (22.9 g, 180.3 mmol) was added to a solution of 2-amino pyridine (10 g, 106.3 mmol) in acetonitrile (200 ml). The mixture was heated at reflux for 14 h (the reaction was monitored by TLC). Upon completion of the reaction, the volatiles were removed under reduced pressure. The residue was diluted with water and adjusted the pH to 7.5 with sodium bicarbonate solution which was extracted with EtOAc. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 12% ethyl acetate in n-hexanes and silica gel (230-400 mesh) to afford 2-(chloromethyl) imidazo[1,2-a]pyridine (8.0 g, 47.9%,) as pale yellow solid. 1 H NMR: 200 MHz, CDCl 3 : δ 8.15 (d, 1H), 7.6 (dd, 2H), 7.1 (t, 1H), 6.8 (t, 1H), 4.75 (s, 2H). MS: [M+H]+: m/z=167.2.
4-(4-(Imidazo[1,2-a]pyridin-2-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one
[0239]
[0240] 4-(4-Hydroxyphenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (2.5 g, 8.06 mmol) was added to a mixture of cesium carbonate (10.5 g, 32.2 mmol) and DMF (20 mL) at RT under nitrogen. The reaction mixture was stirred at RT for 30 min, upon which 2-(chloromethyl)imidazo[1,2-a]pyridine (2.4 g, 12.0 mmol) was added. The mixture was heated at 80° C. for 4 h (reaction was monitored by TLC). The reaction mixture was allowed to cool to RT, diluted with water and extracted with EtOAc. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 20% ethyl acetate in n-hexane and silica gel (230-400 mesh), to afford 4-(4-(imidazo[1,2-a]pyridin-2-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (2.8 g, 77.7%,) as Off-white solid. 1 H NMR: 500 MHz, DMSO-d 6 : δ 8.55 (d, 1H), 8.0 (s, 1H), 7.55 (Ar, 3H), 7.3-6.85 (Ar, 8H), 5.15 (s, 2H) 3.85 (s, 3H), 1.25 (s, 6H). MS: [M+H]+: m/z=441.2. HPLC: (97.3%, Condition-A).
4-(4-(Imidazo[1,2-a]pyridin-2-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one methanesulfonate
[0241]
[0242] Methanesulfonic acid (531 mg, 5.5 mmol) was added to a solution of 4-(4-(imidazo[1,2-a]pyridin-2-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (2.5 g, 5.5 mmol) in DCM (5 ml) and diethyl ether (150 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred for a further 4 h at RT. The solids were collected by filtration, washed with 20% DCM in diethyl ether and dried in vacuo to afford 4-(4-(imidazo[1,2-a]pyridin-2-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one methanesulfonate (2.4 g, 82.7%,) as white solid. 1 H NMR: 500 MHz, DMSO-d 6 : δ 8.75 (d, 1H), 8.1 (s, 1H), 7.65 (Ar, 3H), 7.3-6.85 (Ar, 8H), 5.2 (s, 2H) 3.85 (s, 3H), 1.25 (s, 6H), HPLC: (98.8%, Condition-A).
6-Chloroimidazo[1,2-b]pyridazine
[0243]
[0244] Bromoacetaldehyde diethylacetal (36.5 g, 216 mmol) was added to a solution of aq.cHBr (7.2 ml) and then heated to reflux for 30 min. The mixture was then cooled to 0° C., upon which ethanol (236 ml), sodium bicarbonate (8.09 g, 95 mmol) and 6-chloropyridazin-3-amine (4 g, 30 mmol) were added. The mixture was heated to 80° C. for 3 h (reaction was monitored by TLC) and then allowed to cool to RT. The mixture was concentrated under reduced pressure, diluted with water and extracted with EtOAc. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 15% ethyl acetate in n-hexane and silica gel (230-400 mesh), to afford 6-chloroimidazo[1,2-b]pyridazine (4.0 g, 85.2%,) as Off-white solid. 1 H NMR: 200 MHz, CDCl 3 : δ 7.4-7.2 (Ar, 4H), 3.85 (q, 1H), 3.4 (q, 1H), 3.2 (q, 2H), 1.35 (t, 3H), 1.1 (t, 3H). MS: [M+H]+: m/z=154.3.
Methylimidazo[1,2-b]pyridazine-6-carboxylate
[0245]
[0246] 6-Chloroimidazo[1,2-b]pyridazine (5.0 g, 32 mmol) was added to a solution of methanol (75 ml) and acetonitrile (75 ml) in a steel bomb at RT under nitrogen bubbling. Triethylamine (4.0 g, 39.4 mmol), BINAP (2.0 g, 3.0 mmol) and bisacetonitrile palladium dichloride (0.854 g, 3.0 mmol) were then added to the mixture. The mixture was heated to 100° C. which was maintained for approximately 10 hours (the reaction was monitored by TLC). The reaction mixture was filtered through a bed of Celite® washing with ethyl acetate. The organics were washed with water and brine, dried over sodium sulfate and concentrated under reduced pressure. The residue was purified by flash column chromatography using 10% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford methyl imidazo[1,2-b]pyridazine-6-carboxylate (2.5 g, 43%,) as an off-white solid. 1 H NMR: 200 MHz, DMSO-d 63 : δ 8.55 (s, 1H), 8.3 (d, 1H), 7.95 (s, 1H), 7.55 (d, 1H), 3.95 (s, 3H). MS: [M+H]+: m/z=177.9.
Imidazo[1,2-b]pyridazin-6-ylmethanol
[0247]
[0248] Sodium borohydride (1.1 g, 31.1 mmol) was added to a solution of methyl imidazo[1,2-b]pyridazine-6-carboxylate (2.4 g, 15.5 mmol) in THF (35 mL) and methanol (2.5 ml) at RT. The reaction mixture was stirred at RT for 2 h (the reaction was monitored by TLC) upon which the mixture was concentrated under reduced pressure. The reaction mixture was diluted with water and extracted with EtOAc. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure to afford imidazo[1,2-b]pyridazin-6-ylmethanol (1.6 g, 81%,) as a white solid. 1 H NMR: 200 MHz, DMSO-d 6 : δ 8.5 (s, 1H), 8.3 (d, 1H), 7.9 (s, 1H), 7.55 (d, 1H), 5.65 (t, 1H), 4.6 (d, 2H). MS: [M+H]+: m/z=311.2.
6-(Chloromethyl)imidazo[1,2-b]pyridazine
[0249]
[0250] Thionyl chloride (10 ml) was added to imidazo[1,2-b]pyridazin-6-ylmethanol (1.5 g, 9.0 mmol) at 20° C. under an atmosphere of nitrogen at RT. The reaction mixture was stirred at reflux for 3 h (the reaction was monitored by TLC) upon which the volatiles were removed under reduced pressure. The reaction mixture was diluted with water and extracted with EtOAc. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 15% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford 6-(chloromethyl)imidazo[1,2-b]pyridazine (1.2 g, 69%,) as an off-white solid. 1 H NMR, 200 MHz, DMSO-d 6 : δ 8.35 (s, 1H), 8.3 (d, 1H), 7.85 (s, 1H), 7.35 (d, 1H), 4.95 (s, 2H). MS: [M+H]+: m/z=149.9.
4-(4-(Imidazo[1,2-b]pyridazin-6-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one
[0251]
[0252] 4-(4-Hydroxyphenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (1.2 g, 3.8 mmol) was added to a mixture of cesium carbonate (3.7 g, 11.6 mmol) and DMF (25 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred at RT for 30 min upon which 6-(chloromethyl)imidazo[1,2-b]pyridazine (0.96 g, 5 mmol) was added. The mixture was heated at 80° C. for 4 h (the reaction was monitored by TLC). The reaction mixture was diluted with water and extracted with EtOAc. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 30% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford 4-(4-(imidazo[1,2-b]pyridazin-6-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (0.8 g, 47%,) as Off-white solid. 1 H NMR: 200 MHz, DMSO-d 6 : δ 8.35 (s, 1H), 8.2 (d, 1H), 7.8 (s, 1H), 7.55 (d, 2H), 7.4 (d, 1H), 7.2 (d, 2H), 7.1 (d, 2H), 7.0 (d, 2H), 5.3 (s, 2H) 3.9 (s, 3H), 1.45 (s, 6H). MS: [M+H]+: m/z=442.1. HPLC: (95.8%, Condition-A).
4-(4-(Imidazo[1,2-b]pyridazin-6-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one methanesulfonate
[0253]
[0254] Methanesulfonic acid (54 mg, 0.5 mmol) was added to a solution of compound 4-(4-(imidazo[1,2-b]pyridazin-6-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (250 mg, 0.5 mmol) in DCM (2 ml) and diethyl ether (20 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred at RT for 4 h upon which the mixture was filtered and the solids were washed with 20% DCM in diethyl ether and dried in vacuo to afford 4-(4-(imidazo[1,2-b]pyridazin-6-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one methanesulfonate (240 mg, 80.0%,) as an off-white solid. 1 H NMR: 200 MHz, DMSO-d 6 : δ 8.55 (s, 1H), 8.35 (d, 1H), 78.1 (s, 1H), 7.65 (d, 2H), 7.4 (d, 1H), 7.2 (d, 2H), 7.1 (d, 2H), 7.0 (d, 2H), 5.35 (s, 2H) 3.9 (s, 3H), 2.35 (s, 3H), 1.45 (s, 6H). HPLC: (98.3%, Condition-A).
6-Chloro-2-(chloromethyl)imidazo[1,2-b]pyridazine
[0255]
[0256] 1,3-Dichloroacetone (21.4 g, 168.0 mmol) was added to a solution of 6-chloropyridazin-3-amine (10 g, 77.2 mmol) in acetonitrile (200 ml). The mixture was heated at reflux for 14 h (the reaction was monitored by TLC). The volatiles were removed under reduced pressure and the reaction mixture was diluted with water. The pH was adjusted to ˜7.5 with sodium bicarbonate solution and then extracted with EtOAc. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 14% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford 6-chloro-2-(chloromethyl)imidazo[1,2-b]pyridazine (6.0 g, 64.1%,) as white solid. 1 H NMR: 200 MHz, CDCl 3 : δ 8.0 (s, 1H), 7.9 (d, 1H), 7.1 (d, 1H), 4.75 (s, 2H). MS: [M+H]+: m/z=202.8.
4-(4-((6-Chloroimidazo[1,2-b]pyridazin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one
[0257]
[0258] 4-(4-Hydroxyphenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (200 mg, 0.64 mmol) was added to a mixture of cesium carbonate (838 mg, 2.5 mmol) and DMF (5 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred at RT for 30 min upon which 6-chloro-2-(chloromethyl)imidazo[1,2-b]pyridazine (196 mg, 9.6 mmol) was added. The mixture was heated at 80° C. for 4 h (the reaction was monitored by TLC). The reaction mixture was diluted with water and extracted with EtOAc; the combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The organic residue was purified by flash column chromatography using 30% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford 4-(4-((6-chloroimidazo[1,2-b]pyridazin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (180 mg, 63.0%,) as an off-white solid. 1 H NMR, 500 MHz, DMSO-d 6 : δ 8.45 (s, 1H), 8.2 (d, 1H), 7.55 (d, 2H), 7.4 (d, 1H), 7.15 (d, 2H), 7.1 (d, 2H), 7.0 (d, 2H), 5.25 (s, 2H) 3.8 (s, 3H), 1.25 (s, 6H). MS: [M+H]+: m/z=476.7. HPLC: (96.7%, Condition-A).
4-(4-(Imidazo[1,2-b]pyridazin-2-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one
[0259]
[0260] Palladium hydroxide (36 mg) was added to a solution of 4-(4-((6-chloroimidazo[1,2-b]pyridazin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (180 mg, 0.37 mmol) and diethyl amine (28 mg, 0.37) in methanol (25 ml) at RT under an atmosphere of nitrogen. The nitrogen atmosphere was exchanged for hydrogen and was stirred at RT for 2 h (the reaction was monitored by TLC). The compound was filtered through a bed of Celite® bed washing with methanol. The filtrate was concentrated under reduced pressure to afford 4-(4-(imidazo[1,2-b]pyridazin-2-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (160 mg, 96.7%,) as a white solid. 1 H NMR: 500 MHz, DMSO-d 6 : δ 8.45 (s, 1H), 8.4 (s, 1H) 8.15 (d, 1H), 7.55 (d, 2H), 7.25 (d, 1H), 7.15 (d, 2H), 7.1 (d, 2H), 7.0 (d, 2H), 5.25 (s, 2H) 3.8 (s, 3H), 1.25 (s, 6H). MS: [M+H]+: m/z=442.3. HPLC: (97.4%, Condition-A).
4-(4-(Imidazo[1,2-b]pyridazin-2-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one methanesulfonate
[0261]
[0262] Methanesulfonic acid (34.8 mg, 0.36 mmol) was added to a solution of compound 4-(4-(imidazo[1,2-b]pyridazin-2-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (160 mg, 0.36 mmol) in DCM (3 ml) and diethyl ether (15 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred at RT for 4 h, upon which the mixture was filtered and the solids were washed with 20% DCM in diethyl ether. The solids were dried under vacuo to afford 4-(4-(imidazo[1,2-b]pyridazin-2-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one methanesulfonate (110 mg, 56%,) as a white solid. 1 H NMR: 500 MHz, DMSO-d 6 : δ 8.45 (s, 1H), 8.4 (s, 1H) 8.15 (d, 1H), 7.55 (d, 2H), 7.25 (d, 1H), 7.15 (d, 2H), 7.1 (d, 2H), 7.0 (d, 2H), 5.25 (s, 2H) 3.8 (s, 3H), 2.35 (s, 3H), 1.25 (s, 6H), HPLC: (98.5%, Condition-A).
4-(3-(4-((3,5-dimethylpyridin-2-yl)methoxy)phenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile
[0263]
[0264] 4-(3-(4-Hydroxyphenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile (1.5 g, 4.9 mmol) was added to a mixture of carbonate (6.3 g, 19.6 mmol) and DMF (100 mL) at RT under nitrogen. The reaction mixture was stirred at RT for 30 min upon which 2-(chloromethyl)-3,5-dimethylpyridine (1.14 g, 7.3 mmol) was added. The mixture was heated at 80° C. for 4 h (the reaction was monitored by TLC). The reaction mixture was diluted with water and extracted with EtOAc; the combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 22% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford 4-(3-(4-((3,5-dimethylpyridin-2-yl)methoxy)phenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl) (0.70 g, 35%,) as yellow solid. 1 H NMR, 200 MHz, CDCl 3 : δ 7.45-6.8 (Ar, 11H), 4.9 (d, 1H), 4.6 (d, 1H), 3.75 (s, 3H), 3.2 (d, 2H) 3.1 (q, 1H), 2.5 (q, 1H) 0.95 (t, 6H). MS: [M+H]+: m/z=425.2. HPLC: (96.3%, Condition-A).
4-(3-(4-((3,5-Dimethylpyridin-2-yl)methoxy)phenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile methanesulfonate
[0265]
[0266] Methanesulfonic acid (158 mg, 1.6 mmol) was added to a solution of compound 4-(3-(4-((3,5-dimethylpyridin-2-yl)methoxy)phenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl) (700 mg, 1.6 mmol) in DCM (0.5 ml) and diethyl ether (15 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred at RT for 4 h upon which, the mixture was filtered and the solids were washed with 20% DCM in diethyl ether and dried in vacuo to afford 4-(3-(4-((3,5-dimethylpyridin-2-yl)methoxy)phenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile methanesulfonate (2.1 g, 75%,) as a white solid. 1 H NMR: 200 MHz, CDCl 3 : δ 8.2 (d, 1H), 7.5 (t, 1H), 7.3-6.8 (Ar, 9H) 5.1 (s, 2H), 4.05 (s, 2H), 3.8 (s, 3H), HPLC: (97.1%, Condition-A).
4-(3-(4-(Imidazo[1,2-a]pyridin-2-ylmethoxy)phenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile
[0267]
[0268] 4-(3-(4-Hydroxyphenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile (3.15 g, 10.3 mmol) was added to a mixture of cesium carbonate (13.4 g, 41.3 mmol) and DMF (100 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred at RT for 30 min upon which 2-(chloromethyl)imidazo[1,2-a]pyridine (2.0 g, 12.3 mmol) was added. The mixture was heated at 80° C. for 4 h (the reaction was monitored by TLC). The reaction mixture was diluted with water and extracted with EtOAc, the combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 20% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford 4-(3-(4-(imidazo[1,2-a]pyridin-2-ylmethoxy)phenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile (2.7 g, 60%,) as an off-white solid. 1 H NMR: 500 MHz, DMSO-d 6 : δ 8.55 (d, 1H), 8.0 (s, 1H), 7.55 (Ar, 3H), 7.3-6.85 (Ar, 8H), 5.15 (s, 2H), 1.25 (s, 6H). MS: [M+H]+: m/z=436.2. HPLC: (97.3%, Condition-A).
4-(3-(4-(Imidazo[1,2-a]pyridin-2-ylmethoxy)phenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile methanesulfonate
[0269]
[0270] Methanesulfonic acid (309 mg, 3.2 mmol) was added to a solution of compound 4-(3-(4-(imidazo[1,2-a]pyridin-2-ylmethoxy)phenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile (1.4 g, 3.2 mmol) in DCM (5 ml) and diethyl ether (30 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred at RT for 4 h upon which it was filtered and the solids were washed with 20% DCM in diethyl ether and dried in vacuo to afford 4-(3-(4-(imidazo[1,2-a]pyridin-2-ylmethoxy)phenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile methanesulfonate (1.1 g, 64%,) as a white solid. 1 H NMR: 500 MHz, DMSO-d 6 : δ 8.55 (d, 1H), 8.0 (s, 1H), 7.55 (Ar, 3H), 7.3-6.85 (Ar, 8H), 5.15 (s, 2H) 2.15 (s, 3H), 1.25 (s, 6H), HPLC: (98.5%, Condition-A).
3-Chloro-2-(chloromethyl)imidazo[1,2-a]pyridine
[0271]
[0272] N-Chloro succinimide (329 g, 2.46 mmol) was added to a solution of 2-(chloromethyl)imidazo[1,2-a]pyridine (450 mg, 2.2 mmol) in DCM (15 ml) at RT under an atmosphere of nitrogen. Stirring was continued for 2 h (reaction was monitored by TLC) upon which the reaction mixture was diluted with DCM and washed with water and brine solution. The organic layer was dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 10% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford 3-chloro-2-(chloromethyl)imidazo[1,2-a]pyridine (400 mg, 76%,) as Off-white solid. 1 H NMR: 200 MHz, CDCl 3 : δ 8.4 (d, 1H), 7.7 (d, 1H), 7.5 (t, 1H), 7.1 (t, 1H), 4.85 (s, 2H). MS: [M+H]+: m/z=201.8. HPLC: (98.3%, Condition-A).
4-(4-((3-Chloroimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one
[0273]
[0274] 4-(4-Hydroxyphenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (200 mg, 0.64 mmol) was added to a mixture of cesium carbonate (843 mg, 2.5 mmol) and DMF (20 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred at RT for 30 min, upon which 3-chloro-2-(chloromethyl)imidazo[1,2-a]pyridine (183 mg, 0.77 mmol) was added. The mixture was heated at 80° C. for 4 h (the reaction was monitored by TLC) upon which, the mixture was diluted with water and extracted with EtOAc. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 18% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford 4-(4-((3-chloroimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (250 mg, 81%,) as an off-white solid. 1 H NMR: 500 MHz, DMSO-d 6 : δ 8.4 (d, 1H), 7.7 (d, 1H), 7.55 (Ar, 3H), 7.7-6.9 (Ar, 10H), 5.2 (s, 2H) 3.8 (s, 3H), 1.4 (s, 6H). MS: [M+H]+: m/z=470.7. HPLC: (97.2%, Condition-A).
4-(4-((3-Chloroimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one methanesulfonate
[0275]
[0276] Methanesulfonic acid (50.5 mg, 0.52 mmol) was added to a solution of 4-(4-((3-chloroimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (250 mg, 0.52 mmol) in DCM (2.5 ml) and diethyl ether (25 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred at RT for 4 h upon which the compound was filtered, washed with 20% DCM in diethyl ether and dried in vacuo to afford 4-(4-((3-chloroimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one methanesulfonate (260 mg, 86%,) as white solid. 1 H NMR: 500 MHz, DMSO-d 6 : δ 8.55 (d, 1H), 8.0 (s, 1H), 7.65 (Ar, 3H), 7.3-6.85 (Ar, 7H), 5.2 (s, 2H) 3.85 (s, 3H), 2.15 (s, 3H) 1.25 (s, 6H), HPLC: (98.8%, Condition-A).
Methyl 5-methylpicolinate
[0277]
[0278] 2-Chloro-5-methylpyridine (10 g, 78 mmol) was added to a solution of methanol (75 ml) and acetonitrile (75 ml) in steel bomb at RT under nitrogen bubbling followed by the addition of triethylamine (11.8 g, 117 mmol), BINAP (970 mg, 1.5 mmol) and bisacetonitrile palladium dichloride (0.4 g, 1.5 mmol). The mixture was heated to 100° C. and this temperature was maintained over night (the reaction was monitored by TLC). The reaction mixture was filter through Celite® bed and washing with ethyl acetate. The filtrate was washed with water and brine. The organic layer was concentrated under reduced pressure and purified by flash column chromatography using 10% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford methyl 5-methylpicolinate (6.5 g, 55%,) as an off-white solid. 1 H NMR: 200 MHz, CDCl 3 : δ 8.6 (s, 1H), 8.0 (d, 1H), 7.65 (d, 1H), 4.05 (s, 3H), 2.4 (s, 3H). MS: [M+H]+: m/z=151.9.
(5-Methylpyridin-2-yl)methanol
[0279]
[0280] Sodium borohydride (4.5 g, 115. mmol) was added to a solution of methyl 5-methylpicolinate (6.0 g, 39.5 mmol) in THF (60 mL) and methanol (6 ml) at RT. The reaction mixture was stirred at RT for 2 h (the reaction was monitored by TLC). The mixture was concentrated under reduced pressure and the residue was diluted with water and extracted with EtOAc. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The organic layer was concentrated under vacuo to afford (5-methylpyridin-2-yl)methanol (3.5 g, 72.9%,) as an off-white solid. 1 H NMR: 200 MHz, CDCl 3 : δ 8.5 (s, 1H), 7.7 (d, 1H), 7.15 (d, 1H), 5.0 (s, 3H), 3.4 (s, 3H). MS: [M+H]+: m/z=124.0.
2-(Chloromethyl)-5-methylpyridine
[0281]
[0282] Thionyl chloride (30 ml) was added to (5-methylpyridin-2-yl)methanol (3.0 g, 24.3 mmol) at 20° C. under nitrogen. The reaction mixture was stirred at reflux for 3 h (the reaction was monitored by TLC). The reaction mixture was concentrated under reduced pressure upon which it was diluted with water and extracted with EtOAc. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 6% ethyl acetate in n-hexane and silica gel (230-400 mesh), to afford 2-(chloromethyl)-5-methylpyridine (2.5 g, 73%,) as an off-white solid. 1 H NMR: 200 MHz, CDCl 3 : δ 8.4 (s, 1H), 7.5 (d, 1H), 7.3 (d, 1H), 4.6 (s, 2H), 2.3 (s, 3H). MS: [M+H]+: m/z=142.2.
5-(4-Methoxyphenyl)-2,2-dimethyl-4-(4-((5-methylpyridin-2-yl)methoxy)phenyl)furan-3(2H)-one
[0283]
[0284] 4-(4-Hydroxyphenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (2.0, 6.5 mmol) was added to a mixture of cesium carbonate (10.5 g, 32.2 mmol) and DMF (50 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred at RT for 30 min, upon which 2-(chloromethyl)-5-methylpyridine (1.36 g, 9.6 mmol) was added. The mixture was heated at 80° C. for 4 h (the reaction was monitored by TLC). The reaction mixture allowed to cool, diluted with water and extracted with EtOAc. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 20% ethyl acetate in n-hexane and silica gel (230-400 mesh), to afford 5-(4-methoxyphenyl)-2,2-dimethyl-4-(4-((5-methylpyridin-2-yl)methoxy)phenyl)furan-3(2H)-one (2.0 g, 76.9%,) as an off-white solid. 1 H NMR: 200 MHz, DMSO-d 6 : δ 8.4 (s, 1H), 7.6 (d, 1H), 7.55 (d, 2H), 7.4 (d, 1H), 7.2 (d, 2H), 7.1 (d, 2H), 7.0 (d, 2H), 5.2 (s, 2H) 3.8 (s, 3H), 2.3 (s, 3H), 1.45 (s, 6H). MS: [M+H]+: m/z=415.2. HPLC: (97.5%, Condition-A).
5-(4-Methoxyphenyl)-2,2-dimethyl-4-(4-((5-methylpyridin-2-yl)methoxy)phenyl)furan-3(2H)-one methanesulfonate
[0285]
[0286] Methanesulfonic acid (462 mg, 4.8 mmol) was added to a solution of 5-(4-methoxyphenyl)-2,2-dimethyl-4-(4-((5-methylpyridin-2-yl)methoxy)phenyl)furan-3(2H)-one (2.0 g, 4.8 mmol) in DCM (5 ml) and diethyl ether (50 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred at RT for 4 h upon which the solids were collected by filtration, washed with 20% DCM in diethyl ether and dried in vacuo to afford 5-(4-Methoxyphenyl)-2,2-dimethyl-4-(4-((5-methylpyridin-2-yl)methoxy)phenyl)furan-3(2H)-one methanesulfonate (2.0 g, 90.9%,) as a white solid. 1 H NMR: 200 MHz, DMSO-d 6 : δ 8.5 (s, 1H), 7.6 (d, 1H), 7.55 (d, 2H), 7.4 (d, 1H), 7.2 (d, 2H), 7.1 (d, 2H), 7.0 (d, 2H), 5.2 (s, 2H) 3.8 (s, 3H), 2.35 (s, 3H), 2.3 (s, 3H), 1.45 (s, 6H), HPLC: (99.3%, Condition-A).
4-(5,5-Dimethyl-3-(4-((5-methylpyridin-2-yl)methoxy)phenyl)-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile
[0287]
[0288] 4-(3-(4-Hydroxyphenyl)-5,5-dimethyl-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile (0.4 g, 1.3 mmol) was added to a mixture of cesium carbonate (1.7 g, 5.2 mmol) and DMF (20 mL) at RT under nitrogen. The reaction mixture was stirred at RT for 30 minutes upon which afford 2-(chloromethyl)-5-methylpyridine (306 mg, 1.9 mmol) was added. The mixture was heated at 80° C. for 4 h (the reaction was monitored by TLC). The reaction mixture was diluted with water and extracted with EtOAc. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 25% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford 4-(5,5-dimethyl-3-(4-((5-methylpyridin-2-yl)methoxy)phenyl)-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile (160 mg, 30.1%,) as an off-white solid. 1 H NMR: 200 MHz, DMSO-d 6 : δ 8.4 (s, 1H), 7.6 (d, 1H), 7.55 (d, 2H), 7.4 (d, 1H), 7.2 (d, 2H), 7.1 (d, 2H), 7.0 (d, 2H), 5.2 (s, 2H), 2.3 (s, 3H), 1.45 (s, 6H). MS: [M+H]+: m/z=411.2. HPLC: (97.3%, Condition-A).
4-(5,5-Dimethyl-3-(4-((5-methylpyridin-2-yl)methoxy)phenyl)-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile methanesulfonate
[0289]
[0290] Methanesulfonic acid (36 mg, 0.3 mmol) was added to a solution of 4-(5,5-dimethyl-3-(4-((5-methylpyridin-2-yl)methoxy)phenyl)-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile (150 mg, 0.3 mmol) in DCM (5 ml) and diethyl ether (50 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred at RT for 4 h upon which the solids were collected by filtration, washed with 20% DCM in diethyl ether, dried in vacuo to afford 4-(5,5-dimethyl-3-(4-((5-methylpyridin-2-yl)methoxy)phenyl)-4-oxo-4,5-dihydrofuran-2-yl)benzonitrile methanesulfonate (120 mg, 67.0%,) as a white solid. 1 H NMR: 200 MHz, DMSO-d 6 : δ 8.5 (s, 1H), 7.6 (d, 1H), 7.55 (d, 2H), 7.4 (d, 1H), 7.2 (d, 2H), 7.1 (d, 2H), 7.0 (d, 2H), 5.2 (s, 2H), 2.35 (s, 3H), 2.3 (s, 3H), 1.45 (s, 6H). HPLC: (98.3%, Condition-A).
Methyl 2-oxobutanoate
[0291]
[0292] Trimethylsilyl chloride (1.06 g, 9.8 mmol) was added to a stirred solution of 2-oxobutanoic acid (10.0 g, 98.0 mmol) in 2,2-dimethoxypropane (90 ml) and methanol (20 ml). The mixture was stirred for 18 hours at RT (the reaction was monitored by TLC) upon which the mixture was concentrated under reduced pressure afford crude methyl 2-oxobutanoate (8.0 g) as a brown liquid. 1 H NMR: 200 MHz, CDCl 3 : δ 3.85 (s, 3H), 2.9 (q, 2H), 1.15 (t, 1H), 6.8 (t, 1H), 4.75 (s, 2H).
Methyl 3-bromo-2-oxobutanoate
[0293]
[0294] Copper bromide (30.0 g, 137 mmol) was added to a stirred solution of methyl 2-oxobutanoate (8.0 g, 68.9 mmol) in ethyl acetate (150 ml) and chloroform (100 ml). The mixture was stirred for 18 hours at reflux (the reaction was monitored by TLC). The mixture was filtered and washed with ethyl acetate and the filtrates were concentrated in vacuo to afford crude methyl 3-bromo-2-oxobutanoate (6.5 g) as a colorless liquid. 1 H NMR: 200 MHz, CDCl 3 : δ 5.2 (q, 1H), 3.9 (s, 3H), 1.8 (d, 3H).
Methyl 3-methylimidazo[1,2-a]pyridine-2-carboxylate
[0295]
[0296] Methyl 3-bromo-2-oxobutanoate (6.5 g, 34.3 mmol) was added to a stirred solution of 2-aminopyridine (4.0 g, 42.5 mmol) in acetonitrile (100 ml). The mixture was heated at reflux for 14 h (the reaction was monitored by TLC). The mixture was concentrated in vacuo and the residue was diluted with water and the pH was to 7.5 using sodium bicarbonate solution. The mixture was extracted with EtOAc; the combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 8% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford methyl 3-methylimidazo[1,2-a]pyridine-2-carboxylate (2.0 g, 25.1%,) as a pale yellow solid. 1 H NMR: 200 MHz, CDCl 3 : δ 7.95 (d, 1H), 7.7 (d, 1H), 7.25 (t, 1H), 6.8 (t, 1H), 4.0 (s, 3H), 2.8 (s, 3H). MS: [M+H]+: m/z=191.1.
(3-Methylimidazo[1,2-a]pyridin-2-yl)methanol
[0297]
[0298] Sodium borohydride (1.5 g, 41.6 mmol) was added to a solution of methyl 3-methylimidazo[1,2-a]pyridine-2-carboxylate (2.0 g, 10.5 mmol) in THF (50 mL) and methanol (2.5 ml) at RT. The reaction mixture was stirred at RT for 2 h (the reaction was monitored by TLC) upon which the mixture was concentrated under reduced pressure. The residue was diluted with water and extracted with EtOAc. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure to afford (3-methylimidazo[1,2-a]pyridin-2-yl)methanol (0.8 g, 47.05%,) as off-white solid. 1 H NMR: 200 MHz, CDCl 3 : δ 7.45 (d, 1H), 7.6 (d, 1H), 7.2 (t, 1H), 6.8 (t, 1H), 4.85 (s, 2H), 2.45 (s, 3H). MS: [M+H]+: m/z=162.9.
2-(Chloromethyl)-3-methylimidazo[1,2-a]pyridine
[0299]
[0300] Thionyl chloride (10 ml) was added to (3-methylimidazo[1,2-a]pyridin-2-yl)methanol (0.8 g, 4.9 mmol) at 20° C. under an atmosphere of nitrogen. The reaction mixture was stirred at reflux for 3 h (the reaction was monitored by TLC). The mixture was concentrated under reduced pressure, the residue was diluted with water and extracted with EtOAc. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 6% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford 2-(chloroethyl)-3-methylimidazo[1,2-a]pyridine (400 mg, 45.4%,) as an off-white solid. 1 H NMR: 200 MHz, CDCl 3 : δ 8.15 (s, 1H), 7.6 (s, 1H), 7.55 (d, 1H), 7.15 (d, 1H), 4.75 (s, 2H). MS: [M+H]+: m/z=181.3.
5-(4-Methoxyphenyl)-2,2-dimethyl-4-(4-((3-methylimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)furan-3(2H)-one
[0301]
[0302] 4-(4-Hydroxyphenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (0.1 g, 0.32 mmol) was added to a mixture of cesium carbonate (0.52 g, 1.62 mmol) and DMF (20 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred at RT for 30 min upon which 2-(chloromethyl)-3-methylimidazo[1,2-a]pyridine (87 mg, 0.48 mmol) was added. The mixture was heated at for 4 h (the reaction was monitored by TLC). The reaction mixture was diluted with water and extracted with EtOAc, the combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 20% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford 5-(4-methoxyphenyl)-2,2-dimethyl-4-(4-((3-methylimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)furan-3(2H)-one (2.8 g, 77%,) as an off-white solid. 1 H NMR, 500 MHz, DMSO-d 6 : δ 8.25 (d, 1H), 7.45 (d, 3H), 7.25 (t, 1H), 7.15-6.95 (Ar, 7H), 5.2 (s, 2H), 3.85 (s, 3H), 2.45 (s, 3H), 1.45 (s, 6H). MS: [M+H]+: m/z=455.3. HPLC: (96.3%, Condition-A).
2-(Chloromethyl)-5-methylimidazo[1,2-a]pyridine
[0303]
[0304] 1,3-Dichloroacetone (17.6 g, 138.3 mmol) was added to a solution of 6-methylpyridin-2-amine (10 g, 92.5 mmol) in acetonitrile (200 ml). The mixture was heated at reflux for 14 h (the reaction was monitored by TLC). The mixture was concentrated under reduced pressure, the residue was diluted with water, and the pH was adjusted to 7.5 with sodium bicarbonate solution. The mixture was extracted with EtOAc, the combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 10% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford 2-(chloromethyl)-5-methylimidazo[1,2-a]pyridine (7.0 g, 70.7%,) as a pale yellow solid. 1 H NMR: 200 MHz, CDCl 3 : δ 8.15 (s, 1H), 7.6 (dd, 2H), 7.1 (t, 1H), 6.8 (t, 1H), 4.95 (s, 2H), 2.6 (s, 3H). MS: [M+H]+: m/z=181.5.
5-(4-Methoxyphenyl)-2,2-dimethyl-4-(4-((5-methylimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)furan-3(2H)-one
[0305]
[0306] 4-(4-Hydroxyphenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (250 mg, 0.8 mmol) was added to a mixture of cesium carbonate (1.05 g, 3.22 mmol) and DMF (20 mL) at RT under nitrogen. The reaction mixture was stirred at RT for 30 minutes upon which 2-(chloromethyl)-5-methylimidazo[1,2-a]pyridine (218 mg, 1.2 mmol) was added. The mixture was heated at for 4 h (the reaction was monitored by TLC) upon which the reaction mixture was diluted with water and extracted with EtOAc. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 15% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford 5-(4-methoxyphenyl)-2,2-dimethyl-4-(4-((5-methylimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)furan-3(2H)-one (280 mg, 77.7%,) as a light yellow solid. 1 H NMR: 500 MHz, DMSO-d 6 : δ 7.95 (s, 1H), 7.6 (d, 2H), 7.4 (d, 1H), 7.25 (t, 1H), 7.2 (d, 3H), 7.15 (d, 2H), 7.0 (d, 2H), 6.8 (d, 1H), 5.2 (s, 2H) 3.85 (s, 3H), 2.6 (s, 3H), 1.25 (s, 6H). MS: [M+H]+: m/z=455.6. HPLC: (97.3%, Condition-A).
5-(4-Methoxyphenyl)-2,2-dimethyl-4-(4-((5-methylimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)furan-3(2H)-one methanesulfonate
[0307]
[0308] Methanesulfonic acid (53.1 mg, 0.5 mmol) was added to a solution of 5-(4-methoxyphenyl)-2,2-dimethyl-4-(4-((5-methylimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)furan-3(2H)-one (250 g, 0.5 mmol) in DCM (2.5 ml) and diethyl ether (50 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred at RT for 4 h upon which, the solids were collected by filtration, washed with 20% DCM in diethyl ether, dried in vacuo to afford 5-(4-methoxyphenyl)-2,2-dimethyl-4-(4-((5-methylimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)furan-3(2H)-one methanesulfonate (240 mg, 82.7%,) as white solid. 1 H NMR: 500 MHz, DMSO-d 6 : δ 7.95 (s, 1H), 7.6 (d, 2H), 7.4 (d, 1H), 7.25 (t, 1H), 7.2 (d, 3H), 7.15 (d, 2H), 7.0 (d, 2H), 6.8 (d, 1H), 5.2 (s, 2H) 3.85 (s, 3H), 2.6 (s, 3H), 2.5 (s, 3H), 1.25 (s, 6H), HPLC: (98.4%, Condition-A).
6-Chloro-2-(chloromethyl)imidazo[1,2-a]pyridine
[0309]
[0310] 1,3-Dichloroacetone (7.4 g, 58.3 mmol) was added to a solution of 5-chloropyridin-2-amine (5.0 g, 38.9 mmol) in acetonitrile (100 ml). The mixture was heated at reflux for 14 h (the reaction was monitored by TLC). Upon completion of the reaction as judged by TLC, the mixture was concentrated under reduced pressure. The residue was diluted with water and the pH was adjusted to 7.5 with sodium bicarbonate solution. The mixture was extracted with EtOAc, the combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 10% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford 6-chloro-2-(chloromethyl)imidazo[1,2-a]pyridine (1.5 g, 30%,) as a pale yellow solid. 1 H NMR: 200 MHz, CDCl 3 : δ 8.0 (d, 1H), 7.6 (dd, 2H), 6.8 (d, 1H), 4.75 (s, 2H). MS: [M+H]+: m/z=201.9.
4-(4-((6-Chloroimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one
[0311]
[0312] 4-(4-Hydroxyphenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (300 mg, 0.96 mmol) was added to a mixture of cesium carbonate (1.05 g, 3.8 mmol) and DMF (20 mL) at RT under nitrogen. The reaction mixture was stirred at RT for 30 minutes, upon which 6-chloro-2-(chloromethyl)imidazo[1,2-a]pyridine (201 mg, 1.4 mmol) was added. The mixture was heated at 80° C. for 4 h (the reaction was monitored by TLC). Upon completion of the reaction as judged by TLC, the reaction mixture was diluted with water and extracted with EtOAc. The combined organics were dried over sodium sulfate, filtered and concentrated under reduced pressure. The residue was purified by flash column chromatography using 20% ethyl acetate in n-hexane and silica gel (230-400 mesh) to afford 4-(4-((6-chloroimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)-5-(4-methoxy phenyl)-2,2-dimethylfuran-3(2H)-one (180 mg, 39.3%,) as a white solid. 1 H NMR, 500 MHz, DMSO-d 6 : δ 8.85 (s, 1H), 8.0 (s, 1H), 7.6 (d, 3H), 7.3 (d, 1H), 7.15 (d, 2H), 7.1 (d, 2H), 7.0 (d, 2H), 5.15 (s, 2H) 3.8 (s, 3H), 1.4 (s, 6H). MS: [M+H]+: m/z=475. HPLC: (98.0%, Condition-A).
4-(4-((6-Chloroimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one methanesulfonate
[0313]
[0314] Methanesulfonic acid (53.1 mg, 0.5 mmol) was added to a solution of compound 4-(4-((6-chloroimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one (250 g, 0.5 mmol) in DCM (2.5 ml) and diethyl ether (50 mL) at RT under an atmosphere of nitrogen. The reaction mixture was stirred at RT for 4 h upon which the solids were collected by filtration, washed with 20% DCM in diethyl ether and dried in vacuo to afford 4-(4-((6-chloroimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-dimethylfuran-3(2H)-one methanesulfonate (240 mg, 82%,) as a white solid. 1 H NMR: 500 MHz, DMSO-d 6 : δ 8.8 (s, 1H), 8.3 (s, 1H), 8.0 (s, 1H), 7.6 (d, 2H), 7.4 (d, 1H), 7.15 (d, 2H), 7.1 (d, 2H), 7.0 (d, 2H) 5.35 (s, 2H), 3.8 (s, 3H), 2.3 (s, 3H), 1.4 (s, 6H), HPLC: (99.3%, Condition-A).
Tables
[0315] In the following tables, if a specific example contains multiple instances of R 2 , they will be separated by commas in the table (e.g. Me, Me or Et, Me). If the R 2 column contains a value “—group—” e.g. “—cyclopropyl—”, then both R 2 values are taken together to be a spiro ring.
[0316] In a further aspect the compounds of the disclosure are embodied in with distinct examples listed in the table below taken from Formula (I):
[0000]
Example
#
HET
X
Z
R 2
1
A29
Me, Me
2
A29
Me, Me
3
A29
Me, Me
4
A29
Me, Me
5
A29
Me, Me
6
A29
Me, Me
7
A29
Me, Me
8
A29
Me, Me
9
A29
Me, Me
10
A29
Me, Me
11
A29
Me, Me
12
A29
Me, Me
13
A29
Me, Me
14
A29
Me, Me
15
A29
Me, Me
16
A29
Me, Me
17
A29
Me, Me
18
A29
Me, Me
19
A29
Me, Me
20
A29
Me, Me
21
A29
Me, Me
22
A29
Me, Me
23
A29
Me, Me
24
A29
Me, Me
25
A29
Me, Me
26
A29
Me, Me
27
A29
Me, Me
28
A29
Me, Me
29
A29
Me, Me
30
A29
Me, Me
31
A29
Me, Me
32
A29
Me, Me
33
A29
Me, Me
34
A29
Me, Me
35
A29
Me, Me
36
A29
Me, Me
37
A29
Me, Me
38
A29
Me, Me
39
A29
Me, Me
40
A29
Me, Me
41
A29
Me, Me
42
A29
Me, Me
43
A29
Me, Me
44
A29
Me, Me
45
A29
Me, Me
46
A29
Me, Me
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Me, Me
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Me, Me
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Me, Me
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A31
Me, Me
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A31
Me, Me
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A31
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A31
Me, Me
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A29
-cyclopropyl-
494
A29
-cyclopropyl-
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A29
-cyclopropyl-
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A29
-cyclopropyl-
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A29
-cyclopropyl-
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A29
-cyclopropyl-
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A29
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A29
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A29
-cyclopropyl-
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A29
-cyclopropyl-
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A29
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A29
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A29
-cyclopropyl-
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A29
-cyclopropyl-
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A29
-cyclopropyl-
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A29
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A29
-cyclopropyl-
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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579
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
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A29
-cyclopropyl-
720
A29
-cyclopropyl-
721
A29
-cyclopropyl-
722
A29
-cyclopropyl-
723
A29
-cyclopropyl-
724
A29
-cyclopropyl-
725
A29
-cyclopropyl-
726
A29
-cyclopropyl-
727
A29
-cyclopropyl-
728
A29
-cyclopropyl-
729
A29
-cyclopropyl-
730
A29
-cyclopropyl-
731
A29
-cyclopropyl-
732
A29
-cyclopropyl-
Dosage and Administration
[0317] The present disclosure includes pharmaceutical composition for treating a subject having a neurological disorder comprising a therapeutically effective amount of a compound of Formula (I), a derivative or a pharmaceutically acceptable salt thereof, and a pharmaceutically acceptable excipient, carrier or diluent.
[0000] The pharmaceutical compositions can be administered in a variety of dosage forms including, but not limited to, a solid dosage form or in a liquid dosage form, an oral dosage form, a parenteral dosage form, an intranasal dosage form, a suppository, a lozenge, a troche, buccal, a controlled release dosage form, a pulsed release dosage form, an immediate release dosage form, an intravenous solution, a suspension or combinations thereof. The dosage can be an oral dosage form that is a controlled release dosage form. The oral dosage form can be a tablet or a caplet. The compounds can be administered, for example, by oral or parenteral routes, including intravenous, intramuscular, intraperitoneal, subcutaneous, transdermal, airway (aerosol), rectal, vaginal and topical (including buccal and sublingual) administration. In one embodiment, the compounds or pharmaceutical compositions comprising the compounds are delivered to a desired site, such as the brain, by continuous injection via a shunt.
[0318] In another embodiment, the compound can be administered parenterally, such as intravenous (IV) administration. The formulations for administration will commonly comprise a solution of the compound of the Formula (I) dissolved in a pharmaceutically acceptable carrier. Among the acceptable vehicles and solvents that can be employed are water and Ringer's solution, an isotonic sodium chloride. In addition, sterile fixed oils can conventionally be employed as a solvent or suspending medium. For this purpose any bland fixed oil can be employed including synthetic mono- or diglycerides. In addition, fatty acids such as oleic acid can likewise be used in the preparation of injectables. These solutions are sterile and generally free of undesirable matter. These formulations may be sterilized by conventional, well known sterilization techniques. The formulations may contain pharmaceutically acceptable auxiliary substances as required to approximate physiological conditions such as pH adjusting and buffering agents, toxicity adjusting agents, e.g., sodium acetate, sodium chloride, potassium chloride, calcium chloride, sodium lactate and the like. The concentration of compound of Formula (I) in these formulations can vary widely, and will be selected primarily based on fluid volumes, viscosities, body weight, and the like, in accordance with the particular mode of administration selected and the patient's needs. For IV administration, the formulation can be a sterile injectable preparation, such as a sterile injectable aqueous or oleaginous suspension. This suspension can be formulated according to the known art using those suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation can also be a sterile injectable solution or suspension in a nontoxic parenterally-acceptable diluent or solvent, such as a solution of 1,3-butanediol.
[0319] In one embodiment, a compound of Formula (I) can be administered by introduction into the central nervous system of the subject, e.g., into the cerbrospinal fluid of the subject. The formulations for administration will commonly comprise a solution of the compound of Formula (I) dissolved in a pharmaceutically acceptable carrier. In certain aspects, the compound of Formula (I) is introduced intrathecally, e.g., into a cerebral ventricle, the lumbar area, or the cisterna magna. In another aspect, the compound of Formula (I) is introduced intraocularly, to thereby contact retinal ganglion cells.
[0320] The pharmaceutically acceptable formulations can easily be suspended in aqueous vehicles and introduced through conventional hypodermic needles or using infusion pumps. Prior to introduction, the formulations can be sterilized with, preferably, gamma radiation or electron beam sterilization.
[0321] In one embodiment, the pharmaceutical composition comprising a compound of Formula (I) is administered into a subject intrathecally. As used herein, the term “intrathecal administration” is intended to include delivering a pharmaceutical composition comprising a compound of Formula (I) directly into the cerebrospinal fluid of a subject, by techniques including lateral cerebroventricular injection through a burrhole or cisternal or lumbar puncture or the like (described in Lazorthes et al. Advances in Drug Delivery Systems and Applications in Neurosurgery, 143-192 and Omaya et al., Cancer Drug Delivery, 1: 169-179, the contents of which are incorporated herein by reference). The term “lumbar region” is intended to include the area between the third and fourth lumbar (lower back) vertebrae. The term “cisterna magna” is intended to include the area where the skull ends and the spinal cord begins at the back of the head. The term “cerebral ventricle” is intended to include the cavities in the brain that are continuous with the central canal of the spinal cord. Administration of a compound of Formula (I) to any of the above mentioned sites can be achieved by direct injection of the pharmaceutical composition comprising the compound of Formula (I) or by the use of infusion pumps. For injection, the pharmaceutical compositions can be formulated in liquid solutions, preferably in physiologically compatible buffers such as Hank's solution or Ringer's solution. In addition, the pharmaceutical compositions may be formulated in solid form and re-dissolved or suspended immediately prior to use. Lyophilized forms are also included. The injection can be, for example, in the form of a bolus injection or continuous infusion (e.g., using infusion pumps) of pharmaceutical composition.
[0322] In one embodiment, the pharmaceutical composition comprising a compound of Formula (I) is administered by lateral cerebro ventricular injection into the brain of a subject. The injection can be made, for example, through a burr hole made in the subject's skull. In another embodiment, the encapsulated therapeutic agent is administered through a surgically inserted shunt into the cerebral ventricle of a subject. For example, the injection can be made into the lateral ventricles, which are larger, even though injection into the third and fourth smaller ventricles can also be made.
[0323] In yet another embodiment, the pharmaceutical composition is administered by injection into the cisterna magna, or lumbar area of a subject.
[0324] For oral administration, the compounds will generally be provided in unit dosage forms of a tablet, pill, dragee, lozenge or capsule; as a powder or granules; or as an aqueous solution, suspension, liquid, gels, syrup, slurry, etc. suitable for ingestion by the patient. Tablets for oral use may include the active ingredients mixed with pharmaceutically acceptable excipients such as inert diluents, disintegrating agents, binding agents, lubricating agents, sweetening agents, flavoring agents, coloring agents and preservatives. Suitable inert diluents include sodium and calcium carbonate, sodium and calcium phosphate, and lactose, while corn starch and alginic acid are suitable disintegrating agents. Binding agents may include starch and gelatin, while the lubricating agent, if present, will generally be magnesium stearate, stearic acid or talc. If desired, the tablets may be coated with a material such as glyceryl monostearate or glyceryl distearate, to delay absorption in the gastrointestinal tract.
[0325] Pharmaceutical preparations for oral use can be obtained through combination of a compound of Formula (I) with a solid excipient, optionally grinding a resulting mixture, and processing the mixture of granules, after adding suitable additional compounds, if desired, to obtain tablets or dragee cores. Suitable solid excipients in addition to those previously mentioned are carbohydrate or protein fillers that include, but are not limited to, sugars, including lactose, sucrose, mannitol, or sorbitol; starch from corn, wheat, rice, potato, or other plants; cellulose such as methyl cellulose, hydroxypropylmethyl-cellulose or sodium carboxymethylcellulose; and gums including arabic and tragacanth; as well as proteins such as gelatin and collagen. If desired, disintegrating or solubilizing agents may be added, such as the cross-linked polyvinyl pyrrolidone, agar, alginic acid, or a salt thereof, such as sodium alginate.
[0326] Capsules for oral use include hard gelatin capsules in which the active ingredient is mixed with a solid diluent, and soft gelatin capsules wherein the active ingredients is mixed with water or an oil such as peanut oil, liquid paraffin or olive oil.
[0327] Dragee cores are provided with suitable coatings. For this purpose, concentrated sugar solutions may be used, which may optionally contain gum arabic, talc, polyvinyl pyrrolidone, carbopol gel, polyethylene glycol, and/or titanium dioxide, lacquer solutions, and suitable organic solvents or solvent mixtures. Dyestuffs or pigments may be added to the tablets or dragee coatings for identification or to characterize different combinations of active compound doses.
[0328] For transmucosal administration (e.g., buccal, rectal, nasal, ocular, etc.), penetrants appropriate to the barrier to be permeated are used in the formulation. Such penetrants are generally known in the art.
[0329] Formulations for rectal administration may be presented as a suppository with a suitable base comprising for example cocoa butter or a salicylate. Formulations suitable for vaginal administration may be presented as pessaries, tampons, creams, gels, pastes, foams or spray formulations containing in addition to the active ingredient such carriers as are known in the art to be appropriate. For intramuscular, intraperitoneal, subcutaneous and intravenous use, the compounds will generally be provided in sterile aqueous solutions or suspensions, buffered to an appropriate pH and isotonicity. Suitable aqueous vehicles include Ringer's solution and isotonic sodium chloride. Aqueous suspensions may include suspending agents such as cellulose derivatives, sodium alginate, polyvinyl-pyrrolidone and gum tragacanth, and a wetting agent such as lecithin. Suitable preservatives for aqueous suspensions include ethyl and n-propyl p-hydroxybenzoate.
[0330] The suppositories for rectal administration of the drug can be prepared by mixing the drug with a suitable non-irritating excipient which is solid at ordinary temperatures but liquid at the rectal temperatures and will therefore melt in the rectum to release the drug. Such materials are cocoa butter and polyethylene glycols.
[0331] The compounds can be delivered transdermally, by a topical route, formulated as applicator sticks, solutions, suspensions, emulsions, gels, creams, ointments, pastes, jellies, paints, powders, or aerosols.
[0332] The compounds may also be presented as aqueous or liposome formulations. Aqueous suspensions can contain a compound of Formula (I) in admixture with excipients suitable for the manufacture of aqueous suspensions. Such excipients include a suspending agent, such as sodium carboxymethylcellulose, methylcellulose, hydroxypropylmethylcellulose, sodium alginate, polyvinylpyrrolidone, gum tragacanth and gum acacia, and dispersing or wetting agents such as a naturally occurring phosphatide (e.g., lecithin), a condensation product of an alkylene oxide with a fatty acid (e.g., polyoxyethylene stearate), a condensation product of ethylene oxide with a long chain aliphatic alcohol (e.g., heptadecaethylene oxycetanol), a condensation product of ethylene oxide with a partial ester derived from a fatty acid and a hexitol (e.g., polyoxyethylene sorbitol mono-oleate), or a condensation product of ethylene oxide with a partial ester derived from fatty acid and a hexitol anhydride (e.g., polyoxyethylene sorbitan monooleate). The aqueous suspension can also contain one or more preservatives such as ethyl or n-propyl p-hydroxybenzoate, one or more coloring agents, one or more flavoring agents and one or more sweetening agents, such as sucrose, aspartame or saccharin. Formulations can be adjusted for osmolarity.
[0333] Oil suspensions can be formulated by suspending a compound of Formula (I) in a vegetable oil, such as arachis oil, olive oil, sesame oil or coconut oil, or in a mineral oil such as liquid paraffin; or a mixture of these. The oil suspensions can contain a thickening agent, such as beeswax, hard paraffin or cetyl alcohol. Sweetening agents can be added to provide a palatable oral preparation, such as glycerol, sorbitol or sucrose. These formulations can be preserved by the addition of an antioxidant such as ascorbic acid. As an example of an injectable oil vehicle, see Minto, J. Pharmacol. Exp. Ther. 281:93-102, 1997. The pharmaceutical formulations can also be in the form of oil-in-water emulsions. The oily phase can be a vegetable oil or a mineral oil, described above, or a mixture of these. Suitable emulsifying agents include naturally-occurring gums, such as gum acacia and gum tragacanth, naturally occurring phosphatides, such as soybean lecithin, esters or partial esters derived from fatty acids and hexitol anhydrides, such as sorbitan mono-oleate, and condensation products of these partial esters with ethylene oxide, such as polyoxyethylene sorbitan mono-oleate. The emulsion can also contain sweetening agents and flavoring agents, as in the formulation of syrups and elixirs. Such formulations can also contain a demulcent, a preservative, or a coloring agent.
[0334] In addition to the formulations described previously, the compounds may also be formulated as a depot preparation. Such long acting formulations may be administered by implantation or transcutaneous delivery (e.g., subcutaneously or intramuscularly), intramuscular injection or a transdermal patch. Thus, for example, the compounds may be formulated with suitable polymeric or hydrophobic materials (e.g., as an emulsion in an acceptable oil) or ion exchange resins, or as sparingly soluble derivatives, for example, as a sparingly soluble salt.
[0335] The pharmaceutical compositions also may comprise suitable solid or gel phase carriers or excipients. Examples of such carriers or excipients include but are not limited to calcium carbonate, calcium phosphate, various sugars, starches, cellulose derivatives, gelatin, and polymers such as polyethylene glycols.
[0336] For administration by inhalation, the compounds are conveniently delivered in the form of an aerosol spray presentation from pressurized packs or a nebulizer, with the use of a suitable propellant, e.g., dichlorodifluoromethane, trichlorofluoromethane, dichlorotetrafluoroethane, carbon dioxide or other suitable gas. In the case of a pressurized aerosol the dosage unit may be determined by providing a valve to deliver a metered amount. Capsules and cartridges of e.g., gelatin for use in an inhaler or insufflator may be formulated containing a powder mix of the compound and a suitable powder base such as lactose or starch.
[0337] In general a suitable dose will be in the range of 0.01 to 100 mg per kilogram body weight of the recipient per day, preferably in the range of 0.1 to 10 mg per kilogram body weight per day. The desired dose is preferably presented once daily, but may be dosed as two, three, four, five, six or more sub-doses administered at appropriate intervals throughout the day.
[0338] The compounds can be administered as the sole active agent, or in combination with other known therapeutics to be beneficial in the treatment of neurological disorders. In any event, the administering physician can provide a method of treatment that is prophylactic or therapeutic by adjusting the amount and timing of drug administration on the basis of observations of one or more symptoms (e.g., motor or cognitive function as measured by standard clinical scales or assessments) of the disorder being treated.
[0339] Details on techniques for formulation and administration are well described in the scientific and patent literature, see, e.g., the latest edition of Remington's Pharmaceutical Sciences, Maack Publishing Co, Easton Pa. After a pharmaceutical composition has been formulated in an acceptable carrier, it can be placed in an appropriate container and labeled for treatment of an indicated condition. For administration of the compounds of Formula (I), such labeling would include, e.g., instructions concerning the amount, frequency and method of administration.
Biological Examples
In Vivo Methods
[0340] Subjects: Male C57BL/6J mice (Charles River; 20-25 g) were used for all assays except prepulse inhibition (PPI) which used male DBA/2N mice (Charles River, 20-25 g). For all studies, animals were housed five/cage on a 12-h light/dark cycle with food and water available ad libitum.
[0341] Conditioned avoidance responding: Testing was performed in commercially available avoidance boxes (Kinder Scientific, Poway Calif.). The boxes were divided into two compartments separated by an archway. Each side of the chamber has electronic grid flooring that is equipped to administer footshocks and an overhead light. Training consisted of repeated pairings of the light (conditioned stimulus) followed by a shock (unconditioned stimulus). For each trial the light was presented for 5 sec followed by a 0.5 mA shock that would terminate if the mouse crossed to the other chamber or after 10 seconds. The intertrial interval was set to 20 seconds. Each training and test session consisted a four min habituation period followed by 30 trials. The number of avoidances (mouse crossed to other side during presentation of the light), escapes (mouse crossed to the other side during presentation of the shock) and failures (mouse did not cross during the entire trial period) were recorded by a computer. For study inclusion an animal had to reach a criterion of at least 80% avoidances for two consecutive test sessions.
[0342] PPI: Mice were individually placed into the test chambers (StartleMonitor, Kinder Scientific, Poway Calif.). The animals were given a five min acclimation period to the test chambers with the background noise level set to 65 decibel (dB) which remained for the entire test session. Following acclimation, four successive trials 120 dB pulse for 40 msec were presented, however these trials were not included in data analysis. The mice were then subjected to five different types of trials in random order: pulse alone (120 dB for 40 msec), no stimulus and three different prepulse+pulse trials with the prepulse set at 67, 69 or 74 dB for 20 msec followed a 100 msec later by a 120 dB pulse for 40 msec. Each animal received 12 trials for each condition for a total of 60 trials with an average intertrial interval of 15 sec. Percent PPI was calculated according to the following formula: (1−(startle response to prepulse+pulse)/startle response to pulse alone))×100.
[0343] MK-801-induced hyperactivity: After a 30 min acclimatation to the test room mice were individually placed into test cages for a 30 min habituation period. Following habituation to test cages, baseline activity was recorded for 60 min. Mice were then briefly removed and administered test compound and placed immediately back into the test cage. At 5 min prior to test time mice were again briefly removed from test cages and administered MK-801 (0.3 mg/kg, i.p. in 0.9% saline) and then immediately placed back into test cages and activity level recorded 1 hour. Activity level was measured as distance travelled in centimeters (Ethovision tracking software, Noldus Inc. Wageningen, Netherlands).
[0344] Catalepsy: Mice were placed on a wire mesh screen set at a 60 degree angle with their heads facing upwards and the latency to move or break stance was recorded. Animals were given three trials per time point with a 30 sec cut-off per trial.
[0345] Data analysis: A one-way or two-way ANOVA was used to evaluate overall differences between treatments and a Tukey's post-hoc test or Student's t-test was used to evaluate differences between treatment groups for the one-way ANOVA and a Bonferroni test was used for the two-way ANOVA. The criterion for statistical significance was set to p≦0.05.
In Vitro Methods
[0346] hPDE10A1 Enzyme Activity: 50 μl samples of serially diluted Human PDE10A1 enzyme were incubated with 50 μl of [ 3 H]-cAMP for 20 minutes (at 37° C.). Reactions were carried out in Greiner 96 deep well 1 ml master-block. The enzyme was diluted in 20 mM Tris HCl pH7.4 and [ 3 H]-cAMP was diluted in 10 mM MgCl 2 , 40 mM Tris.HCl pH 7.4. The reaction was terminated by denaturing the PDE enzyme (at 70° C.) after which [ 3 H]-5′-AMP was converted to [ 3 H]-adenosine by adding 25 μl snake venom nucleotidase and incubating for 10 minutes (at 37° C.). Adenosine, being neutral, was separated from charged cAMP or AMP by the addition of 200 μl Dowex resin. Samples were shaken for 20 minutes then centrifuged for 3 minutes at 2,500 r.p.m. 50 μl of supernatant was removed and added to 200 μl of MicroScint-20 in white plates (Greiner 96-well Optiplate) and shaken for 30 minutes before reading on Perkin Elmer TopCount Scintillation Counter.
[0347] hPDE10A1 Enzyme Inhibition: To check inhibition profile 11 μl of serially diluted inhibitor was added to 50 μl of [ 3 H]-cAMP and 50 ul of diluted Human PDE10A1 and assay was carried out as in the enzyme activity assay. Data was analysed using Prism software (GraphPad Inc). Representative compounds of this disclosure are shown in the table below. A compound with the value “A” had an IC 50 value less than or equal to 10 nM. A compound with the value “B” had an IC 50 value greater than 10 nM and less than 50 nM:
[0000]
hPDE10A1
Name
IC 50 Band
4-(4-((3,5-dimethylpyridin-2-yl)methoxy)phenyl)-5-(4-methoxyphenyl)-2,2-
A
dimethylfuran-3(2H)-one
4-(4-(imidazo[1,2-a]pyridin-2-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-2,2-
A
dimethylfuran-3(2H)-one
4-(4-(imidazo[1,2-b]pyridazin-6-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-
B
2,2-dimethylfuran-3(2H)-one
4-(4-((6-chloroimidazo[1,2-b]pyridazin-2-yl)methoxy)phenyl)-5-(4-
B
methoxyphenyl)-2,2-dimethylfuran-3(2H)-one
4-(4-(imidazo[1,2-b]pyridazin-2-ylmethoxy)phenyl)-5-(4-methoxyphenyl)-
A
2,2-dimethylfuran-3(2H)-one
4-(3-(4-(imidazo[1,2-a]pyridin-2-ylmethoxy)phenyl)-5,5-dimethyl-4-oxo-4,5-
A
dihydrofuran-2-yl)benzonitrile
4-(4-((3-chloroimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)-5-(4-
A
methoxyphenyl)-2,2-dimethylfuran-3(2H)-one
5-(4-methoxyphenyl)-2,2-dimethyl-4-(4-((5-methylpyridin-2-
A
yl)methoxy)phenyl)furan-3(2H)-one
4-(5,5-dimethyl-3-(4-((5-methylpyridin-2-yl)methoxy)phenyl)-4-oxo-4,5-
A
dihydrofuran-2-yl)benzonitrile
4-(4-((6-chloroimidazo[1,2-a]pyridin-2-yl)methoxy)phenyl)-5-(4-
A
methoxyphenyl)-2,2-dimethylfuran-3(2H)-one
5-(4-methoxyphenyl)-2,2-dimethyl-4-(4-((3-methylimidazo[1,2-a]pyridin-2-
B
yl)methoxy)phenyl)furan-3(2H)-one
5-(4-methoxyphenyl)-2,2-dimethyl-4-(4-((5-methylimidazo[1,2-a]pyridin-2-
A
yl)methoxy)phenyl)furan-3(2H)-one
|
Phenoxymethyl compounds that inhibit at least one phosphodiesterase 10 are described as are pharmaceutical compositions containing such compounds an methods for treating various CNS disorders by administering such compounds to a patient in need thereof.
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RELATED APPLICATIONS
This invention derives priority from a provisional U.S. patent application Ser. No. 62/196,278, having the same inventors, filed Jul. 23, 2015 and entitled “A Structure to Improve the Mobility and Safety of Medical Patients”.
FIELD OF THE INVENTION
The invention pertains to devices for intravenous administration and physical support for patients.
BACKGROUND
Intravenous (IV) devices date back to 1831, when Dr. Thomas Latta treated a choleric elderly Englishwoman with an IV injection to “throw the fluid immediately into the circulation”. There a vessel containing the fluid was held manually. Today IV infusion therapy is used routinely when fluid administration by another route might be physiologically less effective or simply less convenient for health care professionals. Modern infusion vessels for IV fluids are typically supported by a pole or a stand.
Mobile designs for IV stands are used widely to facilitate patient mobility, particularly in light of recent findings that early ambulation improves patient recovery times and reduces the length of their hospital stays. Yet greater mobility of these IV stands has also been associated with increased risk of in-hospital falls by the patient. Medicare and insurance are not required to cover the cost of treatment arising from such falls, yet by law hospitals and care facilities are responsible for those costs. The average per-patient cost for care after a patient's in-facility fall is $13,316 more than for comparable patients who have not fallen. See: Fisher et al., “Early Ambulation and Length of Stay in Older Adults Hospitalized with Acute Illness,” Archive of Internal Medicine, 170:21 (National Institutes of Health, U.S. National Library of Medicine, Nov. 22, 2010); risk factors in Anonymous, “Understanding Fall Risk Prevention and Protection,” posted at www.sizewise.net/getattachment/2d5c6915-509c-4d99-a653-bef8bcc56fdc/sw-fall-risk-toolkit.aspx; Ganz et al. “Preventing Falls in Hospitals: A Toolkit for Improving Quality of Care,” (Agency for Healthcare Research and Quality, January 2013).
In addition to fall-related hazards, the current design of IV poles is less than ideal for patients in other ways. The pole has a tall mast, the crown of which bears a load of fluids and commonly tips over. Often a single pole has a multitude of IV bags, each for a different drug to treat the hospitalized individual. Each bag has its own tubing to supply the implant on a person's arm. The tubes are cumbersome, may tangle, and sometimes yank the implant from a patient's arm when the stand topples. The addition of sensors, medicines and monitors to the pole adds to the apparatus weight and difficulty of control by patients.
The IV pole designs have disadvantages for nursing as well. Nurses in units for surgery, intensive care, and emergency care commonly criticize the designs as inconvenient due to their bulk, excessive height, large size of base footprint, tipping hazard, poor ergonomics, entanglement of cord and tubing, and lack of user-friendliness for patients who need to slow or stop a traveling pole. The prior art contains a variety of attempts to improve pole designs.
U.S. Pat. No. 2,627,431 A, issued 3 Feb. 1953 to Sechrist, provides methods for attaching a collar to a pole.
U.S. Pat. No. 3,929,210 A, issued 30 Dec. 1975 to Morris et al. teaches use of a spring to retract tubing, cord and or wire.
U.S. Pat. No. 5,865,065 A, issued 2 Feb. 1999 to Chiu, discloses use of a mechanical hand brake for use in walking aids.
U.S. Pat. No. 4,892,279 A, issued 9 Jan. 1990 to Lafferty et al. incorporates a folding tripod feature to facilitate portability of IV stands by allowing quick collapse and redeployment.
U.S. Pat. No. 6,585,683 B2, issued 19 Sep. 2001 to Sutton et al., discloses a structure with a form-fitting clip to hold a single tube.
US Pub. Pat. App. No. 2004/0144673 A1 by Mark Buczek, published 29 Jul. 2004, provides passages in a surgical tray to take up slack in surgical tubing in an operating room.
U.S. Pat. No. 8,313,066 B2, issued 20 Jun. 2012 to Hampton et al., discloses a quick-release system for wheels of an IV stand, and employs a plurality of casters.
U.S. Pat. No. 9,010,709 B1, issued 21 Apr. 2015 to Culpepper et al., teaches use of a ceiling-mounted articulated arm with an electromagnetic braking system to control the momentum of a suspended structure.
Although features of several of those inventions are in common use today, the contemporary design of mobile IV support devices continue to suffer from the disadvantages discussed above. Thus there is an ongoing need for improvements in their design.
SUMMARY OF THE INVENTION
The invention provides a medical intravenous support apparatus that facilitates patient mobility while reducing the likelihood of an accidental fall, and can be used in addition or alternatively for support of components for catheterization or other types of fluid transfer lines. The design incorporates improved features for bag support, tube management, patient steadiness, user-friendly braking, and electric power supply.
In a particular embodiment the invention provides an apparatus for support of components for transfer of fluids to or from medical patients, comprising:
a) a caster module wherein:
i) three or more casters are distributed about the caster module symmetrically relative to each other and equidistant from a virtual central point of the caster module; ii) a receiving collar defines a central passage through the caster module, wherein that passage is symmetrically distributed about a virtual center line that is defined by virtual central points of cross-sections of the passage when the caster module is horizontal; and iii) the receiving collar is configured to receive and hold a mast in an upright orientation when the casters rest on a horizontal floor surface;
b) an upright center mast wherein:
i) the mast passes through and is slidably connected to the receiving collar of the caster module; ii) the bottom of the mast is mated with one or more feet and said one or more feet reside below the receiving collar of the caster module when the casters rest on a horizontal floor surface; iii) one or more peripheral handles are mounted on a central portion of the mast, wherein:
A) at least one peripheral handle defines at least one channel for receiving at least one tube or power cord; and B) at least one power outlet is mounted on the center mast; and
iv) a crown is mounted at the top of the mast and comprises a plurality of supports for hanging, wherein each of at least two of said supports for hanging have sufficient strength to support at least one full bag of an intravenous fluid; and
c) the support apparatus further comprises a brake assembly comprising:
i) at least one hand brake handle, wherein at least one of the central portion of the mast and a peripheral handle has a hand brake handle mounted upon it; ii) a brake for application to at least one of a floor surface and a caster; and iii) a brake line that is connected to each of the hand brake handle and the brake.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a caricature depicting a non-limiting embodiment of the invention comprising the top half of the stand, a crown, hooks, vertical handles defining channels, retaining rings for tubing retention, a handgrip and power receptacles.
FIG. 2 is a caricature depicting a non-limiting embodiment of the invention, showing a cut-away section of a hand brake handle mechanism.
FIG. 3 is a caricature depicting a non-limiting embodiment of the invention, showing a braking mechanism.
FIG. 4 is a caricature depicting a non-limiting embodiment of the invention, showing a drawstring manager for tubing.
FIG. 5 is a caricature depicting a non-limiting embodiment of the invention, showing separately a drawstring spool, mating collar with an interior bezel, and a train that may tide or slide on the bezel.
FIG. 6 is a caricature depicting a non-limiting embodiment of the invention, showing an assembly in which a collar is mated with a spool by means of a train that may rotate inside the collar.
FIG. 7 is a caricature depicting a non-limiting embodiment of the invention, showing features of a bracket that may form either side of a handle.
FIG. 8 is a caricature depicting a non-limiting embodiment of the invention, showing an assembled apparatus according to the invention.
FIG. 9 is a caricature depicting a non-limiting embodiment of the invention, showing non-braking and braking states when a brake handle is turned to move a rod downward for a rod-in-tube mast configuration.
FIG. 10 is a caricature depicting a non-limiting embodiment of the invention, showing a brake that is actuated by a handle on a center mast, and use of pneumatic components to suspend the center mast and its feet out of contact with the floor surface.
FIG. 11 is a caricature depicting a non-limiting embodiment of the invention, showing non-braking and braking states when a brake is actuated by clamping a wheel or caster housing.
DETAILED DESCRIPTION OF THE INVENTION
The invention may be further understood by a consideration of the following definitions for terms as used herein.
The terms “apparatus”, “support apparatus” and “assembled apparatus” are used interchangeably and mean the entire device according to the invention.
The term “components for transfer of fluids to or from medical patients” as used with respect to components, means items useful for the delivery of fluids to or from medical patients, and includes but is not limited to bags such as are used for saline fluids, medicament-containing fluids, blood and platelets; tubes for transferring fluid between bags and needles; needles for intravenous delivery of fluids; catheters; and the like.
The term “transfer of fluids” as used with respect to components means that the fluids are delivered to or from the body of a medical patient.
The term “medical patient” means a patient for whom therapeutic or preventative treatment is being provided by means of a transfer of fluids. The term patient includes but is not limited to human patients, and may also include other mammals such as dogs, cats, primates, livestock, and may also include birds and fish that are medical patients.
The term “apparatus” means a device, and in particular a device that is capable of providing physical support simultaneously both for components for transfer of fluids and for a medical patient.
The term “caster” refers to a rolling element and may include but is not limited to a type of caster such a ball caster, wheel caster, bolt hole caster, leveling caster, plate caster, pneumatic caster, side-mount caster, or stem caster.
The term “caster module” means a base for supporting an apparatus, wherein the base is attached to and can be supported by one or more casters.
The term “distributed about the caster module symmetrically relative to each other,” as used with respect to a plurality of casters means that they are placed symmetrically across opposite sides of a line and/or that the plurality of casters is placed such that their locations at regular intervals around a circle.
The term “equidistant from a central point of the caster modules,” as used with respect to a plurality of casters, means that they are placed around a circle and at a relatively constant distance from a point at its origin, i.e., at the center of the circle.
The term “receiving collar” means the perimeter of an orifice in the caster module having a sufficient size, shape and materials strength such that when the module is upright and resting on an essentially horizontal surface and a suitable mast is inserted into the orifice, the mast can be held essentially erect.
The term “central passage” means the orifice in the caster module that is surrounded by the perimeter referred to as the receiving collar. The term “virtual central point” as used with respect to a central passage means the center of a cross-section of the passage. The term “virtual center line” as used with respect to a central passage means the line defined by the virtual central points as defined by two or more cross-sections of such a mast.
The terms “mast” and “center mast” are used interchangeably and mean a beam such as a rod, post, beam, spar, tube, combined rod-in-tube, or other structure useful for vertical support. As the term is used herein a mast may have a cross-section that is circular, triagonal, square or otherwise rectangular, or otherwise polygonal, or star-shaped with three or more vertices, or another shape, or may vary along the length of the mast. In some embodiments the cross-section of mast is constant but twists in orientation along the length of the mast. In some embodiments the mast is contoured at one or more areas on its surface in a way that provides ridges, cross-hatches, notches, bumps or other features that improve the ability to be gripped by a human hand or held by a handle such as a rubber, plastic or metal handle for gripping by a human hand.
The term “vertically mobile relative to the caster module”, as used relative to the center mast, means that the mast may be moved in upward and downward directions while the caster module remains stationary.
The term “pneumatic” as used with respect to components has its usual and ordinary sense in mechanical engineering. The terms “first site” and “second site” as used with respect to a pneumatic component refer to portions of that component that are mobile relative to each other.
The term “configured to receive and hold,” as used with respect to a receiving collar relative to a mast, means that the mast fits within the orifice in the receiving collar, with sufficiently close tolerances that the mast is held upright. The receiving collar may have grooves and or ridges that are complementary relative to respective corresponding ridges and or grooves of the mast. In some embodiments the receiving collar and or the mast may be lined on one or more of the mated surfaces with a composition that possesses high friction when pressure is applied. In further embodiments the receiving collar and or the mast may contain a brake actuation lever that is engaged when downward pressure is applied to the mast.
The terms “upright orientation” and “upright” as used with respect to a mast are interchangeable and mean that the mast is held at a relatively fixed orientation. In some embodiments the orientation angle is different from vertical and the angle falls within a range for which the outer value in degrees is: 0, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, or 120 degrees.
The “passes through” as used with respect to a mast and a receiving collar means that the mast is inserted into the orifice defined by the receiving collar.
The term “slidably connected as used with respect to a mast and a receiving collar means that when the mast passes through the receiving collar the mast retains significant freedom to slide along the pass-through direction relative to the receiving collar.
The term “bottom” as used with respect to a mast means the lowermost portion of the beam of a mast. In certain embodiments the mast may be split at the bottom to form legs, or may have legs otherwise attached at the bottom.
The term “foot” or “feet” as used with respect to a mast means a feature such as a cap, plug or appendage that may be affixed at or near the bottom of the mast or if present, at or near the bottom of a leg of the mast. In particular embodiments a foot is composed of a friction-enhancing material such as rubber, leather, a textile, or another friction-enhancing material.
The term “mated” as used with respect to a foot on a mast means attached, such as for instance, a cap inserted over and around the bottom of a beam, a protruding plug inserted into a hollow bottom end of a beam, an appendage affixed to a side near the bottom of a beam, irrespective of whether the beam is a simple beam or has legs. In particular the mating may be assisted by means of a device such as a screw, bolt, rivet, clamp or other attachment means.
The term “horizontal floor surface” means a surface such as the floor of a building, irrespective of whether the surface composition is wood, concrete, laminated material, ceramic, textile, or another composition.
The term “rest” as used with respect to a caster on a floor surface means that a rollable portion of the caster is in contact with the floor surface, irrespective of whether the rollable portion is braked or not.
The term “central portion of the mast” as used with respect to the location of a mounted component means that the component is mounted within a region of the mast that is intermediate between the caster module and a crown at the top of the mast.
The term “peripheral handle” means a feature that is attached to but extend away from a center mast. In illustrative non-limiting embodiments a peripheral handle has a configuration such as: forming a “D” shape with the center mast; extending horizontally from the center mast; forming a horizontal circle about the center mast, with attachment by braces to the center mast; linear and parallel to the center mast, with attachment by braces to the center mast; linear and orthogonal to the center mast, with attachment by braces to the center mast; and variations and combinations of the same.
The term “mounted” and “affixed” as used with respect to one component on another means that they are attached. In certain embodiments the attachment is permanent; in alternative embodiments it is susceptible to piecemeal manual disassembly and reassembly; in still other embodiments it affords quick-release disassembly and reassembly, illustrative non-limiting examples of the attachment include by means of a weld, screw, bolt, rivet, adhesive, male and female features of the handle and mast, paired hook-and-loop fabrics, suspension on one or more hooks, and friction fit. The terms mounted and affixed as used herein contemplate that one or more braces for a component may be the portion attached to another component.
The term “channel” as used with respect to a handle means that the handle has a hollow portion running for some length through it suitable for holding an intravenous tube or power cord. In particularly preferred embodiments the proportions and configuration of the handle and channel are such that an intravenous tube or power cord may be inserted into the channel manually and quickly, and supported by the channel without falling when the assembled support apparatus is upright. In particular embodiments the channel has a slot running along one side, where the slot is wide enough to insert a zone of tube or power cord through the slot. In some embodiments the slot is marginally narrower than the tube or power cord, such that either must be manually squeezed in order to fit through a slot. In certain other embodiments the slot is located on the upper half of a channel and sufficiently wide that no squeezing of the tube or power cord is necessary to insert them. In still other embodiments the handle is composed of a flexible material and a slit or slot along the length of a channel is pried open to allow insertion of the tube or power cord. In still other embodiments the channel is located at the interface between the handle and a brace or center mast, and the handle is of a type that may be quickly removed and replaced.
The term “define” as used with respect to a channel defined by a handle means that a channel is located within the handle.
The term “receive” as used with respect to a tube or power cord in a channel means that the channel has proportions and a configuration suitable for reversible placement of the tube or power cord into the channel.
The term “power outlet” means a feature having at least one electrical receptacle bearing at least one socket that has a design suitable for mechanically engaging with and supplying electricity to the plug of a power cord. In some embodiments the outlet is powered by electrical current from a cord that runs to a wall receptacle. In certain embodiments the outlet is alternatively or additionally powered by electrical current from a battery. In particular embodiments multi-socket outlets are mounted both above and below peripheral handles. In certain embodiments a power outlet is mounted at a sufficient distance and orientation relative to a hand brake handle that a user of the upright apparatus is unlikely to grasp the outlet when he or she needs or intends to grab the hand brake handle instead. In certain embodiments a power outlet is supplied by an electrical line for which a length is located within a tubular center mast; in various other embodiments a power outlet is supplied by an electrical line for which a length is located outside but attached to a center mast
The term “crown” means a feature that is located at the top of or above a center mast, and affixed to that center mast, and that comprises at least two supports for hanging. The crown may be in the form of arms that extend upward and or outward. Alternatively the crown may be a circular, polygonal, star-shaped or other shaped component that is attached directly or by means of braces to the center mast. The crown may optionally comprise several parts, for instance where a plurality of arms are individually and independently attached at or near the top of the center mast. The terms “arm” and “hook” as used with respect to a crown are used in a general sense and do not limit the exact shape of those respective components. In general a hook may be regarded as having some portion that curls back on itself while an arm may be regarded as having some portion that does not curl back on itself but extends outward and or upward. Some components may be regarded as having both an arm and a hook. And some arms may be regarded as being hooks as well, and vice versa.
The term “support for hanging” means a feature that is suitable for use in suspending an intravenous bag by its top end. Illustrative nonlimiting examples of support for hanging include arms, hooks, clips, clamps, straps and cords for tying. The term “support for hanging” contemplates optional use of a feature such as a carabiner or key-ring type of clip to attach a fixed component of the crown to an orifice in the sealed top margin of an intravenous bag.
The term “brake” means a component for inhibiting lateral motion of the upright assembled apparatus. In some embodiments a brake is applied by introducing friction between the apparatus and a floor surface. In certain embodiments a brake is applied by introducing friction to restrict motion at one or more casters. Illustrative nonlimiting examples of brakes for apparati according to the invention include a cap on the bottom of a center master where the cap may be pressed against a floor surface; an actuatable clamp for a caster; and a compressible housing for a caster.
The term “brake assembly” means all components involved braking and its actuation, including a hand brake handle, a brake line for conveying mechanical force and or electrical signals to actuate a brake, and the brake itself.
The term “hand brake” means a brake that may be actuated manually. Non-limiting illustrative examples include: pushing down on a center mast to initiate contact between a friction-providing foot and a floor surface; squeezing a handle on a mast to actuate brakes on casters; turning a lateral handle in a mast having a rod-in-a-tube configuration, such that turning the handle outward or alternatively inward lowers the rod such that a foot at the bottom of the rod comes into contact with a floor surface; and pushing down on a peripheral handle to apply pressure to one or more casters below, thereby actuating a brake at the one or more casters.
The term “handle” as used with respect to a hand brake means a handle by means of which the brake may be actuated manually.
The term “brake line” means the series of physically connected components through which brake actuation is necessarily performed. By way of an illustrative nonlimiting example, where a brake is applied by means of pushing a foot of a central mast against a floor surface the brake line is the central mast. Another such example is where a peripheral handle is pushed downward to apply a brake at a caster by compression of the caster housing against a wheel: There the brake line is the center mast, the caster module, a shock absorber if present at the caster, and—to the extent the caster housing is not regarded as part of the brake at that caster—also includes the caster housing exclusive of the zone or composition that serves as the braking material.
The term “engagement mechanism” as used with respect to a brake means the mode of actuation by which by which a user's pressure or motion at a hand brake handle applies the brake. In certain embodiments the mechanism is strictly mechanical in nature. In certain other embodiments the mechanism is by means of an assembly comprising one or more electrical components.
The term “downward force” means force or pressure applied in a substantially downward direction. The downward direction may be orthogonal to a floor surface or at some other angle relative to a floor surface, such as at a number of degrees falling within a range for which the outside value is 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35 or 30 degrees relative to a horizontal floor.
The term “critical threshold” as used with respect to the amount of force required to actuate a brake means the minimum amount of force or pressure that must be applied at the hand brake handle to engage the brake. In some embodiments of the invention the critical threshold is adjustable by the user, such as where a user is substantially lighter, substantially heavier, substantially weaker or substantially stronger or has substantially worse or better balance than an average range for intravenous patients. In certain embodiments the critical threshold is a force selected from an amount in pounds that is at least 2, 5, 10 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190 or 200 pounds.
The term “inhibited from rolling by means of the caster module” means that a brake is applied to at least one caster. Illustrative nonlimiting embodiments including: applying a clamp to a wheel or ball of a caster; and forcing a caster housing to make contact with a wheel or ball of a caster.
The term “rollable component” as used with respect to a caster means the portion of the caster that may rotate when in use, such as a wheel or ball.
The term “caster housing” means the portion of a caster within which a rollable component may rotate.
The term “line management collar” means a component that is attached to a central portion of the center mast, and that comprises at least one channel for receiving a tube and or power cord. The term line in this context applies to both tubes and power cords.
The term “line clasping feature” means a component that attaches to a tube or power cord. Illustrative nonlimiting examples of such features include hooks, clips, clamps, straps, cords for tying, slotted tubes, channel-containing blocks, and paired hook-and-loop textiles such as Velcro®.
The term “drawstring” means a connector that may be retracted to hold a tube or power cord with a reduced likelihood of entanglement. Illustrative nonlimiting examples of drawstring materials include strings, ropes, wires, cables, cords, tubes, chains, tapes and other films.
The term “retractably connected” as used with respect to a connection between a component and a drawstring means that slack in the drawstring may be taken up by an automated mechanism. In some embodiments the automated mechanism is a spring-loaded reel so as to maintain tension in the drawstring at all times. In certain embodiments the automated mechanism is ratcheted and act so that retraction of the drawstring occurs only upon deliberate triggering by a user.
The term “reel” as used with respect to retractable connection means a cylinder on which the drawstring can be wound and unwound. In certain embodiments the reel is spring-loaded. In some embodiments the reel is wound manually. In some embodiments the reel comprises a catch or ratchet so as to prevent motion of the drawstring in the tension-applying direction or alternatively the tension-releasing direction, in the absence of a manual override.
The term “rotatably connected” as used with respect to a collar on the center mast means that the collar is mounted on the mast in a way that permits the collar to be freely rotated at least partially around the circumference of a section of the mast.
The term “bezel” means a circular component having a female feature on the outside edge. The term “partial bezel” means that the female feature does not circle the entire component. The term “full bezel” means that the female feature does circle the entire component. The term “train” means a male feature on a component, where the train fits within and is captured by the bezel, and where the train is free to move freely through the female feature of the bezel.
The terms “hook fabric” and “loop fabric” have their usual and ordinary meaning. Illustrative nonlimiting examples include the types of fabric used in Velcro® connectors. The term “self-adhering strap” means a strap that contains both a hook fabric and a loop fabric. As used with respect to self-adhering straps, the terms “hook fabric portion” and “loop fabric portion” refers to the respective portions of the strap that comprise those respective fabrics.
The term “circularly distributed” as used with respect to components on a crown mean that the components are distributed at regular intervals as defined by a circle.
The term “rectangularly distributed” as used with respect to components on a crown mean that the components are distributed at intervals such that their innermost or alternatively outermost points fall within the perimeter of a square or other rectangle.
The invention may be further understood by consideration of the Figures, which show illustrative nonlimiting embodiments of the invention and its components.
FIG. 1 depicts a portion of an apparatus according to the invention not including a caster module. As shown in the Figure, the apparatus comprises center mast 110 , crown 120 mounted at the top of the center mast; and 121 is an arm on the crown, where the arm bears a terminal hook. In the embodiment shown the crown has eight arms. Moreover the arms support fluid bags 125 A and 125 B, such as intravenous bags. Brackets 130 and 135 mounted on the center mast attach it to two peripheral handles 141 and 142 , which respectively have channels 143 and 144 running through them, which may be milled channels, and which further respectively have clips 145 A, 145 B and 145 C on handle 141 and clips 146 A, 146 B and 146 C on handle 143 , for the purpose of retaining a tube or power cord within the channel when it is in use. A power receptacle 150 is located on lower bracket 135 . A central zone of center mast 110 features a hand brake handle 115 .
FIG. 2 depicts a section of the apparatus in perspective, in which peripheral handle 242 is nearer than peripheral handle 241 and the center mast 210 is between them. Clips 245 B, 245 C and 246 B are provided to retain one or more tubes or power cord in channels within peripheral handles; to simplify the drawing the channels are not depicted. A portion of lower bracket 235 is also shown. Center mast 201 and hand brake handle 215 mounted on the center mast are shown in a cutaway view. Nut features 211 A and 211 B mounted on or integral to the inside of a tubular center mast 210 are capable of receiving screws or bolts 216 A, 216 B, 217 A and 217 B, such that a monolithic hollow molded handle or a molded handle in two parts may be fastened to the center mast by means of the screws or bolts. In an alternative embodiment nut features 211 A and 211 B are mounted on or integral to a rod not shown, that runs up through the center of a tube, where the center mast comprises both the rod and the tube, such that downward pressure applied on the brake handle drives not the tube but the rod downward; in such a design the screws or bolts must have a slot available so that the rod can travel freely for at least some discrete length in order to actuate braking.
FIG. 3 depicts sections of the invention apparatus when the center mast is in the raised position as on the left, allowing mobility of the apparatus, or in the lowered position as on the right, enabling braking by means of contact with a foot on the center mast with the floor. Here the center mast 310 A and 310 B is mounted by a hand brake handle 315 A and 315 B. The center mast passes through the housing of a caster module 370 A and 370 B, having casters 371 A, 372 A, 373 A and 374 A as well as 371 B, 372 B, 373 B and 374 B. To simplify the figure, features such as the attachment of the casters to the rest of the caster module are not shown. When the center mast 310 A is raised, the foot 360 A attached to its lower end is out of contact with the floor surface. When the center mast 310 B is lowered, the foot 360 B attached to its lower end comes into contact with the floor surface and provide braking contact with the floor surface, particularly when the foot has a composition that is a friction-enhancing material. The mechanical actuation of the brake may be further assisted by other means such as supplementary mechanical leverage or a pneumatic or hydraulic component that is activated when the user deploys the brake.
FIG. 4 shows a portion of an apparatus according to the invention. There a center mast 410 has a draw string 481 that is under low tension and is retractable from a port or collar 482 and thus can readily be withdrawn reversibly as illustrated by directions of use 483 . In its tension state the draw string lifts the tubing off the floor and bunches is near the mast. The other end of the draw string has a tube-holding feature 481 such as a clip, clamp, clasp, tie or strap that may be attached to the tube 426 of an intravenous bag 425 . The fluid is delivered at an intravenous injection site 427 on a patient's arm 428 . The collar 482 may optionally be equipped with a groove and train to permit rotation around a collar on the center mast by a spool for the draw string.
FIG. 5 depicts an illustrative nonlimiting set of components for the fabrication of a suitable rotating collar including male 584 A and female 584 B halves for a spool housing, optionally with a spool cover 585 . Two halves 586 A and 586 B of a mating collar for the center mast may be held in place against the center mast for instance by a tab 586 C. Illustrative parts 587 A and 587 B may serve as a train for the exterior of the collar. The mating collar in this embodiment has an interior bezel around which the train may slide, and one viable form of the train is shown but the invention is not so limited. The form in both FIGS. 5 and 6 has the reel free-spinning on the end of the train.
FIG. 6 shows an illustrative nonlimiting assembly in which a clip 681 is located at the terminus of drawstring 680 , which is wound about spool 684 . A train 687 connected to the spool is captured by and may ride the circumference of a mating collar 686 that can encircle and attach to the center mast; the train may occupy an entire bezel or partial bezel. A lubricant 688 such as graphite, chalk, molybdenum sulfate, a petroleum-based lubricant or another type of lubricant may be used to facilitate the free rotation of the train around the collar.
FIG. 7 depicts an illustrative nonlimiting bracket design that may be used to attach the center mast to a peripheral handle. Here the bracket half 730 conforms to the shape and dimensions of one side of a center mast, and the wings of the bracket half permit combination with peripheral handles at its extremities. The bracket half may be attached by means of screws, nut-and-bolts, rivets, or other attachment means passing through shafts 731 A, 731 B, 731 C and 731 D. The design is also amenable to use with a snap fit and or adhesive.
FIG. 8 shows an illustrative nonlimiting apparatus in full with various components. As shown in the Figure, the apparatus comprises center mast 110 , crown 120 mounted at the top of the center mast and having in this example eight arms; as seen for arm 821 on the crown, the arm bears a terminal hook. Moreover the arms support fluid bags 825 A, 825 B and 825 C, such as intravenous bags. From bags 825 A and 825 B proceed tubes 826 A and 826 B respectively. Brackets 830 and 835 mounted on the center mast attach it to two peripheral handles 841 and 842 , which respectively have channels running through them; to simplify the diagram those channels and their clips are not shown, however it will be noted that tubes 826 A and 826 B are shown to enter and exit the peripheral handles; slack in the tubes is taken up by a draw string 880 with a clip or clamp 881 around the tubes, and in this embodiment the other end of the draw string may be held or retracted at a collar or bracket 835 . Power outlets 850 A and 850 B are mounted upon the brackets; in some embodiments the power outlets are integrated into the brackets. A power cord 852 is provided for use when the apparatus is stationary; it passes through and is retractable at a cord collar 851 ; here a power cable runs up inside of a hollow center mast from the cord collar to the power outlets. A hand brake handle 815 facilitates user braking of the apparatus. Caster module 870 has a plurality of caster and permits both rolling and braking. An instrument rack 890 is also shown; in some embodiments the instruments and or rack are mounted permanently directly on the center mast or a bracket; in others they are attached by temporary means; in still others they are attached by means including a quick-release mechanism.
FIG. 9 depicts non-braking (raised-mast) and braking (lowered-mast) states when a brake handle is turned to move a rod downward for a rod-in-tube mast configuration in one embodiment. The center mast ( 910 A and 910 B) is a hollow tube, and its internal rod ( 918 A and 918 B) represent a rod-in-tube configuration. Lateral handles ( 980 A and 980 B) on the center mast are attached to the rod (by elements 982 A and 982 B). The handles are capable of turning (along a path denoted by arrow 984 A) such that when the handles are turned downward they lower the rod relative to the tube. In FIG. 9 the broken lines for the rod and elements connected to it denote that those portions of the component are located within the tube. For the sake of visual clarity and simplicity, vertical slots at each side of the center mast are not depicted here; these allow elements 982 A and 982 B to reach from the rod to the handles, and to travel to the raised and lowered position, comparable to the slot that accommodates motion by internal nuts and bolts 211 of hand brake handle 215 to allow free travel of the rod in FIG. 2 .
FIG. 10 shows a brake that is actuated by a handle affixed on the center mast, and use of pneumatic components to suspend the center mast and its feet out of contact with the floor surface. There center mast 1010 has brake handle 1015 for which force is applied downward (direction 1084 H) to actuate the brake. The center mast passes through caster module 1070 , which has wheels in individual casters such as 1071 . For the sake of visual clarity only two of the casters are shown. Feet such as 1060 are mounted at the bottom of the center mast to serve as braking surfaces on the ground, comparable to braking by use of the foot shown in FIG. 3 . In FIG. 10 for the non-breaking state the feet are suspended above the ground level (the bottom of the wheels being understood to rest on the ground). Pneumatic components such as 1090 are affixed to the center mast by an affixing means such as 1095 and are also affixed at a separate site to the caster module, and provide mechanical force upward (as denoted by direction 1084 P), thereby raising the upright center mast vertically relative to the caster module to keep its feet out of contact with the floor surface.
FIG. 11 shows an embodiment according to the invention in which a foot serves as an actuator or castor brake in lieu of or at the same time as acting as a friction brake with the ground. Here the raised and lowered states of the mast are compared. A hand brake handle ( 1115 A and 1115 B) and peripheral handles ( 1141 A and 1141 B) are affixed to the center mast ( 1110 A and 1110 B); in this embodiment any of these handles can be used for the application of downward force for braking purposes. The center mast passes through and is vertically mobile relative to the caster module ( 1170 A and 1170 B) and has a foot ( 1160 A and 1160 B). For the sake of visual clarity and simplicity only two of the casters are shown, and to illustrate variations in braking mechanism they are of different types. In one type of caster the wheel is exposed on the side toward the foot on the center mast ( 1171 A and 1171 B). In the other type of caster ( 1172 A and 1172 B), a caster housing—shown arc-like in FIG. 11 —is interposed between the wheel and the foot. It can be seen that when the center mast is in the lowered state, i.e., when the brake is actuated, the foot clamps the exposed wheel directly ( 1171 B) whereas for the wheel with a caster housing it compresses the housing against that wheel ( 1172 B). In this embodiment pneumatic components 1190 B serve to release the foot from the wheel and suspend the center mast when the brake is not in use.
The invention provides a combination of features that medical intravenous stands in the prior art lack. These include a brake, ergonomic design for supporting unsteady patients, channels and a multi-axis drawstring to manage tube and cords. The invention design minimizes tipping of the apparatus, tripping over cords, soiling and spoiling of tubes by contact with the floor, and the like. The invention is not limited to use with intravenous bags but can be used in addition or alternatively for support of components for other types of medical fluid management with bags and or tubes, for instance catheterization or other types of fluid transfer lines.
A variety of materials and designs may be used for the center mast. In certain embodiments 6061 raw stock aluminum tubes with a 1.5 inch diameter are employed.
Peripheral handles may be constructed, for example from milled or injected plastic, or from metal. In one embodiment they are held in place by two pairs of bracket halves that clasp together using symmetrical position pegs with opposing holes. Like brackets, hand brake handles may likewise be assembled from sections, e.g., in halves composed of molded plastic. In certain embodiments one or more brackets may house an electric socket fixture. In various embodiments the brackets and the hand brake handle are each assembled as one piece using notches in the center mast as slots to fit protrusions built on the mast side of the bracket or handle piece.
In certain embodiments a hand brake handle is attached to an internal mechanism to deploy a rubber lined foot by pushing a rod down through the middle of a center mast to make contact with the floor.
It is helpful though not required to employ a brake handle that has a grip, ergonomic design and an antimicrobial or easily cleanable surface. A particularly desirable brake handle grip would inhibit pathogens, facilitate patient use, be comfortable to the hand, and be suitable for many hand sizes.
A drawstring assembly is provided—optionally employing a retracting reel—that may be rotated up to 360° horizontally optionally with the aid of a collar that has inset grooves that may accommodate a train component. In combination with the drawstring's ability to rotate 360° in any vertical plane, this adaptability minimizes tangling of tubes and cords held by the drawstring, and further enables following the patient as they move at the outer allowed by the length of the tubing and or, if present, a power cord plugged into a wall. The pivot attached to a train is a helpful feature of this design.
From the description and claims herein, the invention and many useful permutations, variations, and derivatives of it will be apparent to the person having ordinary skill in the relevant arts, and are contemplated within the scope of the invention.
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The invention provides a medical intravenous support apparatus that facilitates patient mobility while reducing the likelihood of an accidental fall. The design incorporates improved features for bag support, tube management, cord management, patient steadiness, user-friendly braking, and electric power supply.
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[0001] This U.S. Non-Provisional Patent Application claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 62/168,299, filed May 29, 2015, the entire disclosure of which is hereby incorporated by reference.
FIELD
[0002] The present disclosure generally relates to lifting inserts for precast or preformed concrete panels. More specifically, the present disclosure relates to lifting inserts for embedment into a precast concrete structure and that comprise a lifting anchor and one or more support members for increasing a shear cone and related pull-out capacity of the insert.
BACKGROUND
[0003] Prior art systems and devices for providing lifting anchors within precast concrete structures generally comprise dog-bone style anchors and related elongate anchor members for providing a connection and lifting interface between a concrete structure and a lifting device. Such devices, including those shown and described in U.S. Pat. No. 8,959,847 to Recker et al., which is hereby incorporated by reference in its entirety, fail to provide for various novel features of the present disclosure, including a base member with a plurality of members extending therefrom to increase lifting capacity and a related shear cone as shown an described herein. Known lifting anchors and devices, including those shown and described in U.S. Patent Application Publication No. 2004/0159069 to Hansort, which is hereby incorporated by reference in its entirety, contemplate a shear cone and pull-out capacity that is limited by the shape of the anchor. Known devices are generally characterized by small shear cones based on the provision of a single member extending into a concrete panel.
SUMMARY
[0004] Accordingly, there has been a long-felt but unmet need to provide a lifting insert with increased capacity and increased pull-out strength. Embodiments of the present disclosure provide a lifting insert comprising a base member and a plurality of extensions extending from the base member, wherein at least one extension comprises a lifting interface for receiving a connecting member and transferring force to the insert and any associated structure in which the insert is provided.
[0005] In one embodiment, a lifting insert for embedment in a concrete component is provided, the lifting anchor comprising a base member having a first side and an opposing second side, a length, a width, and a thickness. The first side of the base member comprises a primary lifting member and at least one secondary support member, and the primary lifting member extends substantially perpendicular to the base member. The primary lifting member comprises a first length with a first end secured to the base member and a second end, the second end comprising at least one of a flange and a fillet adapted for communicating with a lifting device. The at least one second anchor member comprises a second length with a first end secured to the base member, and the first length is greater than the second length. In certain embodiments, the at least one secondary support member comprises four secondary support members geometrically arranged about the primary lifting member, and each of the secondary support members are spaced equidistant from the primary lifting member. In further embodiments, the second side of the base member comprises a planar portion devoid of any features or anchors extending therefrom. In preferred embodiments, the insert comprises a single die-cast component formed from at least one ferrous material, and preferably steel.
[0006] In one embodiment, a plurality of anchors or studs are provided extending from a connecting member or carrier that does not comprise a plate. Specifically, in various embodiments, the present disclosure contemplates providing a non-structural connecting member or carrier comprising at least one of a molded plastic strip and a metal strap. The connecting member comprises a plurality of studs or anchors extending therefrom. In one embodiment, the connecting member comprises a dog-bone anchor and a plurality of two-headed studs extending therefrom, wherein the dog-bone anchor member comprises a lifting element. The studs and/or anchors are secured to the connecting member by at least one of a snap-fit and a tack-weld. The connecting member extends between the studs and/or anchors to generally maintain a desired relative spacing and arrangement of the studs and/or anchors. In such embodiments, the base members or bottom heads of the studs comprise anchoring features, and the device is devoid of a base plate as provided in other embodiments.
[0007] In various embodiments of the present disclosure, lifting anchors are provided or embedded within a concrete structure. The concrete structure(s) may comprise, for example, wall panels, retaining walls, concrete conduit members, drainage and storage members, and any number of concrete or rock structures that may need to be moved or lifted.
[0008] In one embodiment, a lifting insert for embedment in a concrete component is provided, the lifting anchor comprising a base plate, a first side of the base plate comprising a primary lifting member and at least one secondary support member, the primary lifting member extending substantially perpendicular to the base plate. The primary lifting member comprises a first length with a first end secured to the base plate and a second end, the second end comprising at least one of a flange and a fillet adapted for communicating with a lifting device. The at least one secondary anchor member is secured to the base plate and comprises a second length that is different from the first length, the second length extending between a first end of the secondary anchor member and a second end, the second end comprising a free end. Each of the first end of the primary lifting member and the secondary anchor members are provided in the same plane. Each of the primary lifting member and the secondary anchor member are provided substantially perpendicular to the base plate, and the lifting insert is operable to provide an enhanced shear cone and reduce a risk that the lifting insert will be removed from a concrete component during a lifting operation. As used herein, the term “shear cone” generally refers to a cone shaped section of concrete or similar material that is or would be removed from a concrete structure when an item such as an anchor bolt or lifting insert is forcibly pulled from the concrete. One of skill in the art will recognize that the force required to pull out such a cone shaped section of concrete from a larger structure corresponds to the force required to separate the concrete or rock over a total surface area of the cone. Accordingly, larger volume cones correspond to greater pull-out strength and/or shear resistance strengths.
[0009] In one embodiment, a lifting insert for positioning and embedment in a concrete component is provided, the lifting anchor comprising a base member having a first side and an opposing second side, a length, a width, and a thickness. The first side of the base plate comprises a primary lifting member and at least one secondary support member, the primary lifting member extends substantially perpendicular to the base member. The primary lifting member comprises a first length with a first end secured to the base member and a second end, the second end comprising at least one of a flange and a fillet adapted for communicating with a lifting device. The at least one second anchor member is secured to the base member and comprises a second length that is different from the first length.
[0010] In one embodiment, a method of installing a lifting anchor in a precast concrete element is provided, the method comprising the steps of providing a lifting insert for embedment in a precast concrete element, the lifting anchor comprising a base member having a first side and an opposing second side, a length, a width, and a thickness, the first side of the base member comprising a primary lifting member and at least one secondary support member, the primary lifting member extending substantially perpendicular to the base member, the primary lifting member comprising a first length with a first end secured to the base member and a second end, the second end comprising at least one of a flange and a fillet adapted for communicating with a lifting device, and the at least one second anchor member secured to the base member and comprising a second length that is different from the first length; forming a precast concrete element, wherein at least a portion of the lifting insert is provided within the precast concrete element; and forming a void in the precast concrete element, wherein at least a portion of said primary lifting member extends into said void and wherein said at least one second anchor member and said base member are encased within the precast concrete element.
[0011] In various embodiments, lifting inserts of the present disclosure comprise base members. In certain embodiments, the base member(s) comprise substantially planar plate members with supports and/or lifting anchors extending substantially perpendicularly therefrom. In further embodiments, the base member(s) comprises a connecting member including (for example) a rail or extension. In additional embodiments, it is contemplated that the base member comprises a non-planar base member. For example, the base member may comprise a convex member, a concave member, and/or various geometric objects. In one alternative embodiment, for example, a base member comprises a spherical member with lifting members and/or anchors extending therefrom. The base member(s) may also comprise an irregularly shaped object to increase a surface area of the base member and thereby increase a contact area between the base member and a concrete to be provided in combination with the base member.
[0012] In various embodiments, lifting inserts are provided with a lifting interface or primary lifting anchor. Inserts of the present disclosure are also contemplated as comprising a plurality secondary supports that are spaced apart from the primary lifting anchor as shown and described herein. The secondary supports are provided to increase a surface area between the insert and a concrete member, and to provide enhanced anchorage of the insert within the member. The secondary supports preferably comprise heads or protrusions on one end, and the secondary supports are placed in tension during a lifting operation thereby disrupting the formation of a shear cone that would or may result without the secondary supports. The secondary supports create a larger shear cone that would be necessary to pull the insert out from the concrete and shear off a portion or cone of the concrete. The force required to remove the insert or pull-out strength is thereby increased over known devices.
[0013] The Summary is neither intended nor should it be construed as being representative of the full extent and scope of the present disclosure. The present disclosure is set forth in various levels of detail in the Summary as well as in the attached drawings and the Detailed Description and no limitation as to the scope of the present disclosure is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary. Additional aspects of the present disclosure will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the disclosure and together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosure.
[0015] FIG. 1 is a front perspective view of a lifting insert according to one embodiment of the present disclosure.
[0016] FIG. 2 is a side elevation view of the embodiment of FIG. 1 embedded within a concrete structure.
[0017] FIG. 3 is a top plan view of the embodiment of FIG. 1 embedded within a concrete structure.
[0018] FIG. 4 is a top plan view of a lifting insert according to another embodiment of the present disclosure.
[0019] FIG. 5 is a front elevation view of the lifting insert according to the embodiment of FIG. 4 .
[0020] FIG. 6 is a side elevation view of a lifting insert according to another embodiment of the present disclosure.
[0021] FIG. 7 is a top plan view of the lifting insert according to the embodiment of FIG. 6 .
[0022] FIG. 8 is a top plan view of a lifting insert according to another embodiment of the present disclosure.
[0023] FIG. 9 is a top plan view of a lifting insert according to another embodiment of the present disclosure.
[0024] FIG. 10 is a cross-sectional elevation view of a portion of the lifting insert according to FIG. 9 .
[0025] It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary for an understanding of the disclosure or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the disclosure is not necessarily limited to the particular embodiments illustrated herein.
DETAILED DESCRIPTION
[0026] FIG. 1 is a front perspective view of a lifting insert 2 according to one embodiment of the present disclosure. As shown, the lifting insert 2 comprises a base plate 4 comprising a width W, a length L, and a thickness t. In the depicted embodiment, the base plate 4 comprises a substantially planar member. In alternative embodiments, a base plate 4 is provided with a curvilinear shape which may either be convex or concave. Additionally, although a preferred embodiment comprises a base plate 4 having a rectilinear shape ( FIG. 1 ), alternative shapes are also contemplated. The base plate 4 may comprise rounded members including circular and oval shapes, and/or various irregular shapes. The shape of the base plate 4 may be varied based on numerous considerations, including the size of a related structure within which the insert 2 is to be embedded.
[0027] The base plate 4 of FIG. 1 comprises a primary lifting member 6 extending from a first side of the plate 4 . The primary lifting member 6 comprising a lifting interface adapted for communicating with a lifting shackle or similar device as will be recognized by one of ordinary skill in the art. The primary lifting member 6 comprises a body portion 8 with a substantially circular cross section and a head 10 comprising a larger diameter than the body portion. The head 10 extends from the body portion 8 via a flange 12 or fillet. In certain embodiments, the primary lifting member 6 and the base plate 4 comprise a single element, but are described herein as different components for the sake of clarity. In alternative embodiments, the primary lifting member 6 is welded or otherwise secured to the base plate 4 .
[0028] As also shown in FIG. 1 , the insert 2 comprises a plurality of secondary supports 14 . The secondary supports 14 comprise substantially perpendicular extensions of the plate 4 spaced apart from the primary lifting member 6 . In preferred embodiments, the insert 2 comprises a single cast structure. Alternatively, the plate 4 , primary lifting member 6 and the secondary supports 14 are welded together to form a single structure. The secondary support members 14 comprise reinforcing members that extend into a portion of a concrete member (or similar) when the insert 2 is cast in a desired position. The secondary supports 14 increase surface area contact with the structure in which the insert 2 is embedded and provide force transmitting members to increase the capacity and strength of the insert 2 .
[0029] FIG. 2 is a side elevation view of a lifting insert 2 provided at least partially within a concrete structure 16 . Lifting inserts 2 of the present disclosure are suitable for use with various concrete precast structures including, but not limited to, wall panels, columns, dividers, barriers, and similar features. For illustrative purposes, a shear cone 20 associated with preferred embodiments of the present invention is shown. For illustrative and comparison purposes, an alternative shear cone 22 associated with prior art devices is provided. The improved shear cone 20 of the present disclosure comprises a shear cone of increased volume, representing increased shear and pull-out capacity provided by the insert 2 of the present disclosure.
[0030] FIG. 3 is a top plan view of the insert 2 according to the embodiment of FIGS. 1 and 2 . As shown, the insert 2 comprises a base plate 4 , a primary lifting member 6 , and a plurality of secondary supports 14 . In various embodiments, the secondary supports 14 comprise members having a first cross-sectional shape or diameter along a first portion of the length of the member and a second cross-sectional shape or diameter along a second portion of the length of the member. In certain embodiments, the secondary support members 14 comprise rebar members extending substantially perpendicularly from the base plate 4 .
[0031] FIG. 4 is a top plan view of an insert 20 according to one embodiment of the present disclosure. As shown, the insert 20 comprises a base member 22 having a predetermined shape. A primary lifting member 24 is provided on the base member 22 . A plurality of secondary supports 26 are provided on the base member 22 and distributed on the base member 22 .
[0032] As shown in FIG. 4 , the base member 22 comprises a generally symmetrical geometry when viewed from the top. The geometry of the base member 22 comprises a length L 1 . In various embodiments, the length L 1 comprises the same magnitude as the overall width W 1 of the insert and the insert thus comprises a square footprint with void spaces as shown and described. In certain embodiments, the length L 1 is between approximately 5 and 10 inches. In preferred embodiments, the length L 1 is approximately 8 inches. As further shown in FIG. 4 , the insert 20 comprises a plurality of void spaces 28 . The void spaces 28 comprise recesses, voids, or cut-outs in an otherwise solid plate 22 . In the depicted embodiment, the void spaces 28 comprise rectilinear voids at or adjacent to each of the four edges of the base member 22 . The void spaces 28 comprise a length L 2 and a width W 2 . In various embodiments, the length L 2 of the void spaces 28 is between approximately 1 and 5 inches, and preferably about 3 inches. In various embodiments, the width W 2 of the void spaces 28 is between approximately 0.5 and 4 inches, and preferably approximately 1.5 inches. The void spaces 28 preferably comprise areas that are devoid of material, including the metal or other material that forms the base plate. In alternative embodiments, however, it is contemplated that the void spaces are simply areas where no supports are provided.
[0033] As shown in FIG. 4 , a distribution of a primary lifting member 24 and a plurality of secondary supports 26 are provided. The secondary supports 26 are distributed in a substantially symmetrical manner around the primary lifting member 24 . In the depicted embodiment, the secondary supports 26 are provided in a spaced apart manner. Specifically, and in the embodiment provided in FIG. 4 , the centers of the secondary supports 26 are spaced apart at a distance D 1 that is between approximately 5.0 and 10.0 inches, and preferably approximately 6.50 inches.
[0034] In the embodiment of FIG. 4 , the void spaces 28 are provided to reduce the overall weight of the device 20 . Alternative embodiments of the present disclosure contemplate providing a lifting insert 20 that is devoid of void spaces 28 , as well as embodiments that comprise different arrangements of void spaces 28 .
[0035] FIG. 4 . depicts a particular embodiment wherein first and second secondary supports 26 are spaced apart by a first distance D 3 and wherein the first distance D 3 is between approximately 1.0 inches and approximately 5.0 inches, and is preferably approximately 3.5 inches. Outermost secondary supports 26 are spaced apart from the inner secondary supports by a second horizontal distance D 4 , wherein the second horizontal distance is between approximately 1.0 inches and approximately 3.0 inches, and is preferably approximately 2.25 inches.
[0036] FIG. 5 is a side elevation view of the lifting insert 20 according to the embodiment of FIG. 4 . The lifting insert 20 is shown relative to a concrete member 40 . The concrete member comprises at least one void space 42 extending below an outer surface of the concrete member 40 as shown. The primary lifting member 24 extends at least partially into the void space 42 such that an upper portion or the head is exposed within the void space 42 and accessible for connection and lifting purposes, as one of ordinary skill in the art will recognize. The plurality of secondary supports 26 are distributed around the primary lifting member 24 are preferably embedded within the concrete member 40 . An exemplary shear cone 46 is shown. The shear cone 46 represents a potential failure mode of the concrete member 40 when a lifting load exceeds a maximum tolerance. As shown, the shear cone 46 comprises a dimension that is smaller than the insert 20 and wherein at least the outer secondary supports 26 are encased within the concrete member 40 even after a pull out event or failure has occurred.
[0037] As shown in FIG. 5 , the secondary supports 26 are contemplated as comprising a height H 1 extending above the base member 22 . In various embodiments, the height H 1 is between approximately 1.0 and approximately 5.0 inches. In a preferred embodiment, the height H 1 is approximately 2.0 inches. The base member 22 comprises a thickness or height H 2 of between approximately 0.25 inches and approximately 2.0 inches, and preferably of approximately 0.34 inches.
[0038] FIG. 5 depicts one embodiment of the present disclosure installed or encased in a concrete structure 40 , and wherein the base member 22 of the insert 20 is installed at a depth D below an outer surface 44 of the concrete member 40 . The depth D as shown in FIG. 5 is preferably approximately 4.0 inches. Accordingly, an upper portion of the primary lifting member 24 is provided at a depth D 2 below the outer surface 44 of the concrete member 40 . The depth D 2 is between approximately 0.25 inches and approximately 1.0 inches, and is preferably approximately 0.5625 inches. This depth D 2 provides a flush outer surface of the concrete structure such that the primary lifting member 24 does not extend or protrude from the concrete member 40 , while also rendering the primary lifting member 24 generally accessible to users and lifting equipment.
[0039] FIG. 6 is a side elevation view of a lifting insert 20 according to another embodiment of the present disclosure. As shown, the insert 20 comprises a base member 22 and a primary lifting member 24 extending therefrom. The lifting insert 20 is shown in combination with and at least partially embedded within a concrete member 40 . The concrete member 40 comprises a void space 42 formed therein. The void space 42 extends into and comprises a void in an outer surface 44 of the concrete member 40 . The lifting insert 20 of the embodiment shown in FIG. 6 comprises at least one secondary support in the form of an arcuate support member 50 . The arcuate support member 50 is contemplated as comprising an elongate section of reinforcing bar (or “rebar”) that is bent or curved as shown in FIG. 6 (for example). The arcuate support 50 of FIG. 6 comprises at least one linear section 52 provided in connection with the base member 22 of the insert 20 . The linear section 52 is secured to the base member 22 by various methods and devices as will be recognized by one of skill in the art. In various embodiments, the arcuate support member 50 is welded to the base member 22 to provide a secure connection between the base member 22 and the arcuate support member 50 .
[0040] As shown in FIG. 6 , a first linear section 52 of the arcuate reinforcement member 50 is provided in connection with the base member 22 . The arcuate reinforcement member 50 extends upwardly to second and third linear sections 54 a, 54 b. A radius of curvature R 1 is provided wherein the second linear section 54 a is bent or curved with respect to a substantially vertical portion 55 . The substantially vertical portion 55 extends into the first linear section 52 about a second radius R 2 , where R 2 comprises approximately the same radius as R 1 and wherein R 2 is oriented in an opposite direction as R 1 . The second and third linear sections 54 a, 54 b comprise a height H 3 as measured from a lower portion of the base member 22 to an upper portion of the linear sections 54 a, 54 b. The H 3 is between approximately 2.0 and 5.0 inches, and is preferably approximately 3.375 inches. A thickness T of the base member 22 is between approximately 0.25 inches and approximately 1.0 inches, and is preferably approximately 0.375 inches. FIG. 6 depicts one embodiment of the present disclosure installed or encased in a concrete structure 40 , and wherein the base member 22 of the insert 20 is installed at a depth D below an outer surface of the concrete member 40 . The depth D as shown in FIG. 6 is preferably approximately 4.0 inches and more preferably of approximately 4.125 inches. Accordingly, an upper portion of the primary lifting member 24 is provided at a depth D 2 below the outer surface 44 of the concrete member 40 . The depth D 2 is between approximately 0.25 inches and approximately 1.0 inches, and is preferably approximately 0.5625 inches. This depth D 2 provides a flush outer surface of the concrete structure such that the primary lifting member 24 does not extend or protrude from the concrete member 40 , while also rendering the primary lifting member 24 generally accessible to users and lifting equipment.
[0041] FIG. 7 is a top plan view of the insert 20 according to the embodiment of FIG. 6 . As shown in FIG. 7 , two arcuate support members 50 are provided, the arcuate support members 50 securely interconnected to the base member 22 . In the embodiment of FIG. 7 , the arcuate support members 50 are spaced apart on a base member 22 , wherein the base plate comprises a rectangular base plate with a width of preferably approximately 5.0 inches and a length of approximately 6.0 inches. The arcuate support members 50 are spaced equidistant from a center of the insert 20 , wherein a primary lifting member 24 is aligned with and extends from the center of the insert 20 .
[0042] FIG. 8 is a top plan view of another embodiment of a lifting insert 20 . The lifting insert 20 of FIG. 8 comprises a plurality of radially spaced secondary support members 64 . The secondary support members 64 are spaced apart and are radially equidistant from a primary lifting member 66 . The insert 20 comprises a rail member 60 that is generally provided as a hexagon. A secondary support member 64 is provided at each intersection of the sides of the hexagon. A diagonal support 62 is provided that extends across an internal area of the rail member 60 . An anchor or primary lifting member 66 is provided on the diagonal support 62 . Although not shown in FIG. 8 , it is contemplated that the lifting insert 20 comprises a plurality of diagonal supports. In various alternative embodiments, it is contemplated that the insert 20 comprises two or more diagonal supports extending in the interior space formed by the rail member 60 . In one embodiment, two diagonal supports extend within the interior space and form a “X” shaped pattern. In further embodiments, it is contemplated that the insert 20 comprises one or more supports that extend non-diagonally within the interior space formed by the rail member 60 .
[0043] As provided in FIG. 8 , each of the secondary supports 64 are preferably equidistant from a primary lifting member 66 . More specifically, each of the secondary supports 64 in FIG. 8 are radially spaced from the primary lifting member 66 by a radius R that is between approximately 1.0 and 5.0 inches. In a preferred embodiment, the radius R comprises a distance of approximately 2.5 inches.
[0044] Although not shown in the top of FIG. 8 , the secondary supports 64 comprise a height, and wherein each of the secondary supports 64 comprises substantially the same height. That height is preferably between approximately 1.0 and approximately 5.0 inches. The primary lifting member 66 comprises a second height, wherein the second height is greater than the height of the secondary supports 64 and is preferably between approximately 2.0 inches and approximately 5.0 inches, and preferably approximately 3.25 inches. The rail member 60 of the embodiment of FIG. 8 comprises a thickness that is between approximately 0.25 inches and approximately 2.0 inches.
[0045] FIG. 9 is a top plan view of a lifting insert 20 according to another embodiment of the present disclosure. As shown, the lifting insert 20 comprises a primary lifting member 70 and a plurality of secondary support members 72 radially spaced around the primary lifting member 70 . The lifting insert 20 comprises a plurality of extension arms 74 that extend outwardly from the primary lifting member 70 . The secondary support members 72 are provided at distal ends of the extension arms 74 and extend upwardly therefrom. In preferred embodiments, the primary lifting member 70 comprises a first height extending above the extension arms 74 and wherein the extension arms 74 generally comprise a base of the insert 20 . The secondary support members 72 comprise a second height extending above the extension arms 74 , wherein the second height is preferably smaller than the first height. Preferably, each of the secondary support members 72 comprise the same height as the other secondary support members 72 . In alternative embodiments, it is contemplated that the secondary support members comprise a plurality of different heights.
[0046] Although not shown in the top of FIG. 9 , the secondary supports 72 comprise a height, and wherein each of the secondary supports 72 comprises substantially the same height. That height is preferably between approximately 1.0 and approximately 5.0 inches. The primary lifting member 70 comprises a second height, wherein the second height is greater than the height of the secondary supports 64 and is preferably between approximately 2.0 inches and approximately 5.0 inches, and preferably approximately 3.25 inches. The rail member 60 of the embodiment of FIG. 8 comprises a thickness that is between approximately 0.25 inches and approximately 2.0 inches.
[0047] FIG. 10 is a cross-sectional elevation view taken at point A as shown in FIG. 9 . As shown in FIG. 10 , an extension arm 74 of the lifting insert 20 comprises a cross-sectional shape. As shown in FIG. 10 , the extension arm 74 comprises a cross-sectional profile comprising a trough 76 provided between upstanding sidewalls 78 and a base portion 80 .
[0048] Although various dimensions and proportions of lifting inserts contemplated by the present disclosure are provided herewith, it will be expressly recognized that the various dimensions provided are for illustrative purposes only. Various alternative dimensions are within the scope of the present disclosure, and the lifting anchors shown and described herein should not be deemed to be limited to one or more disclosed dimensions. The lifting anchors of the present disclosure may be scaled up or down to render them useful for lifting larger or smaller objects. Additionally, the proportions of the lifting anchors may be altered. For example, it is contemplated that the heights of the primary lifting members and/or secondary supports shown and described herein may be lengthened or shortened without similar altering the size of a base member upon which such features are provided.
[0049] In various embodiments, a method of inserting or forming at least one lifting insert within a portion of a precast concrete member is provided. U.S. Patent Application Publication No. 2002/0195537 to Kelly et al., which is hereby incorporated by reference in its entirety, discloses methods and systems for forming or inserting anchors within concrete members. Similar methods and devices and variants thereof are contemplated as within the scope of the present disclosure.
[0050] In one embodiment, a method of embedding a lifting anchor in a concrete structure is provided, the method comprising the steps of providing a polymeric hollow body having a first and second sections hinged together at their upper portions for movement between a closed condition engageable around an anchor received therebetween and an open condition in which the sections are separated to release an anchor received therebetween. The sections define a passage therebetween for receipt and retention of a lifting anchor and are provided with a latch to selectively secure the sections together. In the method, the sections are moved apart to receive the anchor and then moved together to secure the anchor in place. As so conditioned, the void former is cast in place within a concrete structure and, ultimately, removed from the structure by spreading the first and second sections apart and releasing them from the anchor. The lifting anchors for use with various methods of the present disclosure include lifting inserts as shown and described herein.
[0051] While various embodiments have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. It is to be expressly understood that such modifications and alterations are within the scope and spirit of the present disclosure. Further, it is to be understood that the phraseology and terminology used herein is for the purposes of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof, as well as, additional items.
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An improved lifting insert for provision within a concrete panel or other structural member is provided. The lifting insert comprises a base member, a lifting or contact member, and a plurality of members extending perpendicular to the base member to provide enhanced pull-out capacity for the insert. The lifting or contact member comprises a contact point for receiving a lifting device and for transferring force to a remainder of the insert.
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BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for receiving parallel digital data signals and an aligned frame pulse using a reference clock signal and in particular to aligning the data signals with a locally generated frame pulse which is phase aligned with the reference clock signal.
The requirements of moving vast amounts of information within digital communications systems has led to increases in both the rate at which data is transmitted along a line and the number of lines used in parallel to form data bus structures. Two problems arise when the data signal rate is greater than 10 MHz. The first is devising a technique to sample the data when the data is being clocked at a rate much greater than an order of magnitude above the fastest rate technologically available. The second is providing for a phase shift between the data signal and the reference clock signal of greater than one clock period.
Clock recovery circuits are designed to align the clock signal with the data signal to ensure accurate sampling of the data. One way to provide clocks needed to sample the high rate data signal for aligning the clock signal and the high rate data signal is to provide multiple delayed clock signals by passing the reference clock signal through a multiple tap delay line.
Such a scheme is taught by H. Wong et al. U.S. Pat. No. 4,584,695 issued Apr. 22, 1986 and assigned to National Semiconductor Corporation. In a digital PLL clock recovery scheme Wong et al. disclose a multi-phase clock generator providing clock signals which are phase offset from one another. A single one of these clock signals is then used to sample the data signal, at, slightly before, and after a clock signal transition. The resulting bit pattern is used to determine whether a leading or lagging phase clock should be substituted. The Wong et al. arrangement is applied to Manchester data, that is serial data having an encoded clock signal and a mid-bit transition.
Another scheme is taught by Bergmann et al. U.S. Pat. No. 4,821,297, issued Apr. 11, 1989 and assigned to American Telephone and Telegraph Company. Bergmann et al. use delay lines on both the data and the clock inputs. The delay line on the data input provides phase-shifted data signals to be sampled by a single one of the multiple phase clock signals. As with Wong et al., the resulting bit pattern is used to determine whether a leading or lagging clock signal should be selected. In an alternative embodiment Bergmann et al. use three clock signals of adjacent phase to sample the data signal in place of the data delay line. The Bergmann et al. scheme is applicable to serial data signals and is not dependent upon the coding scheme used for that data.
Silicon CMOS integrated circuits introduce wide time differences or deltas between their best case propagation delays and their worst case propagation delays. The deltas are primarily due to operating temperature variation, supply voltage variation and chip processing variation. As data transmission rates have increased, the magnitude of the deltas can exceed one bit. To transmit the greatest amount of data within the limitations of the technology used, parallel data transmission is chosen, but a scheme for reliable reception of the data is required.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an improved method and circuit for receiving frame aligned parallel digital data.
In accordance with an aspect of the present invention there is provided a method for receiving parallel data signals and a frame pulse aligned with the data signals, comprising the steps of sampling the frame pulse using a plurality of clocks, each clock being phase shifted with respect to each other clock, selecting a number of the plurality of clocks in dependence upon a predetermined value of the sampled frame pulse, sampling the data signals using the selected clocks, choosing a data sample representing a majority of the data samples to provide a sampled data signal, and aligning a sampled data signal with the local frame pulse.
Thus according to the method of the present invention the selection of the sampling clocks is based upon sampled values of the frame pulse rather than of the data signals.
Preferably, the step of selecting a number of the plurality of clocks includes the step of switching to the clocks in a manner to ensure glitchless switching of the clocks used for sampling the data.
In accordance with another aspect of the present invention there is provided apparatus for receiving parallel data signals and a frame pulse aligned with the data signals, comprising means for sampling the frame pulse using a plurality of clocks, each clock being phase shifted with respect to each other clock, means for selecting some of the plurality of clocks in dependence upon a predetermined value of the frame pulse sampled, means for sampling the data signals using the selected clocks, means for choosing a data sample representing a majority of the data samples to provide a sampled data signal, and means for aligning the sampled data signal with a local frame pulse.
Preferably, the means for selecting a number of the plurality of clocks comprises means for switching to the clocks in a manner to ensure glitchless switching of the clocks used for sampling the data.
In an embodiment of the present invention the means for switching to the m selected clocks comprises a tristate driver matrix.
In accordance with a further aspect of the present invention there is provided apparatus for receiving parallel data signals and a frame pulse aligned with the data signals, comprising a first set of latches for sampling the frame pulse using six clock signals, each clock signal being phase shifted with respect to each other clock signal, a shift register for storing several of the frame pulse samples received from the first set of latches, a logic circuit for selecting three of six clock signals which are most centered on a predetermined value of the frame pulse sampled, a tristate drive matrix for switching to the three selected clocks in a glitchless manner, a second set of latches for sampling the data signals and the frame pulse using the three clock signals from the tristate drive, a majority circuit for choosing a data signals sample and a frame pulse sample representing a majority of the three data signals samples and the three frame pulse samples to provide sampled data signals and a sampled frame pulse, and an elastic store for aligning the sampled data signal with a local frame pulse, and whereby writing the sampled data signal to memory is in dependence upon one of the selected clocks and the sampled frame pulse and reading the sampled data signal from memory is in dependence upon a local frame pulse aligned with the local clock signal.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be further understood from the following description with reference to the drawings in which:
FIG. I illustrates in block diagram form a data alignment circuit in accordance with a first embodiment of the present invention; and
FIG. 2 illustrates a timing diagram for the embodiment of FIG. 1.
DETAILED DESCRIPTION
Referring to FIG. 1, there is provided a data alignment circuit 10 in accordance with an embodiment of the present invention. The data alignment circuit 10 includes a frame pulse receiver 20, a state machine 30, a data clock selector 40, a data receiver 50, and an elastic store 60. The data alignment circuit 10 has inputs for a received frame pulse (RFP) 11, multiple phase shifted clock signals (CK1-CK5), including a reference clock signal (CKR) 12, a 10-bit received data signal (RD) 13, a local frame pulse (LFP) 14, and a local clock signal (LCK) 15. The data alignment circuit 10 has outputs for 10-bit aligned output data (OD) 16 and a local frame pulse (LFP) 17.
The frame pulse receiver 20 includes a first set of latches 26 coupled to the input 11 via a line 22 and clock signals input 12 via a 6-line clock bus 24, and a second set of latches 28 coupled to latches 26 via a-6-bit bus 25 and one of the clock signals via a line 27. Output from latches 28 is applied as an input to the state machine 30 via a 6-bit bus 29.
The state machine 30 includes a 15-bit shift register 32 and a decision logic circuit 34. The 15-bit shift register 32 provides storage for two and one-half 6-bit samples received from latches 28. The 15-bit shift register 32 and the decision logic circuit 34 are clocked by the same clock signal as latches 28 via lines 35 and 37, respectively. The decision logic circuit 34 is coupled to the 15-bit shift register 32 via a 15-bit bus 36 and has its output applied as an enabling input to the data clock selector 40 via 6-bit bus 38.
The data clock selector 40 includes a matrix of tristate drivers 42. Each driver provides a switch for glitchless switching of selected clocks. The data clock selector 40 is coupled to the clock input 12 via a 6-line clock bus 44 and outputs selected clock C1, C2, and C3 via lines 46, 47, and 48, respectively.
The data receiver 50 includes latches 52 and a 2 of 3 majority logic circuit 54. The selected clocks C1, C2, and C3 are applied as clock inputs to the latches 52 along with the received data RD via a 10-bit data bus 56 and the received frame pulse RFP via a line 55. Each triple data sample and triple frame pulse sample is input to the 2 of 3 majority logic circuit 54 which outputs the data via a respective line of the bus 58 and the frame pulse via a line 59.
The elastic store 60 includes a dual port RAM 62, a write counter 72 and a read counter 74. The dual port RAM 62 has inputs for receiving the sampled data from the data receiver 50 via a 10-bit data bus 58, for receiving a write address signal from the write counter 72 via a 5-bit bus 76 and for receiving a read address signal from the read counter 74 via a 5-bit bus 80. The dual port RAM 62 has a 10-bit data bus output 16 for outputting data OD aligned with the local frame pulse LFP. The write counter 72 has a clock input via a line 64 for the selected clock signal C1 and an input via the line 59 for the sampled frame pulse. The write counter 72 outputs a write address signal via the 5-bit bus 76 to the dual port RAM 62. The read counter 74 has an input via a line 68 for the local clock signal LCK from the local clock input 15 and an input via a line 78 for the local frame pulse LFP from the input 14. The read counter 74 outputs a read address to the dual port RAM 62 via a 5-bit bus 80.
In operation, the received frame pulse RFP, sent every 64 clock periods, and received via the input 11 and the line 22 is sampled by latches 26 at the intervals provided for by the six phase-shifted clocks (CKR, CK1-CK5) input via the 6-line clock bus 24. The resulting 6-bit sample is clocked into the second set of latches 28 using one of the multiple clocks applied to latches 28 via the line 27. The second set of latches 28 provides a metastable settling time for the sample before being output to the state machine 30.
The 6-bit sample is then clocked, by the clock supplied by the line 35, into the 15-bit shift register 32, of the state machine 30, so that the most recent bit of the sample is the least significant bit. On each clock cycle, the sample is shifted within the 15-bit shift register 32 by 6 bits. Thus the 15-bit register 32 provides two and one-half samples arranged in order from the most recent bit.
The decision logic circuit 34 examines the contents of the register 32, via the 15-bit bus 36, every clock cycle looking for a frame pulse. Once found, based upon the position of the frame pulse within the shift register, the decision logic circuit 34 chooses a set of three clocks most centered on the frame pulse. There are six possible sets of three clocks which may be selected by the decision logic circuit 34. The bus 38 provides 6 lines, one for each of the six possible sets.
The data clock selector 40 using the matrix of tristate drivers 42, coupled to lines 46, 47, and 48, provides the three selected clocks, C1, C2, and C3 to the data receiver 50. When shifting to a phase-delayed clock, the clock period at the time of the switch is extended by the amount of the phase delay. When shifting to a phase-advanced clock, the clock period at the time of the switch is shortened by the amount of the phase delay. As the data alignment circuit 10 is intended to compensate for temperature and voltage drift, the logic used in the tristate matrix for glitchless clock switching provides for a clock change of one phase shift per frame pulse period. Thus although the decision logic circuit 34 is capable of switching from any set of three clocks to any other set of three clocks via the bus 38, glitchless operation is available in this tristate driver matrix for a single phase shift of the clocks, that is, up one, down one, or stay the same.
While a single phase increment circuit has been discussed, it would be possible to provide for a greater rate of phase change by using a different clock selection circuit and tristate matrix.
In the data receiver 50, latches 52 sample the data from the data bus 56 and the received frame pulse via the bus 55 using each of the three clocks C1, C2, and C3. The majority value of sampled values is chosen by the 2 of 3 majority circuit 54 and the data sample is output via the bus 58 and the frame pulse sample FP is output via the line 59 to the elastic store 60.
The dual port RAM 62 provides storage which allows the data to be aligned with the local frame pulse. Data is written into the dual port RAM 62 at the addresses specified by the write counter 72 which is aligned to the sampled data input via the bus 58 using the sampled frame pulse FP and the clock C1. The output from the dual port RAM 62 is obtained from the address specified by the read counter 74 which is aligned to the local frame pulse LFP input via the line 78 and clocked by the local clock LCK input via the line 68. The local frame pulse LFP and the local clock LCK are synchronous prior to being input to the data alignment circuit 10. Thus, the output data OD is brought into phase alignment with the local frame pulse.
In FIG. 2, a timing diagram is illustrated for a typical operation of the circuit of FIG. 1. The reference clock signal CKR is delayed in steps to provide five phase shifted clock signals CK1 through CK5, which together with the reference clock CKR effectively span one clock period. Each of these clock signals is used to sample the received frame pulse RFP. Those clock signals whose edge (1 to 0 transition) A, B, and C lies centered within the frame pulse are selected to sample the received data RD. As the received frame pulse and the received data are aligned, the clock signals centered on the framed pulsed RFP will also be centered on a bit of the received data RD. The local frame pulse LFP and the local clock LCK are synchronous prior to input to the data alignment circuit, and may be offset from the received frame pulse RFP by any number of clock periods (plus or minus) within a limit of the elastic store. In the present embodiment the limit is +16 to -14 clock periods. As shown in FIG. 2, the offset is approximately +6. However, this offset is system dependent and can vary to the full limit of the elastic store, the received clocks and the frame pulse and the local clock and the frame pulse must ultimately be synchronized to the same source. The output data OD is shown having its 0th bit aligned with the local frame pulse LFP, which is the same relationship the received frame pulse RFP has with the received data RD.
While a circuit has been discussed in which the clocks selected are those centered on the frame pulse, which correspond to being centered on the data bit, it is possible to use this circuit in a system using a data coding scheme for which such centering was undesirable by changing the clock selection parameters.
Numerous modifications, variations and adaptations may be made to the particular embodiment of the invention described above without departing from the scope of the invention, which is defined in the claims.
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A method and apparatus are provided for receiving parallel digital data signals and an aligned frame pulse. The frame pulse occurs at a regular interval which is a multiple of the data clock period. A multiple clock sampling scheme includes sampling the frame pulse using a plurality of phase-shifted clock signals, selecting several clock signals which are centered on the frame pulse and therefore the data. Then, sampling the data using the selected clocks, taking a majority value of the multiple samples and aligning the sampled data with a locally generated frame pulse using an elastic store.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of, and claims priority to and the benefit of the filing date of, patent application Ser. No. 13/852,740, filed Mar. 28, 2013, entitled “Managing Capacity of a Thinly Provisioned Storage System”, to be issued as U.S. Pat. No. 9,146,853 on Sep. 29, 2015, and which is hereby incorporated by reference.
BACKGROUND
Thinly provisioned storage systems provide the appearance of having more storage capacity than is actually available. A thinly provisioned storage system is commonly used when actual physical storage capacity is shared among multiple entities, such as people or groups of people, and when the actual physical storage used by those entities is substantially less than an amount provisioned for use by those entities.
In a thinly provisioned storage system, actual physical storage typically is allocated and used when data is written to the storage system. As storage usage increases, actual physical storage can be added into the storage system with little overhead or impact on the rest of the system.
One problem with thinly provisioned storage systems is the risk of data loss, and related outcomes due to data loss. Data loss can occur when operations that write data fail because actual physical storage is not available. Such data loss also can result in a poor user experience because allocation operations may be successful (due to thin provisioning) whereas write operations to successfully allocated storage can fail due to a lack of actual physical storage capacity.
SUMMARY
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
To reduce the risk of data loss and provide a better user experience, a thinly provisioned storage system detects whether actual physical storage capacity is available when there is a request to allocate storage, prior to data being written to the storage system. In particular, at the time when the file system attempts to allocate storage, such as when creating a file or performing an extending write (append) operation, a storage system can verify that actual physical storage capacity is available. Thus, if there is insufficient actual physical storage capacity when there is a request to allocate storage, then an error message can be sent and remedial action can be taken.
In one implementation, a file system maintains an allocation map that associates files with virtual storage locations, and identifying available virtual storage locations. A storage system maintains a thin provisioning map that associates virtual storage locations with actual physical storage locations, and identifying available physical storage locations. The file system can maintain a thin provisioning bitmap as a copy of the thin provisioning map. In response to a request to allocate available storage to a file, if virtual storage locations and their corresponding actual physical storage locations are available, then the virtual and physical storage locations can be allocated. However, if virtual storage locations are available, but there are no actual physical storage locations available to be allocated to those virtual storage locations, then the attempt to allocate storage fails. Because this error occurs at the time of a request for allocation of storage, instead of at the time of writing the data to storage, the risk of data loss is reduced, and a better user experience is achieved.
Accordingly, in one aspect, a file system receives a request to allocate storage for a file. Whether virtual storage space is available for the file is determined. If virtual storage space is available for the file, virtual storage space for the file is reserved, and the storage system determines whether actual physical storage space is available for the reserved virtual space. If actual physical storage space is available for the file, then the actual physical storage space for the file is reserved and associated with the virtual storage space reserved for the file.
The system can maintain an allocation map associating files with virtual storage locations and a thin provisioning map associating virtual storage locations with actual physical storage locations. The allocation operation fails if insufficient virtual storage space is available. The allocation operation also fails, and reserved virtual storage space for the file is released, if insufficient actual physical storage space is available.
In the following description, reference is made to the accompanying drawings which form a part hereof, and in which are shown, by way of illustration, specific example implementations of this technique. It is understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the disclosure.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a computer system using thinly provisioned storage.
FIG. 2 is a schematic diagram illustrating an example implementation of a file system supporting thinly provisioned storage.
FIG. 3 is a schematic diagram of an allocation map and thin provisioning map in an example implementation of the system of FIG. 2 .
FIG. 4 is a flow chart describing an example implementation of an operation of mounting a thinly provisioned volume.
FIG. 5 is a flow chart describing an example implementation of an operation of creating a file on a thinly provisioned volume.
FIG. 6 is a flow chart describing an example implementation of an operation of writing data to a file in append mode on a thinly provisioned volume.
FIG. 7 is a block diagram of an example computer in which such a file system can be implemented.
DETAILED DESCRIPTION
The following section provides an example operating environment in which computer data storage volumes with thin provisioning can be implemented.
Referring to FIG. 1 , an enterprise may include a plurality of computers 100 interconnected by a computer network (not shown). As described in more detail below, each computer 100 accesses a file system 120 which allows applications, as well as a user, to access data stored persistently in files in the file system. In one implementation, the file system is local to the computer and part of the computer's operating system. In another implementation, the file system can be accessed over a computer network and shared by multiple computers.
In general, to store data, the application and/or user selects a volume, indicative of one more storage devices, and a name for a file (such as a path of one or more directories on a volume, and a file name), in which to store the data. In turn, the system manages storing the data persistently in actual physical storage locations on the one or more storage devices that make up the volume. The system maintains information that maps a file to the actual physical storage locations on the one or more storage devices of the volume on which the data for the file is stored. In one implementation of a thinly provisioned storage system as described below, the file system maintains information that maps a file to virtual storage locations within a volume. A storage system maintains information that maps virtual storage locations to physical storage locations. A file system also can maintain a thin provisioning bitmap.
In an enterprise or other arrangement where multiple computers are sharing storage over a computer network, the system of FIG. 1 typically includes a plurality of storage volumes 104 . A storage volume 104 is a logical device that can include one or more physical storage devices 106 .
A storage volume can be shared by multiple users. In some instances, users are grouped into multiple groups, and each group is assigned to a partition, volume or other unit of storage. A partition is a unit of abstraction that allows a single hard drive to host multiple volumes or allowing multiple disk drives to be combined together as a single volume. In such a case, thin provisioning is common, such that each group is assigned an amount of data, e.g., one terabyte per group, but with the actual physical storage devices providing substantially less actual physical storage initially, e.g., 100 gigabytes per group.
To implement thin provisioning, the system uses two maps to allocate files to actual physical storage locations. First, one map (herein called an allocation map) 108 associates files with blocks of virtual storage of a volume. In this map, virtual storage can be either used, reserved or available. Second, for the volume, another map (herein called a thin provisioning map) 110 associates the virtual storage blocks to actual physical storage locations, if any. In this map, physical storage can be either used, reserved, available or unassigned.
For each volume, the system of the computer 100 maintains data indicating whether the volume is thinly provisioned, and, if so, these two maps 108 and 110 . A volume can be represented by a data structure that includes a flag indicating whether the volume uses thin provisioning. If that flag is not set, then the volume does not use thin provisioning and the system may use a single allocation map; if the flag is set, then the volume uses thin provisioning and the system uses the allocation map and the thin provisioning map.
In general, to reduce the risk of data loss and improve the user experience, the availability of actual physical storage capacity is checked when a request to allocate storage is received. For example, when a file is created, the file system reserves blocks of virtual storage for use by the file. Further, using the thin provisioning map, actual physical storage locations for these virtual blocks of storage also are reserved by the storage system. If actual physical storage locations are not available, then an error can be indicated. Also, if actual physical storage locations are available, they can be assigned to available virtual blocks of storage.
Using such a file system, there are two types of available space within the storage system. For example, if a user is allocated one terabyte, and has used 100 gigabytes, and 100 gigabytes of actual storage has been used, the user may believe that 900 gigabytes is available, whereas the volume may report its storage as full. When reporting available space to a user, it can be advisable to report both virtual storage space available and actual physical storage space available, as described below.
Given this context, an example implementation of the thin provisioning will be described in more detail in connection with FIGS. 2-4 .
In FIG. 2 , a schematic diagram of an implementation of the system will now be described. The file system layer 200 manages mapping files to virtual storage locations. The storage system layer 202 manages mapping virtual storage locations to actual physical storage locations in storage devices 206 if the volume is thinly provisioned. Thus the file system layer maintains an allocation map 208 and the storage system layer maintains a thin provisioning map 210 . A reduced copy of the thin provisioning map 210 can be maintained by the file system as a thin provisioning bitmap 212 . The storage system can be part of the same operating system as the file system and implemented as a computer program executed as part of the operating system; or the storage system can be implemented in hardware outside of the operating system.
FIG. 3 illustrates an example implementation of an allocation map 300 and an example thin provisioning map 320 for a thinly provisioned volume. In this example, there are two groups of users to which amounts of storage are assigned on the volume. Range 1 is assigned to group 1 and range 2 is assigned to group 2 . Within range 1 , the allocation map 300 indicates that range A is used, and range B is available. Similarly, in range 2 , range X is used and range Y is available.
Using only the allocation map, if an application asked the file system to create a file, then the file system determines if sufficient space is available, and then selects and allocates storage from among the available space.
The thin provisioning map, however, indicates if actual physical storage is available. For example, within range 1 , range A is assigned to actual physical storage in the thin provisioning map. For the sake of this example, however, assume that only part of range B is associated with actual physical storage. In this example, range B 1 is associated with actual physical storage, and is unused, whereas range B 2 is not associated with any actual physical storage yet. Similarly, within range 2 , range X and range Y 1 are assigned to actual physical storage, whereas range Y 2 is not associated with any physical storage yet.
Thus, for a volume using thin provisioning, after using the allocation map to determine that there is sufficient available virtual storage space available in range Y, the file system then requests the storage system to determine whether there is sufficient actual physical storage available within range Y. For example, if the space to be used for a created file is greater than the amount of actual physical storage available, then physical storage space cannot be allocated for the created file and an error can be signaled.
Another example implementation, the file system maintains a copy of the thin provisioning map as a bitmap where each bit represents a range of virtual address space. In this implementation the range of virtual address space can be a slab, and can be 256 megabytes or more in size. If the bit is set, then actual physical storage has been provisioned. If the bit is not set, then no actual physical storage is assigned to this range (or slab). As the file system selects virtual address space for the file via the allocation map, it also checks this thin provisioning map to see if the slabs being allocated also are mapped to actual physical storage. If the slabs are not mapped to actual physical storage, they are then mapped via the storage system, and if the attempt to map fails, then the operation fails.
Referring now to FIG. 4 , an example implementation of mounting a volume will now be described. Mounting of a volume occurs when a user, such as an administrator, instructs the file system to mount a volume. After receiving 400 an instruction to mount a volume, the file system queries 402 the volume to determine if the volume is thinly provisioned. If the volume is thinly provisioned as determined at 404 , then the file system allocates 406 a thin provisioning bitmap for the volume. Otherwise, a thin provisioning bitmap for the volume is set 408 to null. To allocate the thin provisioning bitmap, the volume also is queried 410 to identify the allocation unit size. Next, the thin provisioning bitmap is created 412 . For example, the storage system can construct the thin provisioning bitmap using its thin provisioning map and provide the thin provisioning bitmap to the file system. Such a volume can be created and mounted without any actual physical storage being provisioned, in which case the thin provisioning bitmap indicates there is not actual physical storage. Otherwise, when mounted, any actual physical storage associated with the volume can be indicated in the thin provisioning bitmap.
By using the thin provisioning bitmap, the file system can make fewer calls to the storage system. Note that the thin provisioning bitmap is a cache of some of the information in the thin provisioning map. Therefore, the file system ensures its thin provisioning bitmap is in sync with the actual thin provisioning map maintained by the storage system. In particular, as described below in FIG. 5 and FIG. 6 , request to allocate or free storage pass through the file system to the storage system. Further, an asynchronous communication can be made from the storage system to the file system to provide the file system with any updated thin provisioning map information, or to instruct the file system to request it. Also, the file system can request a copy of the thin provisioning map from the storage system at any time, such as at the time a volume is mounted.
Referring now to FIG. 5 , an example implementation of creating a file will now be described.
To create a file, the file system receives 500 an instruction to create a file, typically including a name for the file and an amount of space to be allocated for the file. The file system first checks 502 the allocation map to determine if virtual storage space is available in the provisioned volume. If virtual storage space is not available, as determined at 504 , the create command fails, as indicated at 506 . If virtual storage space is available, then virtual blocks within the provisioned volume are reserved 508 for the file. Next, the thin provisioning bitmap is checked 510 to determine if actual physical storage is available. If actual physical storage locations have been previously associated to the reserved virtual blocks, as determined at 512 , then the file system can indicate 514 a successful allocation. If the actual physical storage locations have not yet been associated to the reserved virtual blocks, the storage system is requested to determine 516 if actual physical storage space is available. If actual physical storage is available, then the storage system can associate 518 actual physical storage locations with the virtual blocks, the file system can update its thin provisioning bitmap and indicate 514 a successful allocation. Otherwise, the allocation operation fails, as indicated at 520 and the reserved virtual blocks are released. The file system can report different types of failures in 506 (the assigned virtual storage space is exceeded) and 520 (insufficient actual physical storage available).
Referring now to FIG. 6 , an example implementation of writing to a file to append data to the file will now be described.
To append data to a file, the file system receives 600 an instruction to append data to a file, typically including a name for the file and an amount of data to be appended to the file. The file system first checks 602 the allocation map to determine if virtual storage space is available in the provisioned volume for the additional data. If virtual storage space is not available, as determined at 604 , the append command fails, as indicated at 606 . If virtual storage space is available, then virtual blocks within the provisioned volume are reserved 608 for the file. Next, the thin provisioning bitmap is checked 610 to determine if actual physical storage is available. If actual physical storage locations have previously been associated to the reserved virtual blocks, as determined at 612 , then the file system can indicate 614 a successful allocation. If the actual physical storage locations have not yet been associated to the reserved virtual blocks, the storage system is requested to determine 616 if actual physical storage space is available. If actual physical storage is available, then the storage system can associate 618 actual physical storage locations with the virtual blocks, the file system can update its thin provisioning bitmap and indicate 614 a successful allocation. Otherwise, the allocation operation fails, as indicated at 620 and the reserved virtual blocks are released. The file system can report different types of failures in 606 (the assigned virtual storage space is exceeded) and 620 (insufficient actual physical storage available).
It should be understood that any other operation that allocates storage for a file can be implemented to check for both available virtual blocks in a provisioned volume and actual physical storage available for those virtual blocks. Some example operations include but are not limited to: allocating space to unallocated regions of a sparse file, defragmenting one or more files, explicitly extending file size, compressing a file, and the like. Such operations cause a request to allocate storage due to a direct user request, e.g., create, append, defragment files, internal reservation for internal file system metadata, and internal reservation for anticipated increase in storage needed by a user file, e.g., memory mapping a compressed file or a sparse file for writing.
For example, a file system often allocates storage internally for metadata operations. In these cases, failure to allocate space for internal file system metadata leads to catastrophic failure in the file system and data corruption. To prevent this, the file system reserves storage space for itself, i.e., reserving virtual storage blocks in the allocation map and requesting the storage system to associate actual physical storage locations to these virtual storage blocks in the thin-provisioning map and reflecting this in its thin provisioning bitmap. The file system also can reserve space for user data that the file system anticipates may grow in size. For example, when a user opens a compressed file for writing using memory mapped input/output, the file system is programmed to accommodate the entire file in uncompressed form. In such cases, the system reserves potential virtual and actual physical storage space in a manner similar to how such storage space is reserved for the file system's internal metadata.
The granularity of allocation tracking in the allocation map and the thin-provisioning map can be different. In particular, the granularity of allocation tracking in the thin-provisioning map can be larger (for example, the size of a slab) than the granularity of allocation tracking in the allocation map (for example, the size of a conventional disk block). This different granularity is used so that the storage system assigns actual physical storage locations to a virtual block (which is costly in terms of performance) less frequently than the file system reserves virtual blocks in the allocation map.
Having now described an example implementation of thin provisioning, it should now be apparent that a variety of implementations are possible. For example, the file system can be implemented on a computer that accesses one or more volumes; alternatively, the file system can reside on one computer and be accessed by another computer over a computer network.
The system can be implemented in a variety of ways. While the example above describes a two layer file and storage system, with each layer maintaining a map, the system can be implemented as a single system or with multiple layers, as well as different mappings and data structures that enable a determination of whether available virtual space for a file has associated actual physical storage available for the file.
Having now described an example implementation, a computer in which a file system is designed to operate will now be described. The following description is intended to provide a brief, general description of an example suitable computer on which such a file system can be implemented. The file system can be implemented with numerous general purpose or special purpose computing hardware configurations. Examples of well known computing devices that may be suitable include, but are not limited to, personal computers, server computers, hand-held or laptop devices (for example, media players, notebook computers, cellular phones, personal data assistants, voice recorders), multiprocessor systems, microprocessor-based systems, set top boxes, game consoles, programmable consumer electronics, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like.
FIG. 7 illustrates one example of a suitable computer. In FIG. 7 , this example computer 700 , in its most basic configuration, includes at least one processing unit 702 and memory 704 . The computer may include multiple processing units and/or additional co-processing units such as graphics processing unit 720 . Depending on the exact configuration and type of computer, memory 704 may be volatile (such as RAM), non-volatile (such as ROM, flash memory, etc.) or some combination of the two. This most basic configuration is illustrated in FIG. 7 by dashed line 706 .
Additionally, computer 700 may also have additional features/functionality. For example, computer 700 may also include additional storage (removable and/or non-removable) including, but not limited to, magnetic or optical disks or tape. Such additional storage is illustrated in FIG. 7 by removable storage 708 and non-removable storage 710 . Computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer program instructions, data structures, program modules or other data. Memory 704 , removable storage 708 and non-removable storage 710 are all examples of computer storage media. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can accessed by computer 700 . Any such computer storage media may be part of computer 700 .
Computer 700 may also contain communications connection(s) 712 that allow the device to communicate with other devices over communication media. Communication media typically carries computer program 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, thereby changing the configuration or state of the receiving device of the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Communication connections 712 include any device, such as a network interface, that allows the computer 700 to transmit data to or receive data from such communication media.
Computer 700 may have various input device(s) 714 such as a keyboard, mouse, pen, camera, touch input device, and so on. Output device(s) 716 such as a display, speakers, a printer, and so on may also be included. All of these devices are well known in the art and need not be discussed at length here. Such input and output device may be designed to work together to provide a natural user interface (NUI), which is any interface technology that enables a user to interact with a device in a “natural” manner, free from artificial constraints imposed by input devices such as mice, keyboards, remote controls, and the like
Examples of NUI methods include those relying on speech recognition, touch and stylus recognition, gesture recognition both on screen and adjacent to the screen, air gestures, head and eye tracking, voice and speech, vision, touch, gestures, and machine intelligence, and can include touch sensitive displays, voice and speech recognition, intention and goal understanding, motion gesture detection using depth cameras (such as stereoscopic camera systems, infrared camera systems, and other camera systems and combinations of these), motion gesture detection using accelerometers or gyroscopes, facial recognition, three dimensional displays, head, eye, and gaze tracking, immersive augmented reality and virtual reality systems, all of which provide a more natural interface, as well as technologies for sensing brain activity using electric field sensing electrodes (EEG and related methods).
Such a files system may be implemented in the general context of software, including computer-executable instructions and/or computer-interpreted instructions, such as program modules, being processed by a computer. Generally, program modules include routines, programs, objects, components, data structures, and so on, that, when processed by a processing unit, instruct the processing unit to perform particular tasks or implement particular abstract data types. This system may be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote computer storage media including memory storage devices.
Alternatively, or in addition, the functionally described herein can be performed, at least in part, by one or more hardware logic components. For example, and without limitation, illustrative types of hardware logic components that can be used include Field-programmable Gate Arrays (FPGAs), Program-specific Integrated Circuits (ASICs), Program-specific Standard Products (ASSPs), System-on-a-chip systems (SOCs), Complex Programmable Logic Devices (CPLDs), etc.
The terms “article of manufacture”, “process”, “machine” and “composition of matter” in the preambles of the appended claims are intended to limit the claims to subject matter deemed to fall within the scope of patentable subject matter defined by the use of these terms in 35 U.S.C. §101.
Any or all of the aforementioned alternate embodiments described herein may be used in any combination desired to form additional hybrid embodiments. It should be understood that the subject matter defined in the appended claims is not necessarily limited to the specific implementations described above. The specific implementations described above are disclosed as examples only.
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A thinly provisioned storage system detects whether physical storage capacity is available when there is a request to allocate storage capacity, prior to data being written to the storage system. In particular, at the time when the file system allocates storage, such as when creating a file or performing an extending write (append) operation, allocating storage to an unallocated region of a sparse file, defragmenting a file, and the like, a storage system can verify that actual physical storage capacity is available. Thus, if there is insufficient actual physical capacity at the time when a storage allocation is attempted, then an error message can be sent and remedial action can be taken.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority and benefit under 35 U.S.C. 120 and 365(c) as a continuation of International application No. PCT/CN2008/001941 which was assigned an international filing date of Nov. 28, 2008 and associated with publication WO 2009/079915 and which claims priority under 35 U.S.C. 365(b) to Chinese Application 200710195409.3 filed on Nov. 28, 2007, the disclosures of which are expressly incorporated herein.
FIELD OF THE INVENTION
The present invention relates to a medical instrument, more particularly, to a valve stent for unidirectional flow of human lumen which is used in the interventional treatment for treating diseases of lung and obstructing anisotropic flow.
BACKGROUND OF THE PRESENT DISCLOSURE
Emphysema, bullae and chronic obstructive pulmonary disease, etc. are the common diseases involving the lung. Besides treatment methods like infection resistance with drugs, the surgery is generally based on lung volume reduction surgery. As the patients generally have weak physique and poor pulmonary function, they cannot tolerate the surgery so that a high death rate is caused, and part of the patients cannot be effectively treated or radically cured. Along with maturity of interventional therapeutic methods and technologies, a technology is developed that a stent and a one-way valve are placed in the trachea or bronchial tube below the trachea in the target region of the patient's lung. The one-way valve is opened in case of expiration and is closed in case of inspiration so as to reduce the residual volume at the pathologic lung and discharge the secretions, finally cause the collapse or fibrosis of pathologic lung and exert the compensation of healthy lung's gradual expansion and improve the patient's lung function. Since gall bladder, bile duct and aortic valves of blood have pathological changes or the human lumen has anisotropic flow, so similarly the anisotropic flow needs to be resisted. The stent is provided with a hook body made of elastic metal. After the stent is placed into the lumen, the hook body is penetrated into the wall surface of lumen to position the stent. The hook body has the insuperable shortcomings. For example, since the hook body may cause a different degree of damage to the wall surface of human lumen, complications like puncturing and long-standing inflammation may be produced, and especially displacement of the stent due to larger stress may happened, and then the wall surface of lumen is scratched. Another shortcoming is that after the stent is positioned, if the stent is damaged and deviated or the one-way valve is damaged, the stent can be taken out from the human body only by an operation. Moreover, once the stent is placed into, it cannot be adjusted, so the prior interventional stent and one-way valve urgently need to be improved.
DISCLOSURE OF THE INVENTION
The object of the present invention is to provide a recoverable, safe and reliable valve stent which can be implanted temporarily or for a long term and is used in the interventional therapy for unidirectional flow of human lumen, so as to obstruct from anisotropic flow in the case of diseases of lung, bile duct and aortic valve.
A technical solution for realizing the present invention is as follows: a recoverable valve stent, comprising a cylindrical stent made up of memorial alloy material in which an elastic diaphragm is arranged, wherein there is at least one gap on the diaphragm so that the diaphragm forms a flexible spring piece, one end of the cylindrical stent is provided with a fixed rear clip which is used for fixing the cylindrical stent structured with the memorial alloy material and is equipped with screwthreads which can be connected to a conveyor.
A thread of the memorial alloy material is weaved into the cylindrical stent and forms at least one bundle of alloy wire which is fixed with the rear clip, so that the end of the cylindrical stent which fixed with the rear clip forms at least one opening.
A thread of the memorial alloy material is weaved into the cylindrical stent and forms at least one bundle of alloy wire bundle which is fixed with the rear clip located at the upper edge of the wall of the cylindrical stent, so that the end of the cylindrical stent which fixed with the rear clip forms at least one opening in roughly round shape.
A thread of the memorial alloy material is weaved into the cylindrical stent and forms at least two bundles of alloy wire which are fixed with the rear clip locating at the axis of the cylindrical stent, so that the end of the cylindrical stent which fixed with the rear clip forms at least two openings in sub-oval or roughly oval shape.
A thread of the memorial alloy material is weaved into the cylindrical stent and forms at least three or four bundles of alloy wire which are fixed with the rear clip locating at the axis of the cylindrical stent, so that the end of the cylindrical stent which fixed with the rear clip forms at least three or four openings.
The cylindrical stent is a netlike stent obtained through laser etching treatment to an alloy steel tube, and etched parts of it are in rhombus shape, one end of the stent is provided with at least three supports which are integral with the stent and are connected with the rear clip.
The cylindrical stent is formed by coiling at least one alloy wire, preferably by coiling two to four alloy wires, and one end of the cylindrical stent is provided with the rear clip.
The other end of the cylindrical stent is provided with a front clip, and the front clip and the rear clip are arranged symmetrically or asymmetrically.
The diaphragm is provided with a cylindrical section which is fit to the cylindrical stent, and one end of the cylindrical section is arranged integrally with a convex surface raising towards the center of a circle which has one unclosed round gap on it, so that the bendable spring piece is formed.
The diaphragm is provided with a cylindrical section which is fit to the cylindrical stent, and one end of the cylindrical section is arranged integrally with a convex surface raising towards the center of a circle which has two arch gaps symmetrically arranged and connected by a straight gap on it so as to form an I-shape gap, so that the spring piece is separated into two bendable sections.
The diaphragm is provided with a cylindrical section which is fit to the cylindrical stent, and one end of the cylindrical section is arranged integrally with a convex surface raising towards the center of a circle which has three branched gaps being arranged equiangularly and extending from the center of a circle towards periphery of it, the spring piece is separated into three bendable sections.
The diaphragm is provided with a cylindrical section which is fit to the cylindrical stent, and one end of the cylindrical section is arranged integrally with a convex surface raising towards the center of a circle which has cross-branched gaps extending from the center of a circle towards periphery of it, the spring piece is separated into four two bendable sections.
Each spring piece of the diaphragm is provided with a curved sunken part.
The thickness of the spring piece gradually diminishes from circumference to the convex center of the circle, and there is a cylinder at the intersecting position of the cylindrical section and the convex surface.
There are metal wire supports which can increase elastic deformation and strength of the spring piece, and are arranged inside of the spring piece or on its surface.
The spring piece is a thin slice with raised center of a circle which has a diameter matching that of the cylindrical stent, the spring piece is connected with one clip of the cylindrical stent by means of a metal rod, and at least two gaps, preferably three to four gaps, which extend from the position near the center of the circle to the edge of the spring piece are arranged so as to separate the spring piece into at least two sections.
The stent in the present invention has a structure without hook body, so as to avoid the damage of the hook body to the wall surface of human lumen and the occurrence of complications, and the stent can be accurately positioned and adjusted. When the stent is being placed or recovered, the doctor can at least have one viewable point. The stent also can be placed or recovered in a double direction, so it is safe and reliable. The structure of the one-way valve is reasonable and it has the characteristics of the human heart valve, like strong anti-backflow ability, reliability and durability. It is a unidirectional valve stent which is used in the interventional therapy for unidirectional flow of human lumen, so as to obstruct from anisotropic flow, such as in the case of diseases of lung, bile duct and aortic valve.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a structure diagram of a first embodiment of a stent.
FIG. 2 is a right view of the stent in FIG. 1 .
FIG. 3 is a structure diagram of a second embodiment of a stent.
FIG. 4 is a right view of the stent in FIG. 3 .
FIG. 5 is a structure diagram of a third embodiment of a stent.
FIG. 6 is a right view of the stent in FIG. 5 .
FIG. 7 is a structure diagram of a fourth embodiment of a stent.
FIG. 8 is a right view of the stent in FIG. 7 .
FIG. 9 is a structure diagram of a fifth embodiment of a stent.
FIG. 10 is a right view of the stent in FIG. 9 .
FIG. 11 is a structure diagram of a sixth embodiment of a stent.
FIG. 12 is a right view of the stent in FIG. 11 .
FIG. 13 is a perspective drawing of the stent in FIG. 11 .
FIG. 14 is a sectional view of a first embodiment 1 of a diaphragm.
FIG. 15 is a structure diagram of a first embodiment of a spring piece.
FIG. 16 is a structure diagram of a second embodiment of a spring piece.
FIG. 17 is a structure diagram of a third embodiment of a spring piece.
FIG. 18 is a structure diagram of a fourth embodiment of a spring piece.
FIG. 19 is a sectional view of a second embodiment of a diaphragm.
FIG. 20 is a sectional view of a third embodiment of a diaphragm.
FIG. 21 is a sectional view of a fourth embodiment of a diaphragm.
FIG. 22 is a sectional view of a fifth embodiment of a diaphragm.
FIG. 23 is a sectional view of a sixth embodiment of a diaphragm.
FIG. 24 is a right view of the diaphragm in FIG. 23 .
FIG. 25 is a vertical sectional view of the diaphragm in FIG. 23 .
FIG. 26 is a sectional view of a seventh embodiment 7 of a diaphragm.
FIG. 27 is the right view of the diaphragm in FIG. 26 .
FIG. 28 is a sectional view of a eighth embodiment 8 of a diaphragm.
FIG. 29 is a right view of the diaphragm in FIG. 28 .
FIG. 30 is a sectional view of a ninth embodiment of a diaphragm.
FIG. 31 is a right view of the diaphragm in FIG. 30 .
FIG. 32 is a sectional view of the tenth embodiment of a diaphragm.
FIG. 33 is a right view of the diaphragm in FIG. 32 .
FIG. 34 is an integral structure diagram of the first embodiment of the present invention
FIG. 35 is a right view of the invention in FIG. 34 .
FIG. 36 is an integral structure diagram of the second embodiment of the present invention.
FIG. 37 is a right view of the invention in FIG. 36 .
FIG. 38 is an integral structure diagram of the third embodiment of the present invention.
FIG. 39 is a right view of the invention FIG. 38 .
FIG. 40 is a integral structure diagram of the fourth embodiment of the present invention.
FIG. 41 is a right view of the invention in FIG. 40 .
FIG. 42 is the integral structure diagram of the Embodiment 5 of the present invention.
FIG. 43 is a right view of the invention in FIG. 42 .
FIG. 44 is an integral structure diagram of the sixth embodiment of the present invention.
FIG. 45 is a right view of the invention in FIG. 44 .
FIG. 46 is an integral structure diagram of the seventh embodiment of the present invention.
FIG. 47 is a right view of the invention in FIG. 46 .
FIG. 48 is an integral structure diagram of the eighth embodiment of the present invention.
FIG. 49 is a right view of the invention in FIG. 48 .
FIG. 50 is a solid state diagram of the invention in FIG. 48 .
FIG. 51 is an integral structure diagram of a ninth embodiment of the present invention.
FIG. 52 is a right view of the invention in FIG. 51 .
FIG. 53 is a solid state diagram of the invention in FIG. 51 .
DETAILED DESCRIPTION
FIGS. 1-53 show embodiments of the present invention. Referring to FIGS. 1-2 , a recoverable valve stent comprises a cylindrical stent 1 made up of memory alloy material in which an elastic diaphragm 2 ( FIG. 14 ) is arranged. At least one gap 2 a is arranged on the diaphragm 2 so that diaphragm 2 forms a bendable spring piece 15 ( FIG. 15 ). One end of the cylindrical stent 1 is provided with a fixed rear clip 3 which is used to fix the alloy material which forms the cylindrical stent 1 and the rear clip 3 is provided with screwthreads which can be connected with the conveyor. The memory alloy materials are nickel-titanium alloy wires or alloy steel tubes. The cylindrical stent 1 is a cylindrical hollow tube which can be made by weaving multiple alloy wires or by spirally coiling one or multiple alloy wires. It can also be etched with alloy steel tubes. The elastic diaphragm 2 is arranged in the cavity of the cylindrical stent 1 , and the diaphragm 2 is made of polyester, polytetrafluoroethylene, polyurethane, medical silica gel or polyester fabrics. at least one gap arranged on the diaphragm 2 so that the diaphragm 2 forms the bendable spring piece 15 . One end of the cylindrical stent 1 is provided with the fixed rear clip 3 which is used to fix the alloy material that forms the cylindrical stent. The rear clip 3 is a cylinder, the external end face of which is provided with an internal thread or on which a tapping thread is arranged. The cylindrical stent 1 is provided with a preset expandable shape with relative elongation. It is spirally connected with the guide wire of a tubular conveyor via the screwthreads of the rear clip 3 . The cylindrical stent 1 draws back into the conveyor at a retraction state and it stretches out from the end part of the conveyor when being released. When the cylindrical stent 1 is completely released from the conveyor, its preset shape laterally extends and is tightly combined and positioned with the inner wall of the human lumen, and then the elastic spring piece 15 formed by the gap on the diaphragm 2 produces the unidirectional bending under the action of gas or liquid, to open or close the opening formed in the diaphragm 2 and to enable the unidirectional flow or obstruct flow of gas or liquid. The cylindrical stent 1 is mounted into the conveyor in a compression and stretching way through the spiral connection of the rear clip 3 and the guide wire in the conveyor and then is placed into the human lumen via the conveyor, or the cylindrical stent 1 , which has been placed into the human lumen, is recovered through the spiral connection of the guide wire in the conveyor and the rear clip 3 . The rear clip 3 makes the cylindrical stent 1 have one viewable point.
At least one alloy wire bundle 7 is formed and then fixed with the rear clip 3 after the threadlike memory alloy material in wire structure are weaved into the cylindrical stent 1 . Then the end of the cylindrical stent 1 provided with the rear clip 3 forms at least one opening 5 . The cylindrical stent 1 is a cylindrical hollow net-like tube which is weaved with a mould by multiple nickel-titanium alloy wires. One end of the tube is in opened shape and the net surface of which is in grille shape. After the hollow net-like tube is formed, the alloy wires at the other end of the tube will not be weaved in a net shape from this end, but form at least one alloy wire bundle 7 after being gotten together in a single wire shape. The alloy wire bundle 7 is fixed with the rear clip 3 , and at least one opening 5 is formed at one end of the cylindrical stent 1 arranged with the rear clip 3 . The opening 5 can permit the gas or liquid to flow through. Referring to FIGS. 1-2 , two alloy wire bundles 7 are formed and then fixed with the rear clip 3 located at the axle position of the cylindrical stent 1 after the threadlike memory alloy material are weaved into the cylindrical stent. Then the end of the cylindrical stent 1 provided with the rear clip 3 forms two roughly elliptic openings 5 . After the hollow net-like tube is formed, the alloy wires at the other end of the tube will not be weaved in a net shape from this end, but are equally divided into two alloy wire bundles 7 , and the alloy wires of each alloy wire bundle 7 are bent towards the center of circle of the tube in a single wire shape, and then transitionally curved and gathered together. The two alloy wire bundles 7 slant oppositely to the center of circle of the tube at the same time, and its tail wires are fixed by the rear clip 3 located at the axle of the tube, to form a rough taper (see FIG. 1 ) and form two opposite roughly elliptic openings 5 , see FIG. 2 . The gas or liquid entering from the opening A on the end face of the cylindrical stent 1 is shunted by two openings 5 and then flow through these two openings. As the two alloy wire bundles 7 forms an integrated structure with the cylindrical stent 1 via the rear clip 3 , a support is formed to enhance the radial supporting force of the cylindrical stent. The rear clip 3 makes the cylindrical stent 1 to have a viewable point at the axle of the cylindrical stent 1 . Three or four alloy wire bundles 7 are formed by alloy wires which are weaved into the cylindrical stent 1 , and then are fixed by the rear clip 3 at the axle of the cylindrical stent 1 . Three or four openings 5 (see FIGS. 5-8 ) are formed at one end of the cylindrical stent 1 arranged with rear clip 3 . Multiple alloy wires are equally divided into three alloy wire bundles 7 , the tail wires of the three alloy wire bundles 7 are fixed by the rear clip 3 and then equally divided into three roughly round openings 5 (see FIG. 6 ) on the tapered surface. These three openings 5 can reduce the small flow section as well as the flow volume, and forms four supports to enhance the radial supporting force of the stent 1 . The said alloy wires also can be divided into multiple alloy wire bundles 7 so as to form multiple openings 5 . But the number of openings 5 is selected depending on the required gas or liquid flow. The data obtained in the experiments indicate that the number of openings 5 are preferably 1 to 4. If the number of openings 5 exceed 4, the ability of gas or liquid flow passing through will reduce as the quantity of gas or liquid flow increases. The excess reduction in the flow volume of gas or liquid doesn't have practical significance.
Referring to FIGS. 3-4 , one alloy wire bundle 7 is formed and then fixed at the rear clip 3 located at the upper edge of the lateral wall of the cylindrical stent 1 after the said threadlike memory alloy material are weaved into the cylindrical stent. Then the end of the cylindrical stent 1 provided with the rear clip 3 forms one roughly round opening 5 . In order to make the threadlike cylindrical stent 1 have the maximum drift diameter, after the threadlike cylindrical stent 1 is weaved into a cylinder through multiple alloy wires, the alloy wires at one end of the cylindrical stent 1 get together on one lateral wall towards this end, converge into an alloy wire bundle 7 and then be fixed with the rear clip 3 located at the upper edge of the lateral wall (see FIG. 3 ), so that a roughly round opening 5 (see FIG. 4 ) with diameter approximating the diameter of the cylindrical stent 1 is formed. This opening permits the gas or liquid to flow through at a maximum flow rate, so the cylindrical stent 1 has maximum flow diameter to exert minimal impact on the flow rate.
Referring to FIGS. 38-41 , a front clip 4 is also arranged at one end of the said cylindrical stent 1 , and the front clip 4 and the rear clip 3 can be arranged symmetrically or asymmetrically; in order to realize the bidirectional placement or recovery of the cylindrical stent 1 , after it is weaved into a tube, the alloy wires at its one end are divided into alloy wire bundles 7 and then fixed with the front clip 4 , and opposite openings 5 formed at both ends of the cylindrical stent 1 ; if three alloy wire bundles are provided, three opposite openings (see FIG. 41 ) will respectively form at both ends of the threadlike cylindrical stent 1 and the front clip 4 and the rear clip 3 are at a symmetrical state (see FIG. 40 ) at the axle line of the cylindrical stent 1 . The front clip 4 and the rear clip 3 arranged symmetrically are suitable for the threadlike stent 1 with more than one alloy wire bundles, while the other end of the net-like stent 1 obtained through laser etching is also provided with supports 6 which are fixed with the front clip 4 , so both ends of the stent obtained through laser etching are respectively provided with a clip; for the cylindrical stent 1 with the maximum drift diameter, the front clip 4 and the rear clip 3 are arranged asymmetrically, that is, the front clip and the rear clip are respectively arranged on the opposite lateral walls at both ends of the cylindrical stent 1 and are parallel to the axle line of the cylindrical stent 1 (see FIG. 38 ). A roughly round opening 5 with diameter approximating the diameter of the cylindrical stent 1 (See FIG. 39 ) respectively forms at both ends of the cylindrical stent 1 , and an internal thread is also arranged on the external end face of the front clip 4 , or a tapping thread is arranged on the cylinder, so the front clip 4 is connected with or separated from the conveyor through the thread. By use of the front clip 4 and the rear clip 3 , both ends of the said cylindrical stent 1 are respectively provided with a clip and thus the cylindrical stent 1 has two viewable points and the doctor can release or recover the cylindrical stent 1 through the front clip 4 or the rear clip 3 . The said viewable point refers to the point which is easy to be reflected under ultrasonic wave or X ray. Under the directions of viewable points, the doctor can easily conduct placement and positioning, and also can place or recover the cylindrical stent 1 by choosing the front clip 4 or the rear clip 3 in different directions according to the actual situation, so as to realize the unidirectional placement or recovery and make the operation more convenient and safer.
In order to enhance the radial strength of the threadlike cylindrical stent 1 , at least one sunken ring 18 is arranged on the said threadlike cylindrical stent 1 , the section of the sunken ring 18 is a trapezoid (see FIG. 34 ). The sunken ring 18 not only can enhance the radial supporting strength of the threadlike cylindrical stent 1 , but also make the inner wall of the human lumen extrude into the stent to form an inlay between the stent and the inner wall of the human lumen and maintain the steady positioning of the threadlike cylindrical stent 1 . A bevel edge 21 of the sunken ring 18 forms a supporting and sealing effect on the diaphragm 2 placed in the threadlike cylindrical stent 1 .
Referring to FIGS. 9-10 , the said cylindrical stent 1 is a net-like stent obtained through laser etching of alloy steel tube, the shape of the etched part approximates a rhombus, one end of the stent is provided with at least three supports 6 integrated with the stent, and the supports 6 are connected with the rear clip 3 ; the cylindrical stent 1 is formed through the laser etching of one alloy steel tube, and the shape of the etched part of the alloy steel tube approximates a rhombus. A rhombic grille-shaped cylinder (See FIG. 9 ) is formed, and it has a large radial supporting ability and has a better inlayed support with the inner wall of the human lumen. In order to facilitate the placement or recovery of the cylinder, one end of the cylindrical stent 1 is provided with linear supports 6 obliquely extending towards the axle line of cylindrical stent 1 , supports 6 are integrated with the cylindrical stent 1 and one end of the supports 6 is connected with the rear clip 3 (See FIG. 10 ). At least three supports 6 are provided, and four supports are preferred. The other end of the cylindrical stent 1 also can be provided with supports 6 , so both ends of the cylindrical stent 1 are respectively provided with a clip and then the cylindrical stent 1 can be placed or recovered in a double direction.
Referring to FIGS. 11-13 , the said cylindrical stent 1 is spirally formed by at least one alloy wire, its one end is provided with the rear clip 3 , and two to four alloy wires are preferably chosen; the cylindrical stent 1 forms a spiral cylinder after being spirally wound by one or a plurality of alloy wires, and the number of alloy wires is preferably 2 to 4. By taking three alloy wires as an example in this embodiment (see FIG. 13 ), one end of the three alloy wires is respectively fixed with the rear clip 3 , and then is spirally wound along the axial direction of the rear clip 3 with uniform distribution of equal angles while the rear clip 3 is used as the center of a circle. Each spiral coil is wound into a spiral cylinder in a form of diameter increase, and then the other end of the alloy wires is firmly welded together or is fixed by a front clip 4 . The diameter of the formed spiral cylinder close to the front clip 4 is slightly larger than that of the spiral cylinder close to the rear clip 4 (see FIG. 11 ), so a frustum shape is formed. The frustum-shaped spiral body has good inlaying capability with the inner wall of the human lumen, and three alloy wires of the cylindrical stent 1 fixed by the rear clip 3 form three openings 5 on this end face, and these three openings are staggered with the three openings formed by the alloy wires fixed by the front clip 4 (see FIG. 12 ). The spiral cylindrical stent 1 can greatly reduce the usage amount of alloy wires and has a higher supporting force. As the spiral stent can be made into the stent with a very small diameter and a great contractive pressure and stretching deformation, the stent can be mounted into the conveyor with an extremely small diameter and then be placed into the human lumen with a very small diameter, and the spiral stent with a large diameter can be released or recovered through the conveyor with a small diameter, to avoid the possible damage to the inner wall of the lumen by use of the conveyor with a large diameter. The spiral stent contacts with the wall surface of the human lumen, so the wall surface will have certain roughness to increase the stability.
The said diaphragm 2 is provided with a cylindrical section 8 adaptive to the cylindrical stent 1 . One end of the cylindrical section 8 is integrally connected with a convex surface 9 uplifted towards the center of the circle, and an unclosed round gap 10 is arranged on the convex surface 9 ; or two symmetrical cambered gaps 11 are arranged and a linear gap 12 arranged between the two cambered gaps 11 make the two symmetrical cambered gaps connected to form a nearly H-shaped gap; or a triangular gap 13 , which takes the center of circle as starting point and makes the equal included angle extend toward the circumference, is arranged; or a cross-shaped gap 14 , which takes the center of circle as starting point and makes the equal included angle extend toward the circumference, is arranged; and then one to four bendable spring pieces 15 are respectively formed. By referring to FIG. 14 , the diaphragm 2 is a cylinder, the outer diameter of its cylindrical section 8 is adaptive to the inner diameter of the cylindrical stent 1 and the cylindrical section 8 is also arranged in one end of the cylindrical stent 1 . The cylindrical section 8 with one end open is integrated with the cylindrical stent 1 , in which a cone uplifted towards the center of the circle is arranged. The bottom side of the cone is integrally connected with that of the cylindrical section 8 , while the cone side forms the convex surface 9 . The thickness of the convex surface 9 gradually decreases from the bottom side of the cone to the uplifted position of the center of circle. The section of the diaphragm 2 looks like a vertical M shape (see FIG. 14 ). A very fine gap cut by the cutter is arranged on the convex surface 9 , and this gap presents an unclosed round gap 10 which makes the convex surface 9 form a nearly 75% round flaky spring piece 15 (see FIG. 15 ), and the section of the spring piece 15 presents a V shape. When the diaphragm 2 is not forced by an external force, the spring piece 15 is laminated with the convex surface 9 to form a closed surface. When the gas or liquid enters from the bottom A of the diaphragm 2 , the gas or liquid gathers towards the top of the cone and then moves towards the gap gate along the inner wall surface of the tapered convex surface 9 , so the spring piece 15 bends upward to open an angle by taking the linking section between the spring piece 15 and the diaphragm 2 as a pivot point, and the convex surface 9 at a closed state forms an opening, and thus the gas or liquid can flow out from this opening, and the opening of the spring piece 15 can be increased as the gas or liquid flow rate increases; if the gas or liquid enters from the top B of the diaphragm 2 in a reverse direction, the gas or liquid is divided into two vortexes by the tapered convex surface 9 , so most of the pressure is transferred to the inner wall surface of the cylindrical section 8 . Meanwhile, the spring piece 15 is extruded, so it can be tightly clamped with the round gap 10 to form a closed surface and thus obstruct the flow of gas or liquid; the diaphragm 2 forms a one-way valve, with one-way clearance function and certain anti-backflow ability. When the pressure is very high, a little gas or liquid leaks from the fitting clearance between the spring piece 15 and the round gap 10 , but will not exert an influence. Additionally, the length (axial length) of the cylindrical section 8 can be increased, so as to increase the bonding area between the cylindrical section and the stent; the said gap on the convex surface 9 can be a nearly H-shaped gap, which comprises two symmetrical cambered gaps 11 and one linear gap 12 ; the linear gap 12 is located between the two cambered gaps 11 , and also makes the two cambered gaps 11 communicated with each other. The H-shaped gap makes the convex surface 9 forming two opposite nearly semicircular spring pieces 15 (see FIG. 16 ); these two spring pieces can bend upward or downward, to open an opening; and the anti-backflow ability of the H-shaped gap is stronger than that of the round gap 9 . Or the gap on the convex surface 9 is a triangular gap 13 which makes the convex surface 9 form three vertically opposite triangular spring pieces 15 (see FIG. 17 ) by taking the center of circle as starting point and making the equal included angle extend toward the circumference; the anti-backflow ability of these three spring pieces 15 is stronger than that of the H-shaped gap. Or the said gap on the convex surface 9 is a cross-shaped gap 14 which makes the convex surface 9 form four vertically opposite triangular spring pieces 15 (see FIG. 18 ); the anti-backflow ability of these four spring pieces 15 is stronger than that of the triangular gap. The said gap can also be a gap shaped like the Chinese character “Mi”, to form a plurality of spring pieces, but the effect may decrease because of excess spring pieces.
The said diaphragm 2 is composed of a cylindrical section 8 and a cone (see FIG. 19 ). The diameter of the cone side of the cone is equal to that of the cylindrical section 8 , while the bottom side of the convex surface 9 of the cone's cone side is integrated with the terminal side of the cylindrical section 8 . The process for making the diaphragm 2 in this structure is quite simple.
The said diaphragm 2 is composed of a cylindrical section 8 , a cylinder 21 and a cone (see FIG. 20 ). The diameter of the cylinder 21 is smaller than that of the cylindrical section 8 and the bottom diameter of the cone is smaller than that diameter of the cylindrical section 8 and larger than the diameter of the cylinder 21 . The bottom side of the convex surface 9 formed by the cone side of the cone is integrated with one end side of the cylinder 21 , while the other end of the cylinder 21 is connected with one end side of the cylindrical section 8 . A groove is formed between the cylindrical section 8 and the cone via the cylinder 21 , and the groove enables the diaphragm 2 to have certain deformation margin. Due to existence of this groove, after the cylindrical stent 1 is placed into the human body, the stent may be deformed to a certain degree because of compression, and then the cylindrical section 8 may be deformed accordingly. As the diameter of the cylinder 21 is smaller than that of the cylindrical section 8 , the cylinder 21 only has a minor deformation with the deformation of the cylindrical section 8 , so as to slow down the deformation, make the cone basically not affected by deformation, still maintain the original shape, prevent the cone from being not closed completely with the subsequent deformation of the cone, and then increase the elasticity of the whole diaphragm.
The said diaphragm 2 is composed of a cylindrical section 8 , a cylinder 22 and a cone (see FIG. 21 ). The diameter of the cylinder 22 is smaller than that of the cylindrical section 8 and is equal to the bottom diameter of the cone. The cylinder 22 and the cone are simultaneously placed in the cavity of the cylindrical section 8 . The bottom side of the convex surface 9 of the cone is integrated with one end side of the cylinder 22 , while the other end of the cylinder 22 is connected with the bottom side of the cylindrical section 8 . A space 23 is formed between the outer wall of the cylinder 22 and the inner wall surface of the cylindrical section 8 , and the space 23 has the same deformation margin function as the said groove. As the axial length of the cylindrical section 8 is longer, the contact surface between the cylindrical section and the stent increases and then the cylindrical section fits well with the stent.
The said diaphragm 2 is composed of a cylindrical section 8 , a cylinder 24 , a cylinder 25 and a spherical crown (see FIG. 22 ). The diameter of the cylinder 24 is smaller than that of the cylindrical section 8 , while the diameter of the cylinder 25 is smaller than that of the cylindrical section 8 and is larger than that of the cylinder 24 and the bottom diameter of the spherical crown 26 is equal to the diameter of the cylinder 25 . The cylindrical section 8 , cylinder 24 , cylinder 25 and spherical crown 26 are connected as one integral in sequence, and a groove is formed between the cylindrical section 8 and the cylinder 25 via the cylinder 24 and this groove has the same effect as the said groove; the convex surface 9 of the spherical crown 26 presents a spherical surface. Similarly, a very fine gap cut by the cutter is also arranged on this spherical surface. Such gap can be the unclosed round gap, the H-shaped gap, the triangular gap or the cross-shaped gap, to form the spring piece 15 . The spherical crown 26 can avoid the gas or liquid being compressed, but open an angle of the spring piece 15 , and the spherical crown 26 also has the good anti-backflow ability.
Each spring piece 15 of the said diaphragm 2 is provided with a curved sunken part 20 ; the thickness of the said spring piece gradually diminishes from circumference to raised center of circle, and a cylinder is arranged at the interaction between the cylindrical section and the projecting piece. By referring to FIGS. 23-25 , the diaphragm 2 is integrally connected by a cylindrical section 8 and a cylinder 27 (see FIG. 23 ), and a curved sunken part 20 is formed in the middle position near the cylinder 27 . The two curved sunken parts 20 are opposite and their edges are joined together (see FIG. 25 ), and a straight fine gap (see FIG. 24 ) is formed at the joint between the two edges. The curved sunken part 20 on the cylinder 27 forms the spring piece 15 . When the gas or liquid enters into the cylinder 27 , the gas or liquid is compressed and then intensively impact the fine gap 19 on the top, so as to burst through the flaky spring piece 15 of the curved sunken part 20 . The maximum opening of the spring piece 15 can reach the diameter of the cylinder 27 , and also can be automatically adjusted as the flow rate changes. The flaky spring piece 15 with a curved sunken part 20 not only is favorable for the outflow of the forward gas flow, but also obstructs the flow of the reversed gas and increases the function of the diaphragm on the one-way valve; if the gas or liquid flows back, the pressure directly acts on the curved sunken part 20 , to force the edges of the two spring pieces clamped with each other, seal the fine gap 19 and effectively prevent the backflow phenomenon; the spring piece with the curved sunken part 20 approaches the structure of human heat valve, so the spring piece has the best one-way sealing effect and the strongest anti-backflow ability. When the cylindrical section 8 is deformed under the radial pressure, the space 28 formed at the joint between the cylinder 27 and the cylindrical section 8 can make the cylinder 22 not be influenced by the deformation of the cylindrical section 8 , but still be kept at its original state; the said cylinder 27 can be provided with three curved sunken parts 20 , that is, the top of the cylinder 27 is kneaded together at a trisection angle, to form three vertically opposite curved sunken parts 20 (see FIG. 27 ) which form three spring pieces 15 and three vertically opposite straight fine gaps 19 , with one-way sealing effect and anti-backflow ability further improved; or the top of the said cylinder 27 is kneaded together at a quartering angle, to form four vertically opposite curved sunken parts 20 which form four spring pieces 15 and four vertically opposite straight fine gaps 19 (see FIG. 29 ); a plurality of the said curved sunken parts can also be arranged, but it makes little sense to use more than four spring pieces. The best range is two to three spring pieces.
The said spring piece 15 is a flaky object with the diameter adaptive to the diameter of the cylindrical stent 1 and a raised center of circle. The spring piece 15 is connected with one clip of the cylindrical stent 1 via a metal rod 17 ( FIG. 3 c ), and at least two gaps 29 ( FIG. 31 ) which extend from the position near the center of circle to the edge of the spring piece 15 , to form at least two spring pieces 15 , and three to four gaps 29 are preferably used; diaphragm 2 is an umbrella body (or called a bowl shape). The thickness of diaphragm 2 gradually diminishes from the top to the edge of the umbrella body (see FIG. 30 ), and the umbrella body is provided with a plurality of gaps 29 , the length of which is smaller than the radius of the umbrella body, from the edge to the center of circle of the umbrella body. The gaps 29 are uniformly distributed at an equal angle while the center of the umbrella body is used as the center of a circle. The surface of the umbrella body connected between the two gaps 29 forms spring pieces 15 . In order to make the spring piece 15 have certain strength, improve the elastic deformation of spring piece and enable it to have the shape memory characteristic, a metal wire support 16 is arranged inside or on the surface of the spring piece 15 (see FIG. 31 ). The metal wire support 16 is a memory alloy wire which can be covered in the spring piece or arranged on the surface of the spring piece. The support is equivalent to the ribs of the umbrella surface, which can play the role in forming and fixing to make each spring piece kept at a curved shape, and also can support the spring piece as a framework; in order to maintain the diaphragm 2 at an umbrella state, the top center of the umbrella body is firmly connected with a metal rod 17 which extends outward from the internal part of the umbrella body and then is firmly connected with the rear clip 3 of the cylindrical stent 1 , looking like an opened umbrella. The metal rod 17 can make the spring piece formed by the gaps 29 make opening and closing movements around the metal rod, and maintain the fixed location of the diaphragm 2 ; the said metal rod 17 also can extend outward from the top surface of the umbrella body and then is firmly connected with the front clip 4 of the cylindrical stent 4 (see FIG. 32 ), the function of which is the same as the said metal rod. A plurality of gaps 29 can form a plurality of spring pieces 15 , but three to four spring pieces 15 formed by three to four gaps 29 are preferred.
By referring to FIGS. 34-35 , one end of the cylindrical stent 1 is open, while the other end forms two openings 5 after two alloy wire bundles 7 are fixed by the rear clip 3 . The diaphragm 2 is placed in the cylindrical stent 1 , and is integrated with the stent by seaming, laminating or direct forming on the stent. The bottom side of the cylindrical section 8 of the diaphragm 2 is level with the open edge of the cylindrical stent 1 , and is jointly connected with the inner wall of the cylindrical stent 1 . The bottom side of the tapered convex surface 9 of the diaphragm 2 tightly holds out against an embolic wall surface formed by a sunken ring 18 (see FIG. 34 ). The embolic wall surface of the sunken ring 18 forms one positioning point to the cylindrical section 8 and forms one supporting points to the convex surface 9 , while this supporting point can enhance the anti-backflow ability and sealing effect of the diaphragm 2 in case of backflow; each spring piece (see FIG. 35 ) on the convex surface of the diaphragm 2 is provided with a support 16 (see FIG. 35 ) which is a memory alloy wire. As a framework, the support supports the spring piece and keeps the shape of the convex surface 9 , so as to enhance the strength of the spring piece and make it have the shape recovery memory characteristic. In use, the guide wire in the conveyor lumen is spirally connected with the rear clip 3 of the cylindrical stent 1 , so as to release or recover the cylindrical stent 1 in a single direction.
Referring to FIGS. 36-37 , one end of the said cylindrical stent 1 forms two openings 5 after two alloy wire bundles 7 are fixed by the front clip 4 , while the other end also forms two openings 5 after two alloy wire bundles 7 are fixed by the rear clip 3 . The diaphragm 2 is placed in the cylindrical stent 1 , and the bottom side of the diaphragm 2 holds out against the edge of the alloy wire bundles 7 fixed by the front clip 4 (see FIG. 36 ). Each spring piece on the convex surface 9 of the diaphragm 2 is provided with a support 16 (see FIG. 37 ). The guide wire in the conveyor lumen is spirally connected with the rear clip 3 or the front clip 4 , so as to release or recover the cylindrical stent in a double direction. The said support which is a metal wire can be placed on the surface of the diaphragm, and also can be placed inside the diaphragm. If the diaphragm 2 is integrally processed or is composed of double-layer material, the support 16 can be placed between the two layers of material.
Referring to FIGS. 38-39 , the cylindrical stent 1 in a structure of a front clip 4 and a rear clip 3 is asymmetrically arranged. The convex surface 9 of the diaphragm 2 is a spherical surface, and the gap on the convex surface is an unclosed round gap (see FIG. 39 ). The unclosed round gap is matched with the cylindrical stent 1 which the front clip 4 and the rear clip 3 are arranged asymmetrically, so as to increase the flow area and also the flow rate, and thus release or recover the cylindrical stent 1 in a double direction through the front clip 4 or the rear clip 3 .
By referring to FIGS. 40-41 , diaphragm 2 is placed in the cylindrical stent 1 with a front clip 4 and a rear clip 3 arranged symmetrically (see FIG. 40 ). This stent has three openings 5 . The head of diaphragm 2 presents a spherical surface, and the gap on the diaphragm 2 is a triangular gap 13 . This triangular gap is staggered with the three openings 5 (see FIG. 41 ), and the cylindrical stent 1 can be released or recovered in a double direction through the front clip 4 or the rear clip 3 .
Referring to FIGS. 42-43 , diaphragm 2 is placed in the cylindrical stent 1 with a front clip 5 and a rear clip 4 arranged symmetrically (see FIG. 42 ). This stent has four openings 5 . The head of diaphragm 2 presents a spherical surface, and the gap on the diaphragm 2 is a cross-shaped gap 12 . This cross-shaped gap is staggered with the four openings 5 (see FIG. 43 ), and the cylindrical stent 1 can be released or recovered in a double direction through the front clip 4 or the rear clip 3 .
Referring to FIGS. 44-45 , one end of the cylindrical stent 1 forms two openings 5 after two alloy wire bundles 7 are fixed by the front clip 4 , while the other end forms two openings 5 after two alloy wire bundles are fixed by the rear clip 3 . The umbrella diaphragm 2 is placed in the cylindrical stent 1 . One end of the metal rod 17 is connected with the front clip 4 , while the other end is connected with the central part of the umbrella top of the diaphragm 2 . The peripheral edge of the umbrella body tightly holds out against the embolic wall surface (see FIG. 44 ) formed by the sunken ring 18 of the cylindrical stent 1 . The embolic wall surface forms a seal to the diaphragm 2 (similar to a valve cutting edge), while the metal rod 17 stretches the diaphragm 2 , to make it kept at an umbrella state. When the gas flow or liquid enters from the front clip 4 , the gas or liquid gathers around the periphery of the umbrella top of the diaphragm 2 , so the spring piece 15 formed by the gaps 29 bends toward the direction of the rear clip 3 under compression, and the outer edge of the spring piece is disengaged with the inner wall surface of the sunken ring 18 , so the umbrella diameter of the umbrella diaphragm 2 shrinks and then forms an annular opening. The gas flow or liquid flows out from this annular opening. In case of backflow, the gas flow or liquid tightly compresses the edge of the spring piece 15 together with the embolic wall surface of the sunken ring 18 , so as to form a sealing face and then obstruct the flow of the gas or liquid. The metal rod 17 stretches and supports the diaphragm 2 when the gas or liquid flows forward or backward; the said metal rod 17 can extend outward from the internal part of the umbrella body and then is firmly connected with the rear clip 3 of the cylindrical stent 1 , looking like an opened umbrella. The metal rod 17 stretches and supports the diaphragm 2 when the gas or liquid flows forward or backward (see FIG. 46 ), to make it kept at an umbrella state.
By referring to FIGS. 48-53 , the diaphragm 2 is placed in the spiral cylindrical stent 1 . The shape of the diaphragm 2 can be any of the said diaphragms 2 , while the cylindrical section 8 of the diaphragm 2 is also in a frustum shape, so as to be matched with the spiral cylindrical stent. If the diaphragm 2 is in an umbrella shape, the umbrella diameter of the diaphragm 2 needs to accord with the diameter of some spiral coil of the spiral cylindrical stent, which can be determined by the length of the metal rod 17 .
The said diaphragms 2 are applicable to the said threadlike cylindrical stent, the net-like cylindrical stent etched by laser and the spiral cylindrical stent, and can be selectively matched according to the required gas or liquid flow rate. The metal wire support 16 which can enhance the elastic deformation and strength of the spring piece can be arranged inside or on the surface of the spring piece 15 .
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A recoverable, safe and reliable valve stent for unidirectional flow of human lumen which can be implanted temporarily or for a long term and is used in the interventional therapy so as to obstruct from anisotropic flow, in the case of lung diseases. It comprises a cylindrical stent made up of memory alloy material. In particular, an elastic diaphragm is arranged inside the cylindrical stent and at least one gap is arranged on the diaphragm so that the spring piece is divided into a bendable section. One end of the cylindrical stent is provided with a fixed rear clip which is used to fix the alloy material making up the cylindrical stent. The rear clip is provided with screwthreads which can be connected with the conveyor. The stent in the present invention is in a structure without hook body, so the stent can be accurately positioned, adjusted and placed or recovered in double directions with strong anti-backflow ability.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/640,752, filed on Dec. 30, 2004, the disclosure of which is herein incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates to water heater systems, and more particularly relates to a semi-instantaneous water heater system that can maintain water temperature within a prescribed error band at any rate of flow whether varying or continuous between zero flow and the maximum capability of the energy source.
BACKGROUND
[0003] The commercial water heater industry has been served by storage tank water heaters that are sized to contain sufficient water at a specified temperature to satisfy demand during the highest expected usage. While this method has proven satisfactory for most applications, it requires large storage volumes, with associated losses, large footprint, and excessive set point temperatures to ensure performance. The commercial water heaters are typically operated in various ways.
[0004] One way is to select a maximum and minimum temperature set point relatively far apart from one another in order to minimize the frequency of power cycling of the water heater. For example, the maximum temperature set point might be twenty degrees higher than the desired water temperature. The water heater is cycled on until the actual water temperature reaches the maximum temperature set point. When the actual temperature of water in the heater drops to the minimum temperature set point at around the desired temperature, power to the water heater is cycled on again until the actual temperature reaches the maximum temperature set point. A drawback with this approach is that an inordinate amount of energy is required for heating the water in the water heater to a temperature well in excess of the desired temperature. Moreover, the excessive temperature can lead to scalding should water be drawn toward the end of an operating cycle. Further, employing a large water heater can typically leads to temperature striations along various levels of the water heater leading to high fluctuations in water temperature should a high load demand be suddenly imposed on the water heater.
[0005] A second way to operate a large water heater is to select a maximum and minimum temperature set point relatively close to one another in order to minimize energy consumption. For example, the maximum temperature set point might be only a few degrees higher than the desired water temperature. The water heater is cycled on until the actual water temperature reaches the maximum temperature set point. When the actual temperature of water in the heater drops to the minimum temperature set point at around the desired temperature, power to the water heater is cycled on again until the actual temperature reaches the maximum temperature set point. A drawback with this approach is that the close proximity between the maximum and minimum temperature set points results in frequent on and off power cycling which can shorten the operating life of the equipment for cycling power to the water heater.
[0006] Instantaneous heaters have also been applied with limited success. Their inability to respond to instantaneous flow changes and high cycling rates of the water heater due to recirculation loads has limited use by this method.
[0007] Accordingly, it is a general object of the present invention to overcome the drawbacks associated with prior water heater systems.
SUMMARY OF THE INVENTION
[0008] The present invention resides in a water heater system comprising a boiler including a supply port, an output port and a recirculation input port. A heat exchanger has a first input port, a first output port, a second input port and a second output port. An averaging tank has an inlet and an outlet. A first fluid flow subsystem is for controllably directing water along a primary loop through the boiler and from the output port of the boiler to the input recirculation port via either a first path through the first ports of the heat exchanger or a second path bypassing the heat exchanger. A second fluid flow subsystem is for directing water along a secondary loop through the second ports of the heat exchanger, through the inlet and outlet of the averaging tank, and back to the heat exchanger, whereby water directed through the secondary loop is heated from water directed through the primary loop via the heat exchanger.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic diagram of a water heater system embodying the present invention.
[0010] FIG. 2 is a schematic diagram of a water heater system in accordance with a second embodiment of the present invention.
[0011] FIG. 3 are graphs illustrating various operating parameters of the water heater system in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] A water heater system embodying the present invention is indicated generally by the reference number 10 . The system 10 comprises a boiler 12 , a controller 14 , a heat exchanger 16 , and an averaging tank 18 . The controller 14 is shown as being separate from the boiler 12 , but it should be understood that the controller can be part of the boiler circuitry without departing from the scope of the present invention.
[0013] The boiler 12 includes an input port 20 , an output port 22 and a recirculation input port 24 . A first pump 26 has a control terminal 28 for receiving a control signal from the controller 14 , an input 30 coupled to the output port 22 of the boiler 12 , and an output 32 coupled to the recirculation input port 24 of the boiler. A second pump 34 has a control terminal 36 for receiving a control signal from the controller 14 , an input 38 coupled to the output 32 of the first pump 26 , and an output 40 coupled to a first input port 42 of the heat exchanger 16 .
[0014] As mentioned above, the heat exchanger 16 includes a first input port 42 coupled to the output 40 of the second pump 34 . A first output port 44 of the heat exchanger 16 is coupled to the recirculation input port 24 of the boiler 12 . When the first pump 26 is on and the second pump 34 is on, water flows around a primary loop through the boiler 12 , through the first pump 26 , through the second pump 34 , through the first input and output ports 42 , 44 of the heat exchanger 16 and back to the boiler. When the first pump 26 is on and the second pump 34 is off, water leaving the output port 22 of the boiler 12 flows through the first pump 26 and returns to the recirculation input port 24 of the boiler so as to bypass the heat exchanger 16 for the reason to be explained more fully below.
[0015] The averaging tank 18 includes an inlet 46 coupled to a second output port 48 of the heat exchanger 16 , and an outlet 50 for allowing water to be channeled either back to the averaging tank 18 and to remote locations for end use. A third pump 52 for moving water to the averaging tank 18 has a control terminal 54 for receiving a control signal from the controller 14 , an input 56 coupled to a supply line 58 and to the outlet 50 of the averaging tank, and an output 60 coupled to a second input port 62 of the heat exchanger 16 . When the third pump 52 is on, water flows from the supply line 58 , through the heat exchanger 16 via the second input and output ports 62 , 48 , and through the averaging tank 18 via the inlet 46 and the outlet 50 thereof. Water exiting the averaging tank 18 can then flow via exit line 64 to remote locations for end use. A portion of the water leaving the averaging tank 18 is recirculated by flowing through a return line 66 to the input 56 of the third pump 52 .
[0016] The system 10 further includes a plurality of sensors communicating with the controller 14 for transmitting to the controller signals indicative of the water temperature at various locations in the system. As shown in FIG. 1 , a first sensor 68 is located along the primary loop between the output port 22 of the boiler 12 and the input 30 of the first pump 26 to detect the water temperature of the boiler 12 (Tblr) adjacent to the output port of the boiler. A second sensor 70 is located along the secondary loop adjacent to the outlet 50 of the averaging tank 18 so as to detect the set point water temperature (Tsp) of the averaging tank. A third sensor 72 is located along the supply line 58 to the secondary loop so as to detect water supply temperature (Tc) to the secondary loop. A fourth sensor 76 is located along the secondary loop downstream in the direction of water flow of a junction 78 of the supply line 58 and the secondary loop and upstream of the heat exchanger 16 so as to detect water temperature (Tmix) of a mixture of supply water and water leaving the averaging tank 18 .
[0017] A water heater system in accordance with a second embodiment of the present invention is indicated generally by the reference number 110 . Like elements with the system 10 are indicated by like reference numbers preceded by “1”. The system 110 comprises a boiler 112 , a controller 114 , a heat exchanger 116 , and an averaging tank 118 . The controller 114 is shown as being separate from the boiler 112 , but it should be understood that the controller can be part of the boiler circuitry without departing from the scope of the present invention.
[0018] The boiler 112 includes an input port 120 , an output port 122 and a recirculation input port 124 . A first pump 126 has a control terminal 128 for receiving a control signal from the controller 114 , an input 130 coupled to the output port 122 of the boiler 112 , and an output 132 coupled to an input 133 of a three-way control valve 135 . The three-way valve 135 further has a control terminal 137 for receiving a control signal from the controller 114 , a first output 139 coupled to a first input port 142 of the heat exchanger 116 , and a second output 141 coupled to the recirculation input port 124 of the boiler 112 .
[0019] As mentioned above, the heat exchanger 116 includes a first input port 142 coupled to the first output 139 of the three-way valve 135 . A first output port 144 of the heat exchanger 116 is coupled to the recirculation input port 124 of the boiler 112 . When the first pump 126 is on, the first output 139 of the three-way valve 135 is open, and the second output 141 of the three-way valve is closed, water flows around a primary loop through the boiler 112 , through the first pump 126 , directed by the three-way valve through the first input and output ports 142 , 144 of the heat exchanger 116 and back to the boiler. When the first pump 126 is on, the first output 139 of the three-way valve 135 is closed, and the second output 141 of the three-way valve is open, water leaving the output port 122 of the boiler 112 flows through the first pump 126 and is directed by the three-way valve back to the recirculation input port 124 of the boiler so as to bypass the heat exchanger 116 for the reason to be explained more fully below.
[0020] The averaging tank 118 includes an inlet 146 coupled to a second output port 148 of the heat exchanger 116 , and an outlet 150 for allowing water to be channeled either back to the averaging tank 118 or to remote locations for end use. A second pump 152 for moving water to the averaging tank 118 has a control terminal 154 for receiving a control signal from the controller 114 , an input 156 coupled to a supply line 158 and to the outlet 150 of the averaging tank, and an output 160 coupled to a second input port 162 of the heat exchanger 116 . When the second pump 152 is on, water flows from the supply line 158 , through the heat exchanger 116 via the second input and output ports 162 , 148 , and through the averaging tank 118 via the inlet 146 and the outlet 150 thereof. Water exiting the averaging tank 118 can then flow via exit line 164 to remote locations for end use. A portion of the water leaving the averaging tank 118 is recirculated by flowing through a return line 166 to the input 156 of the second pump 152 .
[0021] The system 110 further includes a plurality of sensors communicating with the controller 114 for transmitting to the controller signals indicative of the water temperature at various locations in the system. As shown in FIG. 2 , a first sensor 168 is located along the primary loop between the output port 122 of the boiler 112 and the input 133 of the three-way valve 135 to detect the water temperature of the boiler 112 (Tblr) adjacent to the output port of the boiler. A second sensor 170 is located along the secondary loop adjacent to the outlet 150 of the averaging tank 118 so as to detect the set point water temperature (Tsp) of the averaging tank. A third sensor 172 is located along the supply line 158 to the secondary loop so as to detect water supply temperature (Tc) to the secondary loop. A fourth sensor 176 is located along the secondary loop downstream in the direction of water flow of a junction 178 of the supply line 158 and the secondary loop and upstream of the heat exchanger 116 so as to detect water temperature (Tmix) of a mixture of supply water and water leaving the averaging tank 118 .
[0022] The present invention embodied in the systems of FIGS. 1 and 2 uses the energy stored in an iron boiler to reduce boiler cycling, the low heat capacity of a plate heat exchanger combined with an averaging tank to maintain temperature accuracy during load changes.
[0023] The advantageous of this type of system are:
1. Accurate temperature delivery over the entire flow range allowing the reduction of set point temperature with the associated reduction in scalding potential and recirculation losses. 2. Small footprint 3. Low cycling rates with a modulating iron boiler of moderate turndown (4:1). (The turndown is the continuous change in BTU/hr of which the boiler is capable.) 4. A low time constant (the speed with which the system can be readjusted to a new set point) allows variation of set point to meet changing water temperature requirements throughout the day.
The averaging tank acts as a “flywheel” to store sufficient energy to maintain temperature during the boiler start delay and rapid changes in load. The second pump 34 (see FIG. 1 ) or the three-way control valve 135 (see FIG. 2 ) in the primary loop moves or directs boiler energy to the secondary loop via the heat exchanger or bypasses the heat exchanger back to the recirculation input port of the boiler. The controller derives the necessary information for the specified performance from the four temperature sensors shown in the embodiments of FIGS. 1 and 2 . A set point (the operating temperature of the water heater system) and a bandwidth (BW—the total temperature error allowed. IE, To max to To min)) are entered in the controller. A maximum boiler temperature (Tblr max) is also entered into the controller. With respect to the system 10 shown in FIG. 1 , the first pump 26 and the third pump 52 operate continuously. The first pump 26 maintains flow through the boiler 12 while the third pump 52 continuously mixes the water in the averaging tank 18 . The second pump 34 is turned on by the controller 14 at the minimum water temperature (Tsp−BW/2) to transfer the energy in the primary loop into the water. The second pump 34 is turned off by the controller 14 at the maximum water temperature (Tsp+BW/2) to stop additional energy transfer to the water. The fast response of the second pump 34 and the low heat capacity (WCp) of the plate heat exchanger 16 ensure a rapid system response to the cycling of the second pump 34 . The boiler is started by the controller when either of two conditions is met as will be now explained with respect to the following equations.
DT available=( Tblr−Tmin )× WCp ( blr )/ WCp (tank) Equation 1
[0033] Where: DT available is the amount of temperature that the averaging tank can be increased from the energy stored in the primary source (in this case, the KN boiler).
FF %=( T setpoint− T mix)/ Tref Equation 2
[0034] Where: Tref=qmax/(500.4×Qmix(pump in secondary loop)
[0035] FF % is the percent of load created by the amount of water drawn from the system. The maximum (100%) load is when the boiler must run at its full output to meet the demand. This signal tells the boiler what energy is needed to meet the instantaneous demand.
[0036] Terms:
Tblr—the temperature of the boiler water Tmin—the minimum allowed temperature of the potable water WCp(blr)—the energy storage capacity of the primary loop (the boiler) WCp(tank)—the energy storage capacity of the averaging tank Tsetpoint—the desired potable water temperature Tmix—the temperature of the water resulting from the mixture of cold water and averaging tank water being drawn into the system by pump in the secondary loop Tref—the maximum temperature difference that could exist at 100% demand qmax—the maximum net energy available to the system from the boiler
The boiler input energy required (FF) is calculated from Eq. [2]. This is the energy at which the boiler operates when it is running. If the value of (FF) is greater than the minimum input capable by the boiler, the controller immediately starts the boiler. If the value of (FF) is less than the minimum boiler input, then: when the second pump 34 (see FIG. 1 ) turns on or the control valve 126 is activated to direct water to the heat exchanger (see FIG. 2 ), the controller determines if there is enough stored energy in the primary loop to raise the temperature of the averaging tank equal to or greater than the bandwidth. If there is, a boiler start is suppressed. If not, the boiler is started by the controller and operates at its minimum input. Once started, the boiler operates until it reaches Tblr max. FIG. 3 illustrates by way of example graphs of various operating parameters of a water heater system in accordance with the present invention. The system being illustrated is operating at about 5% load, has a set point of about 120° F., and has a bandwidth of 6° F. A graph 310 illustrates the water temperature at the output of the boiler (Tboil out) over time. A graph 312 illustrates the water temperature of the averaging tank over time. A graph 314 is indicative of when the boiler is turned on and turned off over time. A graph 316 is indicative of when water flow in the primary loop bypasses the heat exchanger over time. A graph 318 is indicative of water supply demand over time. As can be seen by the graph 312 , a water heater system in accordance with the present invention maintains the temperature of the averaging tank at a generally constant temperature of about 120° F. during the cycling of the boiler and over varying water supply demand conditions. Although this invention has been shown and described with respect to the detailed embodiments thereof, it will be understood by those of skill in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed in the above detailed description, but that the invention will include all embodiments falling within the scope of the appended claims.
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A water heater system includes a boiler having a supply port, an output port and a recirculation input port. A heat exchanger includes first input and output ports, and second input and output ports. An averaging tank has an inlet and an outlet. A first fluid flow subsystem is for controllably directing water along a primary loop through the boiler and from the output port of the boiler to the input recirculation port via either a first path through the first ports of the heat exchanger or a second path bypassing the heat exchanger. A second fluid flow subsystem is for directing water along a secondary loop through the second ports of the heat exchanger, through the inlet and outlet of the averaging tank, and back to the heat exchanger, whereby water directed through the secondary loop is heated from water directed through the primary loop via the heat exchanger.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Priority is claimed of Australian Complete Patent Application number 2011201408 filed 28 Mar. 2011 and Australian Provisional Patent Application 2010905369 filed 7 Dec. 2010, the disclosures of which are incorporated in their entireties by reference herein as if set forth at length.
BACKGROUND OF THE INVENTION
The present invention relates to the connection of wearing elements to machinery. It is particularly directed to the connection of ground engaging tools such as teeth to excavator buckets, but may have wider application.
Excavating equipment is subject to significant abrasive wear during use. For this reason, replaceable ground engaging tools (GET) are located about the bucket in the areas most susceptible to wear. A number of different GET are used, including heel shrouds, adaptors, wear plates and, importantly, teeth.
The connection of teeth to adaptors has presented a consistent challenge, and there are many different systems currently available which seek to perform this task in an efficient manner. Many of the systems use a locking pin, which passes through a bore of the adaptor. Such an arrangement has an inherent problem in that the provision of a bore weakens the adaptor, as well as encouraging stress concentrations within the adaptor.
Other systems use a latching system. These are problematic in that there is usually no ability to adjust or tighten the connection, hence the teeth are liable to become loose.
One such latching system is described in U.S. Pat. No. 7,640,685 (Emrich). Emrich uses a square sectioned, non-resilient pin within a square sectioned, resiliently deformable bore. The pin can be rotated in 90° increments, partially deforming the bore and then ‘snapping’ to the next position. In this way the latching system can be engaged or disengaged.
The present invention seeks to provide an arrangement for connection of wearing elements, particularly teeth, which addresses some of these problems.
SUMMARY OF THE INVENTION
According to one aspect of the present invention there is provided a wear assembly for an excavating bucket comprising:
a base located on a lip of the excavator bucket, the base having a nose;
a wear member having a cavity in which the nose can be received, and an aperture extending between an outside surface of the wear member and the cavity, an internally toothed ring being located within the aperture; and
a lock for releasably holding the wear member to the base; the lock including an operable member and an externally toothed resilient ring, the resilient ring having a central aperture for engagement with the operable member, the operable member and resilient ring being jointly rotatable relative to the cavity and the internally toothed ring between a plurality of rotationally spaced locking positions where the lock secures the wear member to the base with varying tightness, and a release position rotationally spaced from the locking positions, wherein the teeth of the internally toothed ring and the teeth of the resilient ring engage each other in each of the locking positions to reduce the loosening of the lock during use, and wherein the teeth of the resilient member flex to permit rotation of the operable member when the operable member is turned by an operator. Advantageously, this arrangement allows the resilient ring to be formed independently of the operable member, which can then be formed by investment casting. The use of investment casting allows the formation of an operable member with tight tolerances, meaning that the resilient ring can be snugly fitted about the operable member (for instance, in a keyed arrangement) to ensure that there is no rotational slipping of the resilient ring relative to the operable member in use.
It is preferred that the internally toothed ring be located in position within the aperture by a complementary keyed arrangement. Advantageously, the use of a non-resilient ring in this position permits sand casting of the wear member, with associated limits for tolerances.
It is also preferred that the internally toothed ring be formed of a material significantly more rigid than that of the resilient ring, so that the resilient ring preferentially deforms relative to the internally toothed ring. The internally toothed ring may be aluminium or a rigid plastic, and the resilient ring may be rubber.
In a preferred embodiment, each toothed ring has about 40 teeth. This means that tightening of the lock can be performed in increments of less than 10°. In general, it is considered that tightening increments of less than 15° are desirable.
It will be apparent that the lock continues to secure the wear member to the base while moving between locking positions.
According to another aspect of the present invention there is provided a method of connecting a wear member having a cavity to a base located on a lip of an excavator bucket, the base having a nose; the method including the steps of:
locating an internally toothed ring in an aperture which extends between an outside surface of the wear member and the cavity,
inserting a lock into the aperture, the lock including an operable member and an externally toothed resilient ring, the resilient ring having a central aperture for engagement with the operable member;
locating the cavity of the wear member about the nose of the base;
rotating the operable member and resilient ring jointly relative to the internally toothed ring from a release position to a loose locking position; and
continuing to rotate the operable member and the resilient ring relative to the internally toothed ring through a plurality of rotationally spaced locking positions in order to tighten the lock. Advantageously, the lock can be located in the aperture during shipment of the wear member, and need not be removed in order for the wear member to be located about the nose of the base.
According to yet another aspect of the present invention there is provided a coupling for connecting a wear member to a base, the base including a first bearing surface, the wear member including a second bearing surface; the coupling including a rotatable lock having a first face arranged to bear against the first bearing surface and a second face arranged to bear against the second bearing surface, the relative positions of the first and second face varying around a central axis of the lock, such that in use rotation of the lock alters the distance between the first and second bearing surfaces.
It is preferred that the first face and the second face of the rotatable lock are both arcuate and have respective radii of curvature, with the radius of curvature of at least one of the first or second face varying around the lock central axis. In a preferred embodiment of the invention, the second face of the rotatable lock has a constant radius of curvature; that is, is part-cylindrical; whereas the first face has a varying radius of curvature; that is, is shaped like a spiral.
The wear member may be arranged to align about the base along a longitudinal axis. The central axis of the lock may be perpendicular to this longitudinal axis, but it is preferred that that the central axis of the lock be oriented at about 10° to 20° relative to the perpendicular.
The first face and second face of the rotatable lock may be located on a single bearing member. It is preferred that the bearing member includes a body portion, which is cylindrical, and has an outer surface forming the second face of the rotatable lock. It is also preferred that the bearing member has an engaging portion protruding from one side of the body portion, the engaging portion having an outer surface, at least a part of which forms the first face of the rotatable lock.
The engaging portion may be formed from a substantially straight portion joined to a spiralling portion. The engaging portion may be generally annular, with an outside wall and an inside wall. In this arrangement the outside wall of the spiralling portion forms the first face of the rotatable lock.
The height of the engaging portion relative to the body portion may vary around the annulus. It is preferred that the height of the spiralling portion be a minimum at one end of the substantially straight portion, and at a maximum at a location on the spiralling portion which is located on a line which is perpendicular to the straight portion and which passes through the central axis of the lock.
The bearing member may be coupled to an operable member. In a preferred embodiment, the operable member includes a keyed projection which engages with a keyed recess in the bearing member.
It is preferred that the rotatable lock is retained within the wear member. The wear member may have an internal cavity, with an aperture passing through a side wall of the wear member into the cavity, and the lock being receivable within the cavity. It is preferred that the cavity includes an inner region in which the bearing member can be received, the inner region including the second bearing face, and an outer region in which the operable member can be received. In a preferred embodiment of the invention, the inner and outer regions are separated by a toothed ring, arranged to engage with a toothed ring located about the rotatable lock. At least one of the toothed rings is resilient, such that engagement of the respective teeth will maintain the lock in a desired angular position, but whereby the application of an angular force to the operable member will cause deformation of the resilient toothed ring to allow rotation of the lock.
In a preferred embodiment of the invention, the operable member includes a tool-receiving recess in which is located a plug formed at least partially of resilient material. The arrangement is such that insertion of a tool within the tool-receiving recess causes compression of the plug, and removal of the tool allows return of the plug to its uncompressed state.
The base may include a side wall having a recess, the recess having an arcuate wall which forms the first bearing surface. It is preferred that the recess be generally tapered towards the arcuate wall. The recess may include a boss spaced from the arcuate wall, the boss being arranged to engage with the inside wall of the engaging portion of the bearing member in some angular positions, to promote disengagement of the wear member from the base during removal.
The wear member may be an excavator tooth, and the base may be an adaptor. In this embodiment, it is preferred that the adaptor includes a nose having a top and a bottom, each of the top and the bottom including two substantially flat bearing surfaces separated by concave joining surfaces.
The excavator tooth has a cavity substantially complementary in shape to the adaptor nose, having substantially flat bearing surfaces separated by convex joining surfaces. The convex joining surfaces of the tooth have curvature slightly less than the concave joining surfaces of the adaptor nose.
In accordance with yet another aspect of the invention there is provided a coupling for connecting a wear member to a base, the base including a first bearing surface, the wear member including a second bearing surface; the coupling including a rotatable lock having a first face arranged to bear against the first bearing surface and a second face arranged to bear against the second bearing surface, the lock having a central axis about which it can be rotated, the first and second face being both axially and circumferentially spaced relative to central axis of the lock, such that in use the lock can be rotated between a position in which the first and second face bear against the first bearing surface and second bearing surface respectively, and a position in which the first face does not bear against the first bearing surface or the second face does not bear against the second bearing surface. This allows for selective engagement and disengagement of the lock by virtue of turning. Although in a preferred embodiment the present invention allows for tightening of the lock, it will be appreciated that in its simplest form the invention may simply act as a latch to engage the coupling.
BRIEF DESCRIPTION OF THE DRAWINGS
It will be convenient to further describe the invention with reference to preferred embodiments of the coupling mechanism of the present invention. Other embodiments are possible, and consequently the particularity of the following discussion is not to be understood as superseding the generality of the preceding description of the invention. In the drawings:
FIG. 1 is a perspective of an adaptor and tooth having a coupling in accordance with the present invention, shown prior to coupling;
FIG. 2 is a perspective of the adaptor and tooth of FIG. 1 shown coupled;
FIG. 3 is a front perspective of a nose of the adaptor of FIG. 1 , showing a first side;
FIG. 4 is a rear perspective of the adaptor nose of FIG. 3 , showing a second side;
FIG. 5 is an external view of a lock-receiving aperture in the tooth of FIG. 1 , shown prior to receiving a toothed ring;
FIG. 6 is an internal view of the lock-receiving aperture of FIG. 5 ;
FIG. 7 is an external view of the lock-receiving aperture of FIG. 5 , shown with the toothed ring inserted;
FIG. 8 an internal view of the lock-receiving aperture of FIG. 7 ;
FIG. 9 a is a perspective of the lock-receiving aperture of FIG. 5 ;
FIG. 9 b is a cross section through line P-P marked on FIG. 9 a;
FIG. 10 is an exploded view of a lock from the coupling of FIG. 1 , viewed from the outside;
FIG. 11 is an exploded view of the lock of FIG. 10 , viewed from the inside;
FIG. 12 is a set of side and plan views of a bearing member within the lock of FIG. 10 ;
FIG. 13 is a set of side views of an operable member within the lock of FIG. 10 ;
FIG. 14( a ) is a side view of the bearing member of FIG. 12 ;
FIG. 14( b ) is a cross section through line D-D marked on FIG. 14( a );
FIG. 14( c ) is a cross section through line E-E marked on FIG. 14( a );
FIG. 14( d ) is a cross section through line F-F marked on FIG. 14( a );
FIG. 14( e ) is a cross section through line G-G marked on FIG. 14( a );
FIG. 14( f ) is a cross section through line H-H marked on FIG. 14( a );
FIG. 14( g ) is a cross section through line I-I marked on FIG. 14( a );
FIG. 14( h ) is a cross section through line J-J marked on FIG. 14( a );
FIG. 15 a is a rear view of the tooth of FIG. 1 , shown receiving the lock of FIG. 10 ;
FIG. 15 b is a rear view of the tooth of FIG. 15 a , shown with the lock in place;
FIG. 16 is a side view of the adaptor and tooth of FIG. 1 during coupling;
FIG. 17 is a cross section through line A-A marked on FIG. 16 ;
FIG. 18 is a cross section through line O-O marked on FIG. 17 ;
FIG. 19 is an enlargement of a portion of FIG. 17 showing the lock of FIG. 10 ;
FIG. 20 is a side view of the adaptor and tooth of FIG. 1 following coupling;
FIG. 21 is a cross section through line C-C marked on FIG. 20 ;
FIG. 22 is a cross section through line K-K marked on FIG. 21 ;
FIG. 23 is an enlargement of a portion of FIG. 21 showing the lock of FIG. 10 ;
FIG. 24 is a perspective of a driving tool being used to operate the coupling of FIG. 1 ;
FIG. 24( a ) is an exploded view of a portion of the lock of FIG. 1 ;
FIGS. 25( a ) to 25 ( c ) are sequential cross sections of the driving tool of FIG. 24 in use;
FIG. 26 is a plan view of the adaptor and tooth of FIG. 1 ;
FIG. 27 is a cross section through line Q-Q marked on FIG. 26 ;
FIG. 28 is a plan view of the adaptor and tooth of FIG. 1 ;
FIG. 29 is a cross section through line Z-Z marked on FIG. 28 ;
FIG. 30 is a plan view of the adaptor and tooth of FIG. 1 ;
FIG. 31 is a cross section through line R-R marked on FIG. 30 ;
FIG. 32 is a cross section through line W-W marked on FIG. 31 ;
FIG. 33 is a cross section through line X-X marked on FIG. 31 ;
FIG. 34 is a perspective of the nose of the adaptor of FIG. 1 , showing bearing areas;
FIG. 35 is a perspective of a bucket lip and lip shroud having a coupling in accordance with the present invention, shown prior to coupling;
FIG. 36 is a perspective of the bucket lip and lip shroud of FIG. 35 shown coupled;
FIG. 37 is a rear perspective of the lip shroud of FIG. 35 ;
FIG. 38 is a rear perspective of the lip shroud of FIG. 35 shown with an exploded view of a lock from within the coupling of FIG. 35 ;
FIG. 39 is a cross section of the bucket lip and shroud of FIG. 35 during coupling; and
FIG. 40 is a cross section of the bucket lip and shroud of FIG. 35 shown coupled.
DETAILED DESCRIPTION
Referring to the Figures, FIG. 1 shows a portion of a lip 10 of an excavator bucket, onto which is located an adaptor 20 . A tooth 70 is shown ready for attachment to the adaptor 20 .
The adaptor 20 has a body part 21 ; a nose 22 extending forwardly of the body part 21 onto which the tooth 70 can be located, and two legs 24 extending rearwardly of the body part 21 about the lip 10 .
The nose 22 can be more clearly seen in FIGS. 3 and 4 . It has a front wall 26 , a top 28 , a first side wall 30 , a bottom 32 , and a second side wall 34 . The top 28 and the bottom 32 each extend from the body part 21 to the front wall 26 . The top 28 and the bottom 32 are not parallel, but are generally angled towards each other such that the nose 22 reduces in height towards the front wall 26 , with the front wall 26 being about half the height of the body part 21 .
The first and second side walls 30 , 34 , each extend from the body portion 21 to the front wall 26 . The first and second side walls 30 , 34 are each stepped in from the body portion 21 , but thereafter are generally parallel towards the front wall 26 . The top 28 , bottom 32 and front wall 26 are thus all generally rectangular, whereas the first and second side walls 30 , 34 are generally trapezoid.
The precise shapes of these surfaces will be discussed further below.
The first side wall 30 and the second side wall 34 each include a recess 40 . The recess 40 has a rear edge 42 , which is generally parallel to the rearmost part of the respective side wall 30 , 34 , and an arcuate front edge 44 , which extends from either end of the rear edge 42 towards the front wall 26 .
The recess 40 is generally tapered, such that it increases in depth towards the front wall 26 . The recess 40 has a base 46 , which is part frusto-conical in shape, the cone axis being located towards the rear edge 42 , and the cone angle being extremely shallow. The base 46 is thus slightly convex, as well as angling inwardly relative to the side wall 30 , 34 . The rear of the base 46 , which is the rear edge 42 , is level with the side wall 30 , 34 . The front of the base 46 , which is located beneath the centre of the front edge 44 , is spaced from the side wall 30 , 34 . An arcuate recess wall 48 extends between the front edge 44 and the base 46 . The recess wall 48 is oriented at about 75° to the side wall 30 , 34 . The height of the recess wall 48 thus tapers from zero at its outer edges, at the ends of the rear edge 42 , to a maximum height at the centre of the front edge 44 .
Each side wall 30 , 34 also includes a locating boss 50 . The boss 50 is located within the recess 40 , and has an outer face 52 . The outer face 52 is generally rectangular with parallel upper and lower edges 54 extending from the rear edge 42 of the recess 40 towards the front wall 26 . The outer face 52 is slightly convex, with the upper and lower edges 54 being parallel to a central axis of the adaptor 20 and being level with the rear edge 42 , and a centre line of the outer face 52 protruding slightly higher.
The outer face 52 has a front edge 55 . The corners between the front edge 55 and the upper and lower edges 54 are radiussed, with a radius of curvature about one-third of the length of the front edge 55 . The boss 50 has a side wall 56 which is generally perpendicular to the outer face 52 , that is, parallel to the front wall 26 , and extends between the outer face 52 and the recess base 46 . The side wall 56 consists of two flat triangular portions beneath the upper and lower edges 54 , a rectangular front portion 58 , and two part-conical joining portions. The front portion 58 is spaced from front-most part of the recess wall 48 .
The tooth 70 has an internal cavity 72 generally complementary in shape to the nose 22 of the adaptor 20 . The tooth 70 has a first side wall 74 which locates over the first side wall 30 of the nose 22 .
A lock-receiving aperture 76 extends through the first side wall 74 between an outside surface of the tooth 70 and the internal cavity 72 . The aperture 76 is generally circular, and arranged to align with the recess 40 when the tooth 70 is located about the adaptor 20 . The lock-receiving aperture 76 is shown in detail in FIGS. 5 to 9 .
The aperture 76 is not perpendicular to the first side wall 74 , but is in fact oriented at an angle of about 10° to 15° toward the rear of the cavity 72 . This can be most clearly seen in FIG. 9 .
The lock-receiving aperture 76 has three parts: a tooth recess 78 extending into the first side wall 74 from the internal cavity 72 ; a lock-locating recess 80 extending into the first side wall 74 from the outside surface of the tooth 70 ; and a ring-receiving portion 82 located between the tooth recess 78 and the lock-locating recess 80 . The tooth recess 78 and the lock-locating recess 80 are both circular, being coaxial and of similar diameter. The ring-receiving portion 82 is substantially circular, and is of smaller diameter than the tooth recess 78 and lock-locating recess 80 . The aperture 76 therefore has a stepped configuration.
The ring-receiving portion 82 has a number of keyed apertures around its periphery, in order to securely receive a toothed ring 84 within. The toothed ring 84 , which may be made of aluminum, has a generally circular internal surface formed by a plurality of retaining teeth 86 . The toothed ring 84 has outer keyed projections sized and shaped to be press fitted into the ring receiving portion 82 of the aperture 76 . When the toothed ring 84 is thus fitted within the aperture 76 , the teeth 86 define the separation between the tooth recess 78 and the lock-locating recess 80 .
The tooth 70 is coupled to the nose 22 of the adaptor 20 by means of a lock 100 . The lock 100 can be seen in FIGS. 10 and 11 .
The lock 100 includes a bearing member 102 , a toothed engaging ring 104 , and an operable member 106 . The lock 100 also includes a grub screw 108 and a plug 110 .
The bearing member 102 has a generally cylindrical body portion 112 sized to locate within the tooth recess 78 of the tooth 70 . The body portion 112 has a first side 114 oriented, in use, towards the outside of the tooth 70 ; and a second side 116 oriented, in use, towards the cavity 72 .
The first side 114 includes a centrally positioned, keyed recess 118 extending into the body portion 112 .
An engaging portion 120 is located on the second side 116 , extending outwardly from the body portion 112 .
The engaging portion 120 has a generally annular outer face 122 , which is angled relative to the sides 114 , 116 of the body portion 112 . The engaging portion 120 thus has an outside wall 124 and an inside wall 125 which extend at an angle of about 75° to 80° from the second side 116 of the body portion 112 , the outside wall 124 and inside wall 125 both extending between the second side 116 of the body portion 112 and the outer face 122 . The height of the outside wall 124 and inside wall 125 vary circumferentially about the outer face 122 .
Although the outer face 122 has been described as generally annular, the annulus is not circular. It includes a substantially straight portion 126 , and then a spiraling portion 127 which gradually increases in radius through about 300°. The height of the outside wall 124 and the inside wall 125 are at a minimum at the corner of the outer face 122 where the spiraling portion 127 is at its greatest radius, as it meets one end of the substantially straight portion 126 . The height of the outside wall gradually increases along the substantially straight portion 126 and then the spiraling portion 127 , reaching a maximum height at a location about 215° around the annulus from the minimum height portion. The height then decreases through the remaining 135° of the spiraling portion 127 . This can be seen through consideration of the sequential cross sections of FIG. 14 .
It will also be observed that the outside wall 124 and inside wall 125 are not the same height, with the outside wall 124 being higher than the inside wall around the spiraling portion 127 and the insider wall being higher than the outside wall along the straight portion 126 .
A screw receiving aperture 128 passes centrally through the body portion 112 , inside the annulus of the engaging portion 120 . The screw receiving aperture 128 is countersunk on the second side 116 of the body portion 112 , again inside the annulus of the engaging portion 120 .
The toothed engaging ring 104 has engaging teeth 130 arranged about its outside, sized to engage with the retaining teeth 86 of the toothed ring 84 . The toothed engaging ring 104 is formed from a resilient material such as rubber.
The toothed engaging ring 104 has a keyed central aperture 132 which corresponds with the keyed recess of the bearing member 102 .
The operable member 106 has a generally cylindrical body portion 134 sized to locate within the lock-locating recess 80 of the tooth 70 . The body portion 134 has a first side 136 oriented, in use, towards the outside of the tooth 70 ; and a second side 138 oriented, in use, towards the cavity 72 .
The first side 136 includes a centrally positioned, square-sided recess 140 extending into the body portion 134 .
A keyed projection 142 is located on the second side 138 , extending outwardly from the body portion 134 . The keyed projection 142 is sized and shaped to engage with both the central aperture 132 of the engaging ring 104 and the keyed recess 118 of the bearing member 102 . The keyed projection 142 includes a centrally located screw receiving aperture 144 .
The plug 110 is square sided, and arranged to be located within the square-sided recess 140 . The plug 110 is formed of a resilient material fixed to a rigid base plate. The base plate includes an internally threaded screw engaging aperture 145 .
The arrangement is such that the engaging ring 104 and the bearing member 102 can be fitted in turn on the keyed projection 142 of the operable member 106 , and these three elements of the lock 100 can be held together by the screw 108 passing through respective receiving apertures 128 , 144 and being screwed into screw engaging aperture 145 . It will be appreciated that the keyed arrangement prevents relative rotation, and the screw 108 clamps the components together to prevent relative axial movement.
The lock 100 can be fitted into the tooth 70 as shown in FIGS. 15 a and 15 b , with the bearing member 102 inserted from the cavity 72 and the operable member 106 inserted from outside the tooth 70 .
Operation of the lock 100 in coupling the tooth 70 to the adaptor nose 22 will now be described.
To prepare the coupling for use, the lock 100 is rotated within the tooth aperture 76 to a position whereby the straight portion 126 of the engaging portion 120 is oriented towards the front of the tooth 70 . This means that the outer face 122 of the engaging portion 120 is generally parallel to the inside of the tooth side wall 74 , as the maximum height region of the engaging portion 120 is located within the portion of the tooth recess 78 which extends furthest inward from the inside wall.
The tooth 70 can now be slid over the adaptor nose 22 , to the position shown in FIGS. 16 to 19 . In this position the highest part of the outer face 122 of the engaging portion 120 locates adjacent a rear part of the outer face 52 of the boss 50 of the adaptor nose 22 . A straight portion of the inside wall 125 of the engaging portion 120 abuts and bears against the front portion 58 of the side wall 56 of the boss 50 .
Rotation of the lock 100 causes movement of the engaging portion 120 relative to the adaptor recess 40 . Due to the increasing radius of the spiraling portion 127 , as the lock 100 is rotated the inside wall 125 of the engaging portion 120 ceases to bear against the boss 50 , but the outside wall 124 of the engaging portion 120 bears against the recess wall 48 . The higher part of the engaging portion 120 moves into the recess 40 , thus increasing the contact bearing area between the outside wall 124 and the recess wall 48 .
Rotation of the lock 100 through 180° is shown in FIGS. 20 to 23 . In this position the lock 100 firmly holds the tooth 70 relative to the adaptor 20 . In particular, the outside wall 124 of the engaging portion 120 is a first face of the lock 100 , bearing against a first bearing surface 150 being the recess wall 48 of the adaptor 20 ; and the outer periphery of the body portion 112 of the bearing member 102 is a second face of the lock 100 , bearing against a second bearing surface 152 being the tooth recess 78 of the tooth 70 .
It will be appreciated that the arrangement is such that the lock tightens against both first and second bearing surfaces 150 , 152 without necessarily requiring 180° rotation.
When removal of the lock 100 is required, the lock 100 can be rotated in the opposite direction. When the inside wall 125 comes into contact with the boss 50 , further rotation acts to push the tooth away from the body part 21 of the adaptor 20 , allowing for easy removal of the tooth 70 .
The lock 100 is maintained in a desired angular position by engagement between the retaining teeth 86 of the toothed ring 84 and the engaging teeth 130 of the engaging ring 104 . When rotation of the lock 100 is required, this may be effected using a square-ended driver 160 as shown in FIGS. 21 and 22 .
The plug 110 is resilient, with an outer cover 111 . Insertion of the square-ended driver 160 into the square-sided recess 140 causes compression of the plug 110 , within the square-sided recess 140 . When the driver 160 is removed, the plug 110 expands to again fill the recess 140 . This sequence can be seen in FIGS. 25( a ) to 25 ( c ).
In addition to the lock 100 , coupling of the tooth 70 to the adaptor 20 is assisted by the complementary shape of the adaptor nose 22 and the tooth cavity 72 .
The top 28 and bottom 32 of the nose 22 each have a contoured surface, and include a first bearing surface 170 and second bearing surface 172 , which are substantially flat, and are separated by concave joining surfaces 174 . The first and second bearing surfaces 170 , 172 are each narrower than the width of the nose 22 , with the first bearing surface 170 being located within an apparent scooped portion 176 of the top 28 and bottom 32 near the front wall 26 .
The tooth cavity 72 is largely complementary in shape to the adaptor nose 22 , with convex surfaces having curvature slightly less than the concave joining surfaces 174 . This ensures small clearances around the curved surfaces, and full contact along the flat bearing surfaces 170 , 172 .
The bearing connection between the adaptor 20 and the tooth 70 is in a centre portion of the adaptor nose 22 . This can be seen in a comparison between a cross section taken through the centre, as in FIG. 27 , and a cross section taken towards the side, as in FIG. 29 .
Although the coupling has been described as between a tooth and adaptor, it will be appreciated that other GET couplings can be locked together in a similar fashion. FIGS. 35 to 40 show a lip shroud 180 being connected to a bucket lip 10 , onto which has been mounted a lock coupling 182 similar to the first side wall 30 of the adaptor nose 22 . A lock 100 identical to that described in relation to the tooth 70 can be used to couple the lip shroud 180 to the lock coupling 182 in an analogous manner.
Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention.
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An anchor for a wear assembly on an excavating bucket is disclosed. The excavator bucket lip has a base having a nose, and the wear assembly includes a wear member having a cavity in which the nose can be received, and an aperture extending between an outside surface of the wear member and the cavity, an internally toothed ring being located within the aperture; and a lock for releasably holding the wear member to the base. The lock includes an operable member and an externally toothed resilient ring, the resilient ring having a central aperture for engagement with the operable member. The operable member and resilient ring are jointly rotatable relative to the cavity and the internally toothed ring between a plurality of rotationally spaced locking positions where the lock secures the wear member to the base with varying tightness, and a release position rotationally spaced from the locking positions. The teeth of the internally toothed ring and the teeth of the resilient ring engage each other in each of the locking positions to reduce the loosening of the lock during use.
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FIELD OF THE INVENTION
This invention relates to safety arrangements for powered tools and implements. The term "powered tools and implements" covers hand-held power tools, for example hedge trimmers, chain saws and angle grinders and the like, as well as implements which are not hand-held but whose operation is controlled by the hands of a user. Such implements include lawn mowers, scarifiers and cultivators.
BACKGROUND OF THE INVENTION
Hedge trimmers, chain saws and angle grinders are usually provided with two handles to enable the user to control the tool more easily. However, the user will sometimes hold and operate the tool with one hand only and thereby expose himself to the risk of injury either to the hand not holding the tool or to another part of his body because he has insufficient control over the tool.
To minimise the risk of injury some tools, for example electrically-powered hedge trimmers are fitted with two series-connected control switches both of which have to be actuated before the tool is energised. In a hedge trimmer, one switch is built into the main handle of the trimmer and is usually in the form of a trigger-operated switch and will be referred to as a primary switch. Another switch to be referred to as a secondary switch is connected in series with the primary switch and is associated with the other handle of the hedge trimmer in such manner that the secondary switch can be operated only when the user grasps the other handle. Thus, the hedge trimmer will be energised only when both switches are operated and this occurs only when the user grasps the main handle with one hand and the secondary handle with his other hand. Removal of either hand from the respective handle will release the appropriate switch and the tool is de-energized.
It is known to place the secondary switch directly in the other handle and to link the switch to a movable part of the handle that is actuated when a user grasps the handle. In another known arrangement, the secondary switch is mounted in the body of the trimmer and a lever associated with the other handle is linked to the secondary switch. When the user grasps the handle, he actuates the lever which, in turn, operates the secondary switch via the linkage.
Mounting the switch directly in the other handle exposes the user to the risk of electrical shock and is therefore undesirable from the point of view of safety.
However, if the switch is mounted in the body of the trimmer, the risk to the user of electrical shock is small but interconnecting linkage between the switch and the lever has to be provided and accommodated and this increases both the cost and the weight of the tool.
Both known arrangements are also inherently unsatisfactory because there is the possibility that the movable parts required to operate the secondary switch may jam with the switch operated, in which case the tool will not be de-energised when the user removes his hand from the other handle. Such movable parts also require return springs which the user has to overcome to actuate the secondary switch and this gives rise to user fatigue.
SUMMARY OF THE INVENTION
According to the present invention there is provided a hand-held power tool or a hand controlled implement having a primary control system by which a user controls operation of the tool or implement and also having a secondary control system of pneumatic form. Operation of both systems must take place before the tool or implement is energised. A tool with primary and secondary handles has an actuator for the primary system on the primary handle and an actuator for the secondary system on the secondary handle. An implement with a single handle has the actuators mounted at different locations on the single handle that are spaced apart by a distance preventing operation thereof by the same hand of a user.
BRIEF DESCRIPTION OF THE DRAWINGS
By way of example only, embodiments of the invention will now be described in greater detail with reference to the accompanying drawings of which:
FIG. 1 is a perspective view of a hedge trimmer embodying the invention,
FIG. 2 is a section on the line 2--2 of FIG. 1 on an enlarged scale,
FIG. 3 is a perspective view of a part of an actuator,
FIG. 4 is a cross-section of a detail taken on the line 4--4 of FIG. 1,
FIG. 5 is an explanatory diagram,
FIG. 6 is a perspective view of a chain saw embodying the invention, and
FIG. 7 is a perspective view of a lawn mower embodying the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a hedge trimmer in perspective view. The trimmer includes a body 1 housing an electric motor and a drive mechanism for cutter members 2, 3 that extend forwardly from the body 1. Extending rearwardly from the body 1 is a main handle 4 with a trigger 5 for operating an electric switch housed within the main handle. A releasable "lock-off" button 6 projects sideways from the handle. Button 6 must be depressed before actuation of the trigger 5.
Fixed to the forward side of the body 1 is a secondary handle 7 of inverted U-shaped form. The vertical limbs of the U are inturned as at 8 to contact the side walls of the body 1. The handle 7 is secured to the body 1 by screws one of which is shown at 9 and which pass through the inturned portions 8 and into the body 1. A forward guard 10 with a horizontal part 11 secured to the underside of the body 1 has a vertical part 12 interposed between the secondary handle 7 and the adjacent end of the cutter members 2, 3.
The cutter members 2, 3 are arranged one above the other, the lower member 3 being fixed in the body 1 while the upper member 2 extends into the body and is connected to a mechanism which converts the rotary motion of the rotor of the electric driving motor to a reciprocatory motion for reciprocating the upper member 2 relatively to the lower member 3. Both members 2, 3 have laterally extending teeth 13 and they operate in the conventional manner to cut hedges, trim bushes and the like. It is, of course, possible to drive both cutter members.
The secondary handle 7 is of channel form over most of its length, the channel accommodating an elongate, flexible-walled air sac 14 closed at one end and joined at the other end to a length of connector tube described in more detail below. The air sac 14 is indicated in FIG. 1 by the dotted line 14 and as can be seen from that Figure the tube is co-extensive with the U-shaped part of the secondary handle 7.
The channel in the handle 7 has inturned lips 15 which retain an actuator member 16 also of generally U-shaped form as can be seen from FIG. 1 and having grooves 17 in its side walls which coact with the lips 15 to retain the actuator member in the channel in handle 7. The outer face 18 of the actuator member is gently rounded as indicated in FIG. 2 to form a head, the body of the actuator being movable into the channel in the handle as will be described below.
The air sac 14 is shown in more detail in FIG. 3 and, as has been described above, the sac is closed at one end as at 19 and connected at the other to a connector tube 20 which is housed in one of the inturned portions 8 of the handle 7.
The end wall 21 (FIG. 4) of the inturned part 8 housing the connector tube 20 is formed with a nozzle 22 over which the end of the connector tube 20 fits as can be seen in FIG. 4. Extending into the bore of the nozzle 22 is a hollow pin 23 that is a force fit in an aperture 24 in the wall 25 of the body 1. The pin 23 extends into the body 1 and is connected to a pneumatically-operated electric switch--the secondary switch--located inside the body 1 via a connecting tube 26.
A typical pneumatically-operated switch is shown in FIG. 5. Clamped between a base plate 27 and an inverted cup-shaped housing 28 is a flexible diaphragm 29 that supports a cup 30 movable within the housing 28 against the action of a helical spring 31. Fixed to the base of the cup 30 is a shorting bar 32 which, with fixed contacts 33, 34 forms the secondary switch referred to above. The contacts 33, 34 are mounted in but insulated from the housing 28.
As can be seen from FIG. 5, the fixed contacts 33, 34 are in series electrical connection with a primary switch 35 actuated by the trigger 5, supply terminals 36, 37, the field winding 38 and the brushes and commutator 39 of the electric motor housed within the body 1.
The input terminals 36, 37 are connected to the conductors of a supply cable 40 that extends from the main handle 4 as can be seen from FIG. 1.
To operate the hedge trimmer, a user grasps the main handle 4 in one hand and the secondary handle 7 in the other. The trigger 5 is actuated so closing switch 35, the "lock-off" button 6 having been depressed to allow the trigger 5 to be actuated. In addition, the actuator member 16 is depressed thereby compressing part at least of the air sac 14 and increasing the air pressure therein to a value such that the diaphragm 29 is flexed upwardly so moving cup 30 upwardly (as seen in FIG. 5) causing the shorting bar 32 to bridge the fixed contacts 33, 34 and thereby complete the energising circuit of the driving motor.
If, during use of the hedge trimmer, the user removes either hand from the tool, the motor will be de-energised because either the primary switch 35 will open or the secondary switch will open.
The air sac 14 and the connecting tubes 20 and 26 are made of an electrically-insulating material, for example a plastics or rubber material and thereby isolate the user from the secondary switch. Only a light spring loading of the diaphragm is required thereby requiring only a little pressure to compress the air sac 14 to operate the secondary switch and in this manner user fatigue is prevented.
Moreover, because the secondary switch is operated pneumatically and the connecting tubes are flexible, the switch can readily be located in a position where it can easily be protected against ingress of moisture. In the present case, the secondary switch is located in the body 1 which is "splash-proofed" or protected against the ingress of moisture.
The pneumatic system is also of the "fail-safe" type because if a leak develops in the air sac or elsewhere in the pneumatic circuit, the secondary switch cannot be operated.
Furthermore, because of the elongate form of the air sac and because it extends round the greater part of the handle, the user will always operate the secondary switch irrespective of the exact point at which he grasps the handle.
FIG. 6 is a perspective view of a chain saw embodying the invention. Except as described below, the chain saw is of conventional form having a housing 41 accommodating an electric driving motor whose output shaft drives, via gearing contained in a gear case 42 joined to the housing 41, a cutter chain 43 supported in conventional manner on a cutter bar 44. Extending rearwardly from the gear case 42 is a main handle 45 with a trigger 46 that actuates a primary switch (not shown) housed in the handle 45.
Projecting from the gear case 42 is a secondary handle 47 in whose upper surface is located an actuator member 48 of similar design to actuator member 16 described above. Member 58 is located in a channel in the handle 47 and the channel also houses an elongate air sac (not shown) joined by a connecting tube (not shown) to a diaphragm-operated switch (not shown) similar to that described above with reference to FIG. 5 and located in the motor housing 41. The diaphragm operated switch is the secondary switch and is series connected with the primary switch actuated by trigger 46.
The operation of the components just described is similar to that of the corresponding components of the hedge trimmer described above. A user must actuate the trigger 46 and the actuator member 48 before the driving motor can be energised. Release of either trigger or actuator member results in de-energisation of the motor.
The actuator member 48 is, as can be seen from FIG. 6, co-extensive with the handle 47 and is, therefore, operated by the user regardless of the precise position of the user's hand on the handle.
FIG. 7 is a perspective view of a lawn mower embodying the invention. The mower shown is of the air cushion supported type but it could be a cylinder mower or a rotary mower.
Housing 49 accommodates the mower driving motor and is mounted upon a cutter cover 50 that accommodates the impeller and cutter bar of the mower, these latter components being driven by the motor.
Extending from the cover 50 is a handle 51 by which a user guides the mower over a grassed surface. Mounted on the handle 51 adjacent a horizontal portion 52 thereto is a housing 53 incorporating an electric switch--the primary switch--that controls the application of electric power to the motor via a connecting cable 54. The primary switch is operated by a lever 55.
Mounted in the horizontal portion 52 is an actuator member 56 similar to member 16 described above. The end of member 56 is spaced from the lever 55 by a distance sufficient to prevent a user operating both the lever 55 and the actuator member 56 by the same hand. If desired, the actuating member 56 may extend for a short distance down the vertical limb of the handle as indicated at 57.
Accommodated beneath the actuator member 56 in a groove in the portion 52 is an elongate resilient air sac similar to sac 14 described above. The air sac is joined by a connector tube located within the handle to a secondary switch located in the housing 53 and in series connection with the primary switch with that housing.
It will be appreciated that a user must employ both hands to operate the lever 55 and the actuator member 57 and that removal of either hand will result in de-energisation of the motor driving the mower. Again, the position of the hand operating the actuator member 57 is not limited to a precise position.
If desired, the safety arrangement according to the invention may be supplemented by a unit for controlling the flow of energy to the motor only if both switches are operated within a particular time, for example within fifteen seconds. The unit may be an electronic circuit incorporating a type 555 timer actuated when either the primary or secondary switch is closed and de-actuated when the secondary or primary switch is closed. Unless de-activated, the time will "time-out" after fifteen seconds and open the motor energising circuit. The unit is energised from the supply terminals and is shown schematically in dotted lines in FIG. 5.
The circuit incorporating the 555 timer is shown as rectangle 58 with inputs from primary switch 35 and the secondary switch and an output controlling the operation of a switch 59.
In operation, a user may actuate the primary switch 35 before he compresses the air sac, or he may carry out both operations substantially simultaneously, or he may compress the air sac before he actuates the primary switch.
In the first and third cases, the timer is actuated when the first component is operated and de-activated when the second component is actuated provided the latter takes place within the fifteen seconds. In the second case, the timer is not activated.
If the timer is de-activated within the fifteen seconds or is not activated, a control signal is sent out at the expiry of the fifteen seconds which results in closure of switch 59 and energisation of the motor.
If both components are not activated within the fifteen seconds, switch 59 remains open.
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A hand-held power tool or a hand controlled implement having a primary control system by which a user controls operation of the tool or implement also has a secondary control system of pneumatic form. Operation of both systems must take place before the tool or implement is energized. A tool with primary and secondary handles has an actuator for the primary system on the primary handle and an actuator for the secondary system on the secondary handle. An implement with a single handle has the actuators mounted at different locations on the single handle that are spaced apart by a distance preventing operation thereof by the same hand of a user.
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REFERENCE TO COPENDING APPLICATION
This is a continuation-in-part application of our copending application U.S. Ser. No. 610,847 filed Sept. 5, 1975, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to an apparatus for forming a desired pattern on a plate-like object with a beam of electrons or ions, and more particularly to such a pattern forming apparatus which is useful in engraving a desired electric circuit pattern on the properly treated major surface of a semiconductor substrate.
In fabricating integrated circuits and other precision semiconductor devices, the photolithography technique has hitherto been used. But disadvantageously, the accuracy with which a desired pattern can be formed on a substrate is limited by the diffraction effect which depends on the wave length of the light used (ultra-violet rays). In this connection, in fabricating highly compact IC's, acoustic wave transducers and other devices having a minute pattern of a sub-micron order, a scanning type electron beam pattern generator such as shown in FIG. 1 is used.
In FIG. 1, a beam of electrons from an electron gun 1 passes through a condenser lens 3 and an objective lens 5 so that it is focused on an object 7 in the form of a minute spot. 4 and 4a are aperture diaphragms to limit the converging angle of the beam. A blanking unit 2 is responsive to blanking signals for the on-off controlling of the beam. A beam-deflector unit 6 is responsive to deflecting signals for causing the beam to scan the object and permits the minute spot of the beam to draw a desired pattern thereon. The pattern can be formed by causing the minute spot 8 of the beam to scan the object in such a way that a selected portion 9 is uniformly exposed as shown in FIG. 2.
In actual practice, the scanning type pattern generator is controlled by an associated electronic computer. Specifically, the pattern generator is responsive to blanking and deflecting signals both supplied from the electronic computer for stopping and shifting the electron beam so as to draw a desired pattern on the object. It is required for obtaining an accurate pattern that the beam control system involve complicated compensations for distortion, astigmatism and the shift of the focus each of which varies with the deflection angle of the beam.
With a view to reducing the adverse effect by the aperture aberration of the objective lens on the precision of the pattern to be formed, the converging angle of the beam must be reduced, but this accordingly decreases the beam current, and the pattern exposure time increases by as much. The exposure time can be decreased if a high-sensitivity electron resist is used. In such case there arises a necessity for providing beam on-off and beam deflection and correction controls having high speed response.
An object of this invention is to provide a pattern forming apparatus which permits the formation of a desired pattern on an object at a high speed and with high accuracy, requiring no complicated control.
SUMMARY OF THE INVENTION
To attain the object described above, the present invention provides an apparatus for forming a rectangular or linear shape pattern on an object with a beam of electrically charged particles, which comprises a source for a beam of electrically charged particles; a diaphragm having a rectangular aperture for forming said beam into a rectangular beam; a quadrupole lens system comprising at least one quadrupole for reducing or increasing the lengths of the four sides of said rectangular beam at a desired ratio; a means for controlling said quadrupole lens system and a means for shifting the resultant beam to fall at a desired position on the object. The apparatus according to the present invention also has such a construction that it is possible to easily include a means for correcting third order aperture aberration of the quadrupole lens into the quadrupole lens system when it is necessary to form a pattern of high accuracy, and therefore it can be applied to devices having a minute pattern of a sub-micron order, such as an LSI.
This invention will be better understood from the following description of preferred embodiments of this invention made with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a scanning type electron beam pattern generator.
FIG. 2 is an explanatory view showing the manner in which a desired pattern is drawn with a scanning type electron beam pattern generator.
FIGS. 3(A) and 3(B) are perspective views of an electrostatic quadrupole lens and a magnetic quadrupole lens respectively.
FIG. 4 is an explanatory view showing the manner in which the cross section of the beam is modified while the beam passes through the quadrupole lens.
FIG. 5 is a sectional view showing the structure of a pattern forming apparatus according to this invention.
FIG. 6 is a schematic illustration showing the trajectory of the electron beam in the X-Z plane (above) and that of the electron beam in the Y-Z plane (below) while passing through the quadrupole lens system.
FIG. 7 is an explanatory view showing the manner in which a desired pattern is formed on a substrate, using a pattern forming apparatus according to this invention.
FIG. 8 is a perspective view showing a lens system which comprises in combination a quadrupole lens and an octopole lens.
FIG. 9 is a perspective view showing a fundamental lens system which comprises a quadrupole lens and a means for correcting third order aperture aberration of the quadrupole lens.
FIG. 10 is a cross sectional view of the lens system of FIG. 9.
FIG. 11 is a diagram showing characteristic functions of the lens system of FIG. 9.
FIG. 12 is a cross sectional view of the lens system of FIG. 8.
FIG. 13 is a diagram showing characteristic functions of the lens system of FIG. 8.
FIG. 14 is a perspective view showing an embodiment of the lens system which comprises quadrupole lenses and a means for correcting third order aperture aberration.
FIG. 15 is a graph showing the results obtained by correcting third order aperture aberration of the lens system of FIG. 9.
FIG. 16 is a perspective view showing another fundamental lens system which comprises a quadrupole lens and a means for correcting third order aperture aberration of the quadrupole lens.
FIG. 7 is a perspective view showing still another embodiment of the lens system which comprises quadrupole lenses and a means for correcting third order aperture aberration.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention takes full advantage of the unique electrooptical nature of the quadrupole lens. Most of the patterns which appear on IC devices are composed of line and rectangle elements, some of these being of the same shape and size. The principle of this invention is to control the shape (cross section) of a beam of electrically charged particles and to project a variety of rectangular cross section beams onto a substrate, thus composing the desired pattern from line and rectangle pattern elements.
FIG. 3(A) shows an electrostatic quadrupole lens 10, and FIG. 3(B) shows a magnetic quadrupole lens 10. When a beam of electrically charged particles travels in the direction of the "Z"-axis, the quadrupole lens functions as a converging (convex) lens in the X-Z plane whereas it functions as a diverging (concave) lens in the Y-Z plane.
Referring to FIG. 4, the cross section of an electron beam 12 is limited by the rectangular aperture 11, and while passing the quadrupole lens 10, the rectangular beam diverges along the "Y"-axis (or vertical direction) and at the same time it converges along the "X"-axis (or horizontal direction).
As a result, the vertical length is increased and the horizontal length is reduced, thus forming a rectangular beam 12' shown at the exit of the quadrupole lens 10. A beam of desired rectangular cross section can be provided by properly controlling the voltage (or current) supplied to the quadrupole lens.
Referring to FIG. 5, there is shown a pattern forming apparatus according to this invention. A beam of electrons 12 from an electron gun 1 are converged by a condenser lens 3 to fall on a rectangular aperture 4. The cross section of the beam is shaped by the rectangular aperture 4, and the resultant rectangular beam passes through a quadrupole lens system 13 and through a beam-deflection unit 6 so that a beam 12' having a desired rectangular cross section falls on a desired position of the substrate 7. The blanking unit 2 is responsive to blanking signals for controlling the exposure time, depending on the size of the rectangular cross section beam. The beam-deflection unit 6 is not necessary if means are provided instead for shifting the object 7 relative to the beam.
FIG. 6 shows the trajectories of the electron beam in the X-Z plane (FIG. 6(A)) and Y-Z plane (FIG. 6(B)) while passing through an electrostatic quadrupole triplet.
In actual practice it is often advantageous to use two or more quadrupole lenses to produce rectangular beams of several micron or smaller in the variety of shapes required to compose the desired pattern.
FIG. 7 shows the manner in which a desired pattern is drawn or formed on an object 7 by a pattern forming apparatus according to this invention. In forming a line pattern element 14 on the object surface, the beam-deflection unit 6 is controlled so that the electron beam is shifted from the origin "O" to a selected point "A", and the rectangular cross section of the electron beam is changed into the desired rectangle by controlling the voltage supplied to the quadrupole lens system 13. In forming a rectangle pattern element 15 on the object surface 7, the electron beam is shifted to a selected point "B", and the quadrupole lens system is properly controlled to give the required size and the shape to the beam. These two similar and subsequent operations permit the formation of an "L"-shaped pattern on the object.
In forming a plurality of identical rectangle pattern elements, it is only necessary to repeatedly shift the beam to different positions as required while the quadrupole lens system remains at the same excitation.
It it is desired to form the same rectangle pattern element at a symmetrical place with respect to the origin "O" (rectangel pattern elements 16 and 17), it is only necessary to reverse the polarity of the deflection signal. Specifically, the rectangle pattern element 18 can be formed by reversing the polarity of the excitation of the quadrupole lens system and by reversing the polarity of the "X"-axis deflection signal against the element 16. Similarly, the element 19 can be formed by reversing the polarities of the quadrupole excitation and of the "X"-axis deflection signal against the element 17.
As mentioned above, a desired pattern can be formed by controlling the quadrupole lens system to give different sizes and shapes to the cross section of the beam for forming corresponding different pattern elements, rectangles and lines on an object; by controlling the beam-deflection unit to cause the beam to fall on a desired position of theobject; and by controlling the beam on-off to supply the amount of exposure requied for forming the pattern element on the object.
In the pattern forming apparatus according to this invention, control of beam on-off and beam deflection is much less complicated than in the conventional pattern generator using a scanning beam and the control can be more easily performed. The volume of control signals required to form the pattern elements with the quadrupole lens system is not small, but the total volume of control signals required for forming a desired pattern is relatively small because the same pattern elements are repeatedly used in forming the desired pattern.
The use of the quadrupole lens system permits the beam to focus in a line of several millimeters in length by 0.5 or less microns in width, and this fine line is useful in forming IC wiring elements. As for the quadrupole lens, differently from the rotationally symmetrical lens conventionally used, the major component of the electric or magnetic field of the quadrupole lens extends transverse to the path of the beam as a strong lesn. Therefore, a quadrupole lens system of large bore diameter can be designed, which makes it possible to reduce the effects of distortion and aperture aberration.
In the quadrupole lens system described above, the resolution at the edge portion of a rectangular or linear pattern element varies in proportion as the size of said pattern element changes. This is because the aperture aberration varies with the change in lens strength of the individual quadrupoles composing said quadrupole lens system.
To permit formation of a pattern of higher accuracy, therefore, it is desirable that such aberration be eliminated as much as possible.
Generally in the quadrupole, desired correction of the third-order aperture aberration which is unattainable in the conventional round lens can be accomplished by combining said quadrupole 10 with an octopole 10' as shown in FIG. 8.
In the quadrupole-octopole lens system, high machining accuracy is required. A slight alignment error in the positional relationship between the quadrupole and the octopole, therefore, not only results in a severe degradation of the aperture aberration correcting characteristic but also brings about mechanical aberration as an extra disadvantage. Thus these adverse effects render the materialization of the quadrupole-octopole lens system extremely difficult. The desired correction of the aperture aberration can easily be accomplished by disposing in front of and/or behind the quadrupole an electrode defining an aperture on the optical axis of the quadrupole as illustrated in FIG. 9 and supplying thereto positive or negative voltage.
FIG. 9 illustrates a basic arrangement which composes an aperture aberration correction lens system. When the aperture electrode 19 defining of an aperture is disposed coaxially with the optical axis of the electrostatic quadrupole 10 and a voltage is supplied thereto, the fringing effect is brought about in the neighborhood of the end surface of the quadrupole 10 and consequently the action of the electrostatic octopole lens is formed. As a consequence, there can be formed an aperture aberration correction lens which combines the quadrupole lens action with the action of the octopole lens which is maintained in automatical alignment with the quadrupole electrode (hereinafter referred to as "self-alignment correction quadrupole lens"). In FIG. 9, 10 denotes an electrostatic quadrupole and 19 an electrode which has an aperture coaxial with the optical axis of said quadrupole 10, namely the portion forming the path of the beam of charged particles. By supplying a certain positive or negative voltage to the aperture electrode 19, there can be formed the self-alignment correction quadrupole lens which incorporates into the quadrupole lens action the octopole lens action exactly aligned with the quadrupole (viz., which enables an octopole field exactly aligned with the quadropole within a quadrupole field).
Now, the relationship between the voltages supplied to the electrodes and the distribution of lens potential which determines the lens characteristic will be described.
FIG. 10 shows the self-alignment correction quadrupole lens of FIG. 9 in a cross section taken in the plane Y-Z.
By Cartesian co-ordinates like those shown in FIG. 10, the potential of an electrostatic lens system possessed of four planes of symmetry is generally expressed as follows.
Φ(X, Y, Z) = [Φ.sub.0 (Z) - 1/4Φ.sub.0 " (Z) (X.sup.2 +Y.sup.2) + 1/64Φ.sub.0 "" (Z) (X.sup.2 +Y.sup.2).sup.2 - . . . ] + [Φ.sub.2 (Z) (X.sup.2 -Y.sup.2) - 1/12Φ.sub.2 " (Z) (X.sup.4 -Y.sup.4) + . . . ] + [Φ.sub.4 (Z) (X.sup.4 -6X.sup.2 Y.sup.2 +Y.sup.4) - . . . ](1)
in the foregoing formula (1), the first term within the brackets, [ ], is a term corresponding to the potential of a unipotential lens component, the second term within the brackets is a term corresponding to the electrostatic quadrupole lens component and the third term within the brackets is a term corresponding to the electrostatic octopole lens component respectively.
Assume that a voltage +φ 2 [V] is supplied to the electrodes (poles) 10a and 10c and a voltage -φ 2 [V] to the electrodes 10b and 10d and a voltage φ 0 [V] is supplied to the aperture electrode, then the values of Φ 0 (Z), Φ 2 (Z) and Φ 4 (Z) of the formula (1) will be expressed as follows.
Φ.sub.0 (Z) = C.sub.0 ·φ.sub.0 k.sub.0 (Z)
Φ.sub.2 (z) = c.sub.2 (φ.sub.2 /a.sup.2)k.sub.2 (Z)
Φ.sub.4 (z) = c.sub.4 (φ.sub.0 /a.sup.4)k.sub.4 (Z)
wherein, a is the aperture radius of the quadrupole lens, k 0 (Z), k 2 (Z) and k 4 (Z) are characteristic functions representing in the normalized form of distribution the respective lens components along the Z axis and C 0 , C 2 and C 4 are constants determining the maximum value of distribution.
The distribution of these characteristic functions and the constants C 0 , C 2 and C 4 are determined by the geometry of the self-alignment correction quadrupole lens in actual use, namely the length of the quadrupole and the thickness of aperture electrode in the direction of Z axis, the radii of their apertures and the distance between the quadrupole and the aperture electrode.
Typical distributions, corresponding to the positions of the electrodes of FIG. 10, of said characteristic functions along the Z axis are shown in FIG. 11. The electrostatic octopole lens action is sufficiently effective, even though the voltage supplied to the aperture electrode 19 of FIG. 9 is less than a few percent of the accelerating voltage of the beam of charged particles. Accordingly, the unipotential lens action represented by the first term in the brackets of said Formula (1) is very weak, so that the lens focussing characteristic depends mainly on the quadrupole lens action represented by the second term in the brackets of said Formula (1).
The distribution of the constant k 4 (Z) corresponding to the electrostatic octopole lens component occurs within the lens field of quadrupole 10 and has its peak near the edge portion of quadrupole 10 as is evident from FIG. 11.
To facilitate comprehension of the specificity of the characteristic function distribution, a cross section taken in the plane Y-Z of the quadrupole-octapole lens of FIG. 8 is shown in FIG. 12 and the distribution of the characteristic functions k 2 (Z) and k 4 (Z) of this lens along Z axis, corresponding to the positions of quadrupole and octopole of FIG. 12, are shown in FIG. 13. FIG. 9 represents a type having one aperture electrode disposed on one side of just one quadrupole. FIG. 14, by contrast, illustrates a preferred embodiment in which aperture electrodes are disposed one each at the extremities of a multi-stage quadrupole 13 and between the two quadrupoles.
In FIG. 14, the aperture electrodes 19a and 19b serve to give the octopole lens action to the neighborhood of each end surface of the quadrupole 13a. In the case of the quadrupoles 13b and 13c, the aperture electrodes 19b and 19c serve to give the octopole lens action to the neighborhood of the end surfaces of said quadrupoles facing their respective aperture electrodes.
Generally, the aperture aberration of image plane in a rotationally symmetrical lens can be defined as satisfying the equation Δr(Z i ) = C A γ 3 in third order approximation (wherein, γ is the semi-aperture angle of the charged particle ray in the image plane). In the case of the quadrupole lens, let α and β be the semi-aperture angles in the Y-Z and X-Z planes respectively, and the third-order aperture aberrations Δy(Z iy ) and Δx(Z ix ) in the respective directions of Y and X axes will be expressed as follows.
Δy(Z.sub.iy) = C.sub.A30 α.sup.3 + C.sub.A12 αβ.sup.2
Δx(Z.sub.ix) = C.sub.A03 β.sup.3 + C.sub.A21 α.sup.2 β(2)
in the quadrupole lens, there are a total of four third-order aperture aberration coefficients (C A30 , C A12 , C A03 and C A21 ). FIG. 15 shows the results of measurement of the correction characteristic of third-order aperture aberration by the self-alignment correction quadrupole lens illustrated in FIG. 16. In the lens used in this particular measurement, the electrode of the quadrupole had a length of 3cm, the aperture electrodes had a thickness of 0.1cm, the aperture radii of the quadrupole and the aperture electrode were 0.52cm and the quadrupole and the aperture electrodes were separated by a distance of 0.6cm.
These results are from the measurement of the aperture aberration due to the aperture aberration coefficient C A03 . The voltage φ 0 [V] supplied to the aperture electrode 19a was changed under the condition of a constant focal length of 3.1cm and a constant accelerating voltage of electron beam of 20KV, while the aperture electrode 19b was fixed at 0[V]. The values of C A03 found in the table inserted in the graph (FIG. 15) are those calculated on the basis of the results of said measurement.
Exp. (1) represents a case in which the aperture electrode 19a was at 0 V and Exp. (6) a case having the aperture electrode 19a at -800 V (4% of the accelerating voltage). Comparison clearly shows that the aberration coefficient which was as much as 3.7cm in the case of Exp. (1) was corrected to 0.25cm.
Further in the case of Exp. (6), the voltage supplied to the quadrupole was 2.5 V less than that in Example (1). This difference represents the extent to which the unipotential lens action indicated in Formula (1) was compensated by the quadrupole lens, showing that the unipotential lens action was very weak.
In the lens system shown in FIG. 16, the aperture aberration coefficients C A03 and C A21 can be corrected by supplying a negative and a positive voltages to the aperture electrodes 19a and 19b.
For sufficiently eliminating the aberration in the lens system as shown in FIG. 14, it is required to supply voltages of 1 - 10% of the accelerating voltage of the beam of electric charged particles to each of three or four aperture electrodes.
The voltage required when the aperture aberration coefficients C A03 and C A21 are corrected simultaneously is higher than that required when only one of the aperture aberration coefficients is corrected.
In the case of an electron beam having an accelerating voltage of 20KV, for example, if a positive voltage of 648.9V is applied to the quadrupole, a negative voltage of 900V to the aperture electrode 19a and a positive voltage of 1,100V to the aperture electrode 19b, then both the aperture aberration coefficients C A03 and C A21 are corrected to 0.05cm. The magnitude of the octopole lens action increases with the decreasing distance between the aperture electrode and the end surface of the quadrupole.
However, said distance is desirably about 0.5 to 2 times the radius of the aperture of the quadrupole in consideration of the machining accuracy of the lens.
The description has so far covered the self-alignment correction quadrupole lens which combines the electrostatic quadrupole with the aperture electrode. From the foregoing description, it is plain that the electrostatic octopole lens action can also be formed near the end surface of a magnetic quadrupole by virtue of the fringing effect when an aperture electrode possessed of an aperture on the optical axis of a magnetic quadrupole is disposed and voltage is supplied thereto. The combination of the magnetic quadrupole and the aperture electrode of the present invention is effective, therefore, as a self-alignment correction quadrupole lens.
FIG. 17 illustrates a preferred embodiment wherein aperture electrodes are disposed one each at both extremities of a two stage magnetic quadrupole lens system (Doublet) 13 and between the two component magnetic quadrupoles, and voltages are supplied to the aperture electrodes 19 respectively whereby the fringing effects are brought about in the neighborhoods of the end surfaces of the magnetic quadrupoles and consequently the actions of the electrostatic octopole lens are formed.
The embodiments mentioned above use a beam of electrons to form a desired pattern on a substrate. The electrostatic quadrupole lens has the same functions for a beam of ions, which are much heavier than electrons, and therefore the apparatus according to this invention is useful in ion implantation. In carrying out a maskless ion implantation process, it is very difficult to provide a very small diameter beam spot because of the space charge effect, and the formation of such a beam spot is not preferred in view of the corresponding loss of beam current. To the contrary, if the maskless ion implantation is carried out according to this invention, the ion implantation is performed in an extensive shape and size determined by the quadrupole lens system, and advantageously the unsymmetrical ion beam ejecting from a mass separator can be used effectively.
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Disclosed is a pattern forming apparatus using a quadrupole lens system to control the cross section of a beam of electrons or ions to be projected onto a plate-like object. A variety of rectangular beams can be formed by electrically controlling the quadrupole lens system, and thus a desired pattern can be produced in the form of combination of rectangle and line pattern elements when the plate-like object is exposed to the beam of electric charged particles. The pattern forming apparatus according to this invention is useful particularly in fabricating integrated circuits, semiconductor devices and other precision devices.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of preparing a crystalline ingot of Hg 1-x .sbsb.o Cd x .sbsb.o Te of a substantially uniform composition by the THM method (Traveling Heater Method) in which:
at the bottom of a substantially cylindrical vertical enclosure is disposed a solidified mixture of Te, Hg Te and Cd Te in proportions corresponding to those of the liquid phase, at said predetermined temperature (T) of said ingot to be prepared,
a cylindrical source ingot of Hg Te and a cylindrical source ingot of Cd Te are disposed in contact with said solidified mixture, the ratio of their respective sections being equal to the desired Hg/Cd ratio of said prepared ingot,
said enclosure is closed, under a vacuum,
the zone of the enclosure corresponding to said solidified mixture is heated so as to melt this latter and to bring it to said predetermined temperature (T), thus obtaining a solvent zone for dissolving the parts of said source ingots in contact with the solvent zone, and
said heated zone is moved along said enclosure so as to move said solvent zone and to progressively dissolve said source ingots at one of the ends thereof and so as to obtain, at its other end, the crystallization of said Hg 1-x .sbsb.o Cd x .sbsb.o Te ingot to be prepared.
The crystalline ingots thus prepared are used for manufacturing infrared radiation detectors or else avalanche diodes. Such devices are obtained by known processes of doping a substrate cut from such an ingot.
2. Description of the Prior Art
A method of the above defined type is already known, described in French Pat. No. 81 05387 in the name of the applicant. This method allows crystalline ingots to be prepared having the shape of a circular cylinder of a diameter of the order of 20 mm. By cutting such a cylinder into slices of appropriate thickness, a large number of disks is obtained. Each of these disks forms a flat wafer from which, considering its relatively large area, a large number of electronic components of the above type may be obtained, whose area is relatively small. The disk is then cut up so that each component is available individually. However, a relatively large amount of these components, having characteristics out of tolerance, must be rejected. This is due to the fact that these components, in order to operate satisfactorily, must be formed on a monocrystalline substrate, that is to say formed of a crystal having, on the macroscopic scale, an orientation and only one, and only having defects if there are any, on the atomic scale. Now, the Hg 1-x .sbsb.o Cd x .sbsb.o Te ingot obtained by the above mentioned method is of a polycrystalline structure, that is to say formed, on the macroscopic scale, of a plurality of monocrystals of different orientations, of maximum dimensions of the order of 10 mm, separated by grain joints and having crystalline defects. The electronic components to be rejected are those which are formed on the parts of the disk comprising the joints and the defects. To avoid such rejects, the consequence of which is harmful in so far as the manufacturing costs are concerned, it would then be necessary to use monocrystalline disks of defined orientation.
A method of manufacturing such a monocrystalline layer of Hg 1-x .sbsb.o Cd x .sbsb.o Te is known by epitaxy in the liquid phase from a monocrystalline substrate of Cd Te, for example. However, the thickness of such a layer is limited to 10 microns or so, and the method, which only allows one layer to be manufactured at a time and requires a new germ each time, is costly.
In order to obtain using the THM method a monocrystalline ingot of appreciable volume, attempts have already been made to use a monocrystalline germ of Cd Te, for example, previously disposed at the bottom of the preparation enclosure. However, it has been discovered in this case that, at the beginning of the process for drawing the ingot, a beginning of the dissolution of the germ by the solvent occurs which disturbs the appearance of the composition balance which normally takes place within the solvent zone. This uncontrolled phenomenon introduces longitudinal variations of the composition of the ingot obtained, in which there still exists a considerable density of crystalline defects, and sometimes grain joints. A zine or selenium doping reduces this crystalline defect density, but the grain joints still exist.
SUMMARY OF THE INVENTION
The present invention aims at overcoming the above drawbacks by providing a method for preparing monocrystalline Hg 1-x .sbsb.o Cd x .sbsb.o Te ingots in which the crystalline defect density is further reduced with respect to the preceding method, the diameter and the volume of the prepared ingots being relatively large, so as to obtain wafers of a large area on which a large number of multielement patterns may be etched which are met with more and more often in present applications. For this, it provides a method of the above defined type wherein
before disposing said solidified mixture at the bottom of said enclosure, a monocrystalline germ of Hg 1-x .sbsb.1 Cd x .sbsb.1 Te is disposed at the bottom of said enclosure such that:
x.sub.o <x.sub.1 ≦1
said germ being provided with a flat and polished face.
and after disposing said solidified mixture in the bottom of said enclosure, in contact with said solidified mixture is disposed a piston of a density less than that of the solvent having a flat base, said enclosure is closed, under a vacuum, without disposing said source ingots inside, the zone of the enclosure is heated corresponding to said solidified mixture so as to bring the solvent obtained to said predetermined temperature, for the time necessary for dissolving the part of said germ which has been work hardened by polishing, then the mixture is cooled at a given rate so as to obtain the crystallization of an adaptation zone, said enclosure is opened and said piston is withdrawn so as to dispose said source ingots in contact with said solidified mixture.
In the method of the invention, the ingot obtained is monocrystalline. This result is obtained for, during a step prior to the step for drawing the ingot, and separate therefrom, a perfect balance of the composition is obtained by heating, without movement of the heated zone, in the solvent zone in the presence of the germ, then by cooling crystallization is obtained of an adaptation zone in which the variation of the parameters of the crystal is continuous. When this step is finished, drawing out is proceded with, during which and in a way known per se the balance is obtained, at the predetermined temperature, of the composition of the solvent zone with the ingot sources, which are dissolved in constant proportions. The Hg 1-x .sbsb.o Cd x .sbsb.o Te ingot which is crystallized at the rear of the solvent zone has a monocrystalline structure initiated by the germ, via the adapatation zone. Furthermore, the adjustment provided by this latter confers on the ingot obtained a longitudinal profile of a composition whose variations are smaller than in the known method.
Advantageously, since said solidified mixture has a flat face, when it is disposed at the bottom of said enclosure, its flat face is disposed against said flat and polished face of said germ.
Again advantageously, and as in the THM method described in the cited patent, said solidified mixture with a flat face is prepared by heating, in said closed enclosure, the solid constituents of said mixture, disposed under said piston, until they are molten, said mixture being removed from said enclosure after solidification.
It is possible to put the method of the invention into practice using a solid germ or a germ obtained by epitaxy on a substrate of a different kind.
In order to obtain several ingots having strictly the same composition, the same germ can be used for preparing these ingots.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood from reading the following description of the preferred embodiment of the method of the invention, with reference to the accompanying drawings in which:
FIG. 1 illustrates schematically a first phase in the preparation of an ingot using the known THM method,
FIG. 2 illustrates schematically a second phase of the method of FIG. 1,
FIG. 3 illustrates the preparation of the solvent zone required in the method of FIG. 1,
FIG. 4 illustrates schematically a first phase of the method of the invention, and
FIG. 5 illustrates schematically a second phase of the method of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The method of the invention for preparing a monocrystalline ingot of Hg 1-x .sbsb.o Cd x .sbsb.o Te uses in particular the known so called THM method (Traveling Heater Method) described in the French Pat. No. 81 05387 in the name of the applicant in connection with the preparation of a polycrystalline ingot of Hg 1-x .sbsb.o Cd x .sbsb.o Te, which method will now be briefly recalled.
In the known method, and as shown in FIG. 1, an annular heating device 4, including a conducting winding, locally surrounds a substantially cylindrical enclosure 1. Enclosure 1, made from a refractory material and hermetically closed, has a vertical axis and contains, in its upper part, a source ingot 2 of Hg Te and a source ingot 3 of Cd Te, these two ingots being cylindrical, having any, but constant, sections S 2 and S 3 and with a vertical axis. Sections S 2 and S 3 are such that:
x.sub.o =S.sub.3 /(S.sub.2 +S.sub.3) (1)
that is to say:
S.sub.2 /S.sub.3 =(1-x.sub.o)/x.sub.o (2)
The lower parts of the source ingots 2 and 3 are dissolved in a solvent zone 5 brought to a temperature T by the annular heating device 4. The enclosure 1 is then caused to move vertically downwards, at a very slow speed, of the order of a few millimeters per day, and for example of 100 microns per hour. As shown in FIG. 2, in the lower part of zone 5 which is cooled after passing through the annular device 4, there occurs a recrystallization which gives rise to a single polycrystalline ingot 6 of Hg 1-x .sbsb.o Cd x .sbsb.o Te. This step is called the ingot drawing step.
In this known method, the temperature T for heating the solvent is between 600° and 700° C. When x o is less than 0.5, a temperature T is preferably chosen close to 650° C. and when it is greater than 0.5, a temperature T is preferably chosen close to 700° C.
In order to obtain a polycrystalline ingot of Hg 1-x .sbsb.o Cd x .sbsb.o Te in which x o is constant over the whole of its length, the above patent provides for the use of a tellurium rich solvent containing Hg Te, Cd Te and Te in proportions determined for example empirically in the following way.
After choosing the temperature T for heating the solvent, a polycrystalline ingot is prepared using pure tellurium as starting solvent for two source ingots of Hg Te and Cd Te, having sections in a ratio corresponding to x o in accordance with the equations (1) and (2). Since pure tellurium is used as starting solvent, the composition of the Hg 1-x Cd x Te ingot is not constant over the whole of its length, the head of the ingot, that is to say the part which was crystallized first after passing through the solvent zone being too rich in cadmium, that is to say that:
x>x.sub.o (3)
However, as the enclosure descends with respect to the fixed heating device, the solvent zone, corresponding at the outset to pure tellurium, then enriched with Cd Te and Hg Te in a ratio equal to that of the sections of the source ingots, will be progressively impoverished in cadmium and enriched in mercury so as to finally arrive at a balance composition, such that the solvent zone, brought to temperature T and fed with Hg Te and Cd Te in a ratio of the sections of the source ingots, related to x o , gives rise to an ingot whose x composition is equal to x o . This composition corresponds to that of the liquid phase, at temperature T, of the ingot of composition x o .
This composition could be determined theoretically taking into account the temperature T and the desired ratio x o , but it is possible to determine it empirically by suddenly cooling the solvent zone after a sufficient drawing time for an ingot zone to be reached where x is equal to x o . Then the solvent zone is subjected to an analysis.
By way of example, for T=700° C. and x o =0.7 we find:
Te=68 molar %
CdTe=2 molar %
HgTe=30 molar %
For T=650° C. and x o =0.2, we find:
Te=32.5 molar %
CdTe=4 molar %
HgTe=63.5 molar %
After this preliminary step for determining the composition of the solvent, this latter is prepared as described in the above mentioned patent, that is to say by placing in the enclosure 1, here with a flat bottom, tellurium Te, mercury telluride Hg Te and cadmium telluride Cd Te, in the form of solid pieces. As shown in FIG. 3, a quartz piston 10 with a flat base is disposed on these products, a vacuum is formed by means of the valve 11, a neutral gas is introduced, under a pressure of 2 to 3 atmospheres, and the products are heated in an oven 12, to a sufficient temperature to cause them to melt.
The piston 10 floats on this molten mixture for its density is less than that of this latter. After 2 to 3 hours, the heating is stopped and the mixture 13 solidifies with a very flat upper face 14 because of the flat base of piston 10.
In the method of preparing polycrystalline ingots described in the above mentioned patent, the enclosure 1 which has served for preparing the solidified mixture 13 is opened, the piston 10 is withdrawn, source ingots are introduced and, after heating of the solidified mixture 13 so as to obtain the solvent 5, an operation is proceeded with for drawing out a polycrystalline ingot of homogeneous composition over the whole of its length, with x=x o .
In the preparation method which will now be described, for preparing a monocrystalline ingot of Hg 1-x .sbsb.o Cd x .sbsb.o Te, where x o is between o and 1, the step for drawing out the ingot is identical to that which has just been described. It is preceded by a preliminary step which will now be described.
This step includes first of all the preparation of a solid monocrystalline germ of Hg 1-x .sbsb.1 Cd x .sbsb.1 Te where x 1 is such that
x.sub.o <x.sub.1 ≦1
By way of example, for x o =0.2, x 1 =0.22 can be chosen.
This germ is obtained either from a monocrystalline block available in a polycrystal or else using the method of the invention, as will be seen further on. As shown in FIG. 4, this germ is machined so as to have the shape of a disk 15, one face 16 of which is polished and oriented with respect to the orientation of the crystal (100 or 111). It is disposed at the bottom of the enclosusre 1 of which it has substantially the shape, and the polished face 16 is directed upwards. Above is disposed a block of solvent 13, prepared as in the known method, so that the flat face 14 of the block is in contact with the flat and polished face 16 of the germ 15. The quartz piston 10 is placed on top and the enclosure 1 is closed under a vacuum. With the enclosure 1 held immobile, the solvent block is heated to the temperature T by means of the heating device 4 for a sufficient time for dissolving the germ over a thickness of a few tens of microns. By way of indication, this time is of the order of an hour for a temperature T of 650°, a cadmium tellurium germ Cd Te and the solvent whose composition was stated above.
The purpose of this operation is to dissolve the zone which was work hardened by polishing the face 16 of germ 15, which presents dislocations and impurities due to the mechanical treatment. After this heating, the first undissolved layer of the monocrystalline germ 15 is a layer having no defect and perfectly clean.
After the preceding heating operation, the heated zone is cooled at a given rate, less than the cooling rate which is that of the solvent zone 5 during the drawing out operation already desribed. There is then crystallization of an adaptation zone, or crystallization interface, in the neighborhood of germ 15. Inside this monocrystalline adaptation zone, there is a continuous variation of the interatom distance that is to say of the mesh parameter, as well as of other parameters of the crystal, such as the temperature, expansion and conduction coefficients for example.
The cooling rate, determined experimentally, influences the formation of this adaptation zone. If it is too fast, crystalline defects appear in the solidified zone, if it is too slow the segregation continues and the adaptation zone disappears to the benefit of an inhomogeneity of the crystal.
After complete cooling of the contents of enclosure 1, the preliminary step is finished and, after opening enclosure 1, piston 10 is withdrawn and source ingots 2 and 3 of Hg Te and Cd Te are disposed as in the known method.
After reclosing the enclosure 1 under a vacuum, the solidified mixture 13 is heated until balance is reached at temperature T of solvent 5 with the source ingots and then the enclosure is moved, as shown in FIG. 5, so as to go ahead with drawing out the ingot 6 as in the known method. Because of the adaptation zone 18, ingot 6 is on the one hand monocrystalline and on the other has a very good radial and longitudinal homogeneity of composition.
It is possible to provide an enclosure of a diameter slightly greater than the diameter of the germ, the connection being provided by a truncated cone shaped part.
Thus a monocrystalline ingot may be obtained of a diameter slightly greater than that of the germ, from which a new germ of a larger diameter may be cut. Thus, proceeding gradually and from a first germ available in the natural state in a polycrystalline ingot, germs and ingots are obtained of a larger and larger diameter. The length of the ingot is only limited by the possibilities of the installation.
By way of example for x o =0.2, the applicant has obtained ingots of 20, 30 and 40 mm in diameter and 60 mm in length, with a dispersion with respect to the value of x o such that x o =0.200∓0.007 on the length and x o =0.2000∓0.0015 on the diameter.
In the preceding description, a solid monocrystalline germ was used. This is not obligatory and a monocrystalline germ may also be used obtained by epitaxy on a substrate of a different nature, such as for example gallium arsenide or sapphire.
If so desired, and in order to obtain a set of ingots of strictly uniform composition, a first ingot may be formed from a certain germ, the base of the first ingot may be cut so as to recover the germ and so on, so as to obtain several ingots prepared from the same germ.
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A method is disclosed for preparing a crystalline ingot of Hg 1-x .sbsb.o Cd x .sbsb.o Te. Before moving a heated solvent zone for progressively dissolving ingot sources and giving rise to a single ingot, an adaptation zone is created from a monocrystalline germ by heating and cooling the solvent in contact with the germ, the ingot obtained is monocrystalline. The method of the invention in particular reduces the manufacturing costs of components such as infrared detectors and avalanche diodes.
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BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a semiconductor device and more particularly to a method for manufacturing a semiconductor device capable of forming a high-performance BiCMOS LSI easily with a high accuracy.
Conventional semiconductor devices each comprise a bipolar transistor (hereinafter referred to simply as "Bip"), an n-channel MOS transistor (simply as "nMOS" hereinafter) and a p-channel MOS transistor (simply as "pMOS" hereinafter), as described, for example, in the Institute of Electronics, Information and Communication Engineers (IEICE) Technical Report, Integrated Circuit Devices (ICD) 87-33, 1987, (see FIG. 1).
Usually, such BiCMOS is formed as follows. First, an n-type buried layer is formed in part of a p-type substrate and subsequently a p-type epitaxial layer is allowed to grow. Then, an N well is formed in the p-type epitaxial layer, and also formed is a thick silicon dioxide film for isolation by selective implantation. Then, a gate electrode is formed, and after the deposition of an insulating film, there are formed source and drain regions of each of nMOS and pMOS by a known method. Subsequently, a base and an emitter of Bip are formed, then contact holes are formed, followed by the formation of interconnection, to complete the BiCMOS LSI shown in FIG. 1.
According to the conventional manufacturing method, as is apparent from the above explanation, first a MOS transistor is formed and thereafter a bipolar transistor is formed. In many cases, moreover, the depth of emitter, xjE(Bip), is about 0.15 μm, while the depth of the source and drain regions of nMOS is about 0.20 μm, and that of the source and drain regions of pMOS is about 0.35 μm, thus there exists the relation of xj(CMOS) > xjE(Bip) wherein xj(CMOS) represents the depth of the source and drain regions of CMOS.
The above prior art involves the problem that if the transistors are made very fine, the characteristics of the MOS transistor are deteriorated so it becomes difficult to realize a BiCMOS LSI of high integration density. Also, there has been the problem that if the transistors are attenuated while retaining the relation of xj(MOS) > xjE(Bip), the characteristics of the bipolar transistor are deteriorated, thus making it impossible to realize a high-performance BiCMOS LSI.
In NIKKEI MICRODEVICES, February 1988, pp. 70-71, there are shown many BiCMOS's, in which there are included, though not many, examples of xj(CMOS) being smaller than xjB(Bip). But the details, including how to manufacture, are not shown therein at all, so it is quite uncertain whether they are practically employable or not.
Reference is also here made to IEEE Transaction on Electron Devices, Vol. 36, No. 5, May 1989, pages 890-896. In this transaction there is described a BiCMOS, in which emitter and base electrodes of Bip are formed using a two-layer polysilicon film; a gate electrode of nMOS is formed using a polysilicon film; and a gate electrode of pMOS is formed using a two-layer film comprising a titanium silicide film and a polysilicon film. If the gate electrode of pMOS formed by the two-layer film comprising a titanium silicide film and a polysilicon film is annealed at a high temperature, the boundary between the two films will be extinguished, so that the titanium silicide comes into direct contact with the gate insulating film. In this case, since the interface characteristics between the silicide and the gate insulating film is poor, such direct contact of the titanium silicide with the gate insulating film will cause leakage current to flow, leading to marked deterioration in the characteristics of pMOS. Therefore, after the formation of the titanium silicide film, it is necessary to avoid a high-temperature annealing and maintain the boundary between the above two films. To this end, in the article referred to above, after annealing at a high temperature (950° C.), a titanium silicide film is formed by deposition to constitute a gate electrode of pMOS, and thereafter source and drain regions of pMOS and nMOS are formed. The emitter thickness in the bipolar transistor formed is 0.05 μm, while the thickness of the source and drain regions of pMOS and nMOS are 0.2 μm and 0.3 μm, respectively. Thus, the source and drain thicknesses are much larger than the emitter thickness.
SUMMARY OF THE INVENTION
It is the object of the present invention to eliminate the above-mentioned drawbacks of the prior art and provide a semiconductor device manufacturing method capable of forming a BiCMOS device of a high integration density easily in a relatively simple process.
In the present invention, in order to achieve the above-mentioned object, source and drain regions of MOS transistors are formed after the formation of an emitter of a bipolar transistor, whereby a BiCMOS having the characteristic of xj(MOS) ≦ xjE(Bip) ≦ 0.15 μm can be formed easily.
Generally, if the impurity diffusion coefficient and diffusion time in silicon are D and t, respectively, the depth of doped region, xj, is expressed as √DX. And if the constant of proportion is D o , absolute temperature is T, Boltzman constant is k and activation energy is E, the diffusion coefficient D is expressed as ##EQU1## That is, assuming that the diffusion time is constant, the lower the heat treatment temperature, the smaller the xj.
With increase in the integration density of semiconductor devices, it is necessary to attenuate both MOS transistor and bipolar transistor. However, if a MOS transistor is attenuated by the prior art, there will occur contact between source, drain regions and a depletion layer, thus causing punch through. Therefore, in proportion to the reduction in planar size of transistors, it is necessary to make xj smaller to thereby prevent the expansion of the depletion layer. To this end, it is absolutely necessary to reduce the heat treatment temperature to thereby prevent the increase of xj.
On the other hand, since the characteristics of a bipolar transistor depend on an impurity distribution in the vertical direction, it is scarcely necessary to make xj so small as xj(MOS). Further, if the heat treatment temperature is reduced, it becomes difficult to control the base width, resulting in variations in the characteristics of bipolar transistors. Consequently, it becomes difficult to form bipolar transistors which are uniform in characteristics.
More particularly, according to the planar technology presently adopted generally, an emitter is formed after the formation of a base, so the base width depends on the difference in depth of the two. However, if the heat treatment temperature is set lower than 850° C., the difference between the diffusion coefficient of boron contained in the base and that of arsenic contained in the emitter becomes larger, resulting in that the base width (vertical spacing between the emitter and the collector) becomes larger and the transistor characteristics are deteriorated. Thus, in the manufacture of bipolar transistors, it is not desirable to set the heat treatment temperature excessively low. In view of this point, in the present invention, an emitter of a bipolar transistor is formed by heat treatment at a temperature of 900° C. or higher and thereafter source and drain regions of MOS transistors are formed by heat treatment at a temperature of 850° C. or lower, whereby the base width ca be controlled with a high accuracy and it is possible to obtain a BiCMOS LSI having high integration density and high performance. Besides, the formation of sufficiently shallow source and drain can be effected. Moreover, by satisfying the relation xj(MOS) ≦ xjE(Bip) ≦ 0.15 μm, it is possible to form both an extremely fine MOS transistor and a high-performance bipolar transistor at a time. Further, with attenuation, it is necessary to thin a gate oxide film of the MOS transistor. The thickness of the gate oxide film is about 25 nm, but in future it will surely become as thin as 10 nm or smaller. In the present invention, a MOS transistor is formed after the formation of a bipolar transistor, whereby the quality of the gate oxide film is improved to a remarkable extent and it is possible to realize a thin film of 10 nm or less and form a BiCMOS LSI having high integration density and high performance.
By forming source and drain regions of the MOS transistors after the formation of an emitter of the bipolar transistor, the heat treatment temperature in the formation of the MOS transistors can be made lower than that in the emitter formation. So it is easy to make xj(MOS) smaller than xjE(Bip), even to a value of 0.13 μm or smaller. Further, by satisfying the relation xj(MOS) ≦ xjE(Bip) ≦ 0.15 μm, both attenuation and the improvement of integration density can be realized while maintaining xjE(Bip) to 0.15 μm or less.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing an example of a sectional structure of a conventional BiCMOS;
FIGS. 2 to 6 are process charts showing an embodiment of the present invention;
FIG. 7 is a graph showing changes in time and temperature of a series of annealing operations performed in the present invention;
FIG. 8 is a sectional view showing an example of a principal portion of a BiCMOS formed according to the present invention;
FIGS. 9(a) and 9(b) are diagrams explanatory of a memory cell used in the BiCMOS formed by the present invention;
FIG. 10 is a diagram for explaining the construction of the said BiCMOS;
FIGS. 11 and 12 are circuit diagrams respectively showing an example of an input circuit and that of an output circuit in an ECL interface of a BiCMOS circuit formed by the present invention;
FIGS. 13-16 and FIGS. 17(a)-17(c) are process charts and partially enlarged views, respectively, showing another embodiment of the present invention; and
FIG. 18 is a partially sectional view showing a further embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1
In this embodiment the present invention was applied to the production of a BiCMOS having the sectional structure illustrated in FIG. 2.
First, as shown in FIG. 3, an n-type buried layer 2 is formed in part of a p-type silicon base 1 by a known ion implantation method, and an epitaxial layer is allowed to grow on the whole surface by a known epitaxial growing method. Next, a silicon dioxide film 6 is formed on the epitaxial layer, and phosphorus is implanted through the silicon dioxide film 6 into the portions where Bip and pMOS are to be formed, while boron is implanted in the portion where nMOS is to be formed, to thereby form N wells 3, 5 and p well 4, respectively. Next, according to a known selective oxidation method using a silicon nitride film as a mask, there is formed a silicon dioxide film 7 for element isolation, as shown in FIG. 4. Thereafter, as shown in FIG. 5, phosphorus is implanted into the portion which is to serve as a collector lead-out portion, followed by heat treatment at 950° C. to form an n-type region 8. Further, boron is implanted into the portion which is to serve as a base region, followed by heat treatment at 900° C. to form a p-type base 9. Next, an opening is formed in part of the silicon dioxide film 6, and an n + -type polycrystalline silicon film 11 which contains a high concentration of impurity is formed therein, followed by heat treatment at 900° C. to form an n + -type emitter 10. Then, as shown in FIG. 6, a gate electrode is formed by an n-type polycrystalline silicon film 12, and a silicon dioxide film 13 is formed thereon. Further, arsenic and boron are implanted in the portions where nMOS and pMOS are to be formed, respectively, followed by heat treatment at 850° C. to form n + -type source, drain 14 and p + -type source, drain 15, respectively. Lastly, as shown in FIG. 2, a silicon dioxide film 16 is formed on the side walls of the gate electrode 12 to complete the BiCMOS LSI illustrated in FIG. 2 which has MOS transistors of a single drain structure. FIG. 7 shows changes of the heat treatment temperature in this embodiment. Since the MOS transistor is formed after the formation of the bipolar transistor, the annealing for forming source and drain of the MOS transistor is performed after the high-temperature annealing for forming the emitter of the bipolar transistor. Thus, the source and drain formation is not followed by the high-temperature annealing and hence it is possible to realize xj(pMOS) = 0.13 μm and xjE(Bip) = 0.15 μm. Actually, the relation xj(MOS) ≦ xjE(Bip) ≦ 0.15 μm was satisfied, and it was also possible to reduce xj(MOS) to 0.12 μm or less.
FIG. 8 shows a sectional structure of a BiCMOS formed according to the present invention and having LDD (lightly doped drain) type MOS transistors. This structure was obtained by forming the BiCMOS shown in FIG. 2 having MOS transistors of a single drain structure and subsequently forming deep portions 17, 19 of source and drain by additional boron ion implantation. In the LDD type MOS transistors, unlike the single drain type MOS transistors, the source and drain have both thin portions 18, 20 and deep portions 17, 19, as shown in FIG. 8. Therefore, the width of the gate electrode 13 can be made small while effectively preventing the drop of threshold voltage and short-circuit between source, drain electrodes (not shown) and the semiconductor substrate. This is extremely effective in improving the integration density. Also in this case, since the MOS transistors are formed after the formation of the bipolar transistor, there was satisfied the relation xj(MOS) ≦ xjE(Bip) ≦ 0.15 μm. The xj(MOS) represents the thickness of the thin portions 18, 20 of the source and drain. Also in the prior art, it is possible to make xj(MOS) smaller than xjE(Bip) by adjusting the acceleration voltage at the time of ion implantation. As previously noted, however, since in the prior art a bipolar transistor is formed after the formation of MOS transistors, there is performed a heat treatment at 900° C. or higher to form an emitter after the formation of source and drain, so it is difficult to form source and drain not larger than 0.20 μm in thickness and is difficult to obtain a high-performance MOS transistor. Besides, xjE(Bip) must be made very large in order to hold the relation xj(MOS) < xjE(Bip). But if xjE(Bip) is larger than 0.15 μm, the direct current and alternating current characteristics of the bipolar transistor will be deteriorated markedly, so it becomes impossible to obtain a high-performance BiCMOS.
In connection with this embodiment, it goes without saying that whether nMOS and pMOS are formed to have LDD structure and single drain structure, respectively, or conversely they are formed to have single drain structure and LDD structure, respectively, the present invention is applicable to both. Further, although the p-type silicon substrate 1 was used in this embodiment, it goes without saying that an n-type silicon substrate 1 is also employable.
Embodiment 2
A second embodiment of the present invention will now be described with reference to FIGS. 9 to 17. In this embodiment, the present invention is applied to the formation of a BiCMOS having a dynamic memory cell (one transistor + one capacitor) which is illustrated in FIG. 9(a). Of course, the present invention is also applicable to the formation of a BiCMOS having a static memory cell which is shown in FIG. 9(b). Further, without being limited to BiCMOS LSI having a read-only memory cell, the present invention is widely applicable to the formation of BiCMOS LSI's each having both MOS transistor and bipolar transistor in a chip. In this embodiment there is illustrated a BiCMOS DRAM in which a memory cell includes nMOS, and a peripheral circuit is composed of pMOS and Bip. But the present invention is also applicable to a BiCMOS including a DRAM memory cell in which a memory cell is composed of plural nMOS's and pMOS's, and a peripheral circuit is composed of plural nMOS's and pMOS's.
Referring first to FIGS. 10 to 12, there is shown an example of a BiCMOS circuit produced according to the present invention. FIG. 10 shows an entire chip construction, FIG. 11 shows an input circuit of an ECL interface, and FIG. 12 shows an output circuit thereof. In FIG. 10, at a voltage dropped lower than the source voltage by a voltage drop circuit L 1 or L 2 , a memory cell using a fine MOS transistor not larger than 0.5 μm in gate length, or a logical circuit such as decoder, is operated. In the input and output circuits there is performed level change between external ECL or TTL signals and intra-chip signals. In this way a high-speed BiCMOS LSI can be constituted at a high integration density while using the same input-output interface as in the prior art. Of course, a CMOS interface is employable as the input-output interface. Where the source voltage is lower than the withstand voltage of the fine MOS, a BiCMOS LSI may be constituted under the omission of the voltage drop circuits L 1 and L 2 shown in FIG. 10.
Now, an example of how to manufacture the above semiconductor device will be described with reference to FIGS. 13 to 16. First, as shown in FIG. 13, an n-type impurity doped region 22 and a p-type impurity doped region 26 are formed in part of a p-type silicon substrate 21, thereafter an epitaxial layer is allowed to grow by a known epitaxial growth method. Then, n-wells 23, 27 and p-well 28 are formed using an ion implantation method and subsequently a thick silicon dioxide film 24 for element isolation is formed by selective oxidation. Thereafter, a silicon dioxide film 25 is formed over the whole surface. Next, as shown in FIG. 14, an n + -type region 29 for collector lead-out is formed by an ion implantation method, followed by formation of a p-type region 30 which serves as a base. Then, gate electrodes are formed in the peripheral pMOS and the memory cell nMOS. First, part of the silicon dioxide film 25 is removed and a gate oxide film 33 is formed by a known thermal oxidation method. The film thickness was set at about 6.5 nm. Thereafter, an n-type polycrystalline silicon film 34 and a silicon dioxide film 35 were formed by deposition, and unnecessary portions of these two films were removed using the photolithography technique and the dry etching technique to form a gate electrode. In this embodiment, the gate length of nMOS and that of pMOS are 0.3 μm and 0.4 μm, respectively. Next, an n-type polycrystalline silicon film 31 was formed by deposition and unnecessary portions were removed by patterning, followed by heat treatment at 900° C. to form an n-type region 32 serving as an emitter of Bip. Then, source and drain regions 38 of the nMOS are formed by a known ion implantation method. Further, a side spacer 36 formed by a silicon dioxide film is provided on the side faces of the gate electrode in each of the nMOS and pMOS. Thereafter, an n-type polycrystalline silicon film 40 is formed by deposition and patterning is performed to provide an n-type region 39. Further, p-type source and drain regions 37 of the pMOS were formed by known ion implantation and heat treatment. By so doing, the xj(MOS) of the nMOS can be made smaller than that of the bipolar xjE(Bip), and further shortening of the MOS transistor channel could be realized.
Next, as shown in FIG. 15, a silicon dioxide film 41 is formed on the whole surface by deposition, then the portion of the silicon dioxide film 41 deposited on the memory cell portion is removed by a known selective etching method, and thereafter an n-type polycrystalline silicon film 42 is formed, followed by heat treatment at 850° C. to form an n-type doped region 46. Next, an insulating film 43 and a metallic interconnection 44 are formed on the n-type polycrystalline silicon film 42 to constitute a capacitor. Although in this embodiment tantalum pentoxide and tungsten are used as the materials of the insulating film 43 and the metallic interconnection 44, respectively, it goes without saying that other materials may be used for them. Next, as shown in FIG. 16, a silicon dioxide film 45 is formed by deposition, followed by formation of contact holes and electrodes to complete a contact hole BiCMOS LSI. FIGS. 17(a), (b) and (c) are enlarged views of (a) Bip portion, (b) memory cell nMOS portion and (c) peripheral pMOS portion, respectively, which are main components of the above BiCMOS LSI. Since the source and drain regions of the MOS transistors were formed after the formation of the Bip emitter, there were obtained the values of xjE(Bip) = 0.12 μm, xj(nMOS) = 0.10 μm and xj(pMOS) = 0.12 μm. Thus, xj(MOS) ≦ xjE(Bip) ≦ 0.15 μm could be realized and the BiCMOS obtained was extremely superior in characteristics. The numeral 50 in FIG. 16 denotes a metallic electrode.
Embodiment 3
A third embodiment of the present invention is illustrated in FIG. 18. In this embodiment, the present invention is applied to a dynamic memory cell in which an electric charge is stored in a capacitor constituted by utilizing a trench formed in a silicon substrate. More specifically, an electric charge is stored in a capacitor composed of the metallic interconnection 44, an insulating film 53 and an n-type polycrystalline silicon 55. In this embodiment, the trench for the capacitor can be used in common to an isolation trench of a bipolar transistor. Consequently, a parasitic capacitor of the bipolar transistor can be reduced and so it is possible to realize a BiCMOS LSI of higher performance.
It goes without saying that in the above embodiments 1 to 3, even if all of the n- and p-type regions are reversed, the present invention is applicable to that case.
In the formation of an LSI according to the present invention, as set forth above, there could be formed at a time without increase in the number of processes a bipolar transistor having an emitter depth of xjE(Bip) = 0.12 μm, an emitter area of 0.5×4.0 μm 2 , a current gain of 100 and a cut-off frequency of 10 GHz, an nMOS having a gate length of 0.3 μm and xj(nMOS) = 0.10 μm, and a pMOS having a gate length of 0.4 μm and xj(pMOS) = 0.12 μm. Further, if a 4 Mbit BiCMOS DRAM is formed using the above transistors, there are attained a memory cell area of 1.28 μm 2 and an access time of 7 ns, and it is possible to obtain a circuit velocity five times as high as the conventional CMOS DRAM. According to the present invention, moreover, it is possible to realize a high-speed memory LSI of high integration density such as, for example, a 64 Mbit BiCMOS DRAM, or a 16 Mbit BiCMOS DRAM, having an access time of not longer than 20 ns. Additionally, the present invention is applicable not only to memory LSI's but also widely to various BiCMOS LSI's, including ordinary logical LSI's and LSI's containing analog circuits.
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Sources and drains of MOS transistors are formed after the formation of an emitter of a bipolar transistor, whereby the sources and drains are made smaller in thickness than the emitter. Since the sources and drains are not subjected to a high-temperature heat treatment conducted in the formation of the emitter, there is no fear of increase in thickness of the sources and drains caused by the diffusion of impurities. There can be formed a BiCMOS having a high integration density and superior characteristics.
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TECHNICAL FIELD
The invention relates to imaging systems and more particularly to a light valve for use in an imaging system.
BACKGROUND
Commonly employed fabrication techniques for displays and polymer based devices or other semiconductor electronic devices involve several imaging steps. A substrate coated with a resist or other sensitive material is exposed to radiation through a photo-tool mask to effect some change. By nature these fabrication processes involve a large number of separate steps, each step commonly having a finite risk of failure, thus reducing the overall process yield and increasing the cost of fabricating the finished article. A specific example is the fabrication of color filters for flat panel displays. Color filter fabrication can be a very expensive process because of the high cost of materials and low process yield. Traditional photolithographic processing involves applying color resist materials to a substrate using various coating techniques such as spin coating, slit and spin and spin-less coating. The material is then exposed via a photo-tool mask followed by a development process.
Direct imaging has been proposed for use in the fabrication of displays and in particular color filters. U.S. Pat. No. 4,965,242 to DeBoer et al. describes a dye transfer process for making a color filter element. A dye receiving element is overlaid with a dye donor element which is then imagewise heated to selectively transfer the dye from the donor to the receiver. The preferred method of imagewise heating is by means of a laser beam. Diode lasers are particularly preferred for their ease of modulation, low cost and small size.
Direct imaging has the potential for replacing a multiplicity of steps associated with traditional photolithographic processes with a single imaging step. A downside of direct imaging is that the laser beam is required to scan over the entire surface of the substrate. This necessitates very fast imagewise scanning of the substrate in order to preserve the advantages of direct imaging over flood exposure. Flood exposure through a photo-tool mask is by nature a very fast imaging process because a small substrate may be exposed at once, or a series of quick step repeat exposures may be used for larger substrates. One way to increase the speed of the direct imaging is to expose the substrate simultaneously with a plurality of laser beams. U.S. Pat. No. 6,146,792 to Blanchet-Fincher et al. describes the production of a durable image on a receiver element, such as a color filter. The laser head suggested in the examples consists of thirty-two 830 nm laser diodes, each having approximately 90 mW of single-mode output.
Imaging heads with even more channels are now commonly available, exemplified by the SQUAREspot® thermal imaging heads manufactured by Creo Inc. of Burnaby, British Columbia, Canada. These imaging heads are available with up to 240 independent imaging channels each channel having upwards of 100 mW of optical output power per channel. Such imaging heads offer imaging of a small 370×470 mm color filter substrate in around 3 minutes for a media sensitivity of 450 mJ/cm 2 .
Further improvement in imaging speed is often frustrated by the trade-off between imaging resolution and speed. Color element edge definition requirements dictate that a small pixel size be used (i.e. high resolution imaging). However, the smaller the pixel, the longer it takes to scan over the substrate to effect the imagewise exposure. The availability of imaging heads with progressively more channels does not entirely address this problem since the required number of channels are difficult to provide in an economical and practical imaging system.
The speed/resolution trade-off, coupled with the industry trends towards processing larger and larger substrates presents a unique challenge for direct imaging systems. Larger substrates are not only of application in producing larger displays but also in improving the economy and yield of smaller display panel fabrication. A large substrate may be processed and later separated into a number of smaller panels. Having more panels per processed substrate reduces the chance that an entire substrate that has been processed will be un-unusable (2 faults on a 4 panel substrate is a 50% yield while the same 2 faults on a 12 panel substrate is an 83% yield). In the display fabrication industry, so-called “sixth generation” flat panel display substrate sizes are around 1500×1800 mm. For the example above having 450 mJ/cm 2 media sensitivity the imaging time with the 240 channel imaging head would be in the region of 45 minutes, which is prohibitively long, particularly when compared to flood exposure, which is only marginally slower for a larger substrate where relatively large areas are imaged in a series of step and repeat exposures.
There remains a need for higher productivity direct imaging techniques used in the fabrication of color filters and other polymer based electronic devices.
SUMMARY OF THE INVENTION
The present invention is described in relation to a light valve specifically adapted for direct imaging of patterns that have some regular form with relatively large features in a pre-determined pattern.
In a first aspect of the present invention a light valve for use in an imaging system has a plurality of individually driven channels. The channels have non-uniform size in accordance with a predetermined regular pattern to be imaged.
In another aspect of the present invention a method for imaging a regular pattern of features with a multi-channel imaging system is provided. The pattern is analyzed to identify the features. A body portion of the feature is imaged with a low resolution channel and an edge of the feature is imaged with at least one high resolution channel.
In yet another aspect of the invention a method of fabricating a light valve for imaging a regular pattern of features with a multi-channel imaging system is provided. The pattern is analyzed to identify the features. A plurality of uniform regularly spaced light valve elements are fabricated on a light valve substrate and groups of elements are connected to form low resolution channels and high resolution channels corresponding to the pattern.
For an understanding of the invention, reference will now be made by way of example to a following detailed description in conjunction by accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In drawings which illustrate by way of example only preferred embodiments of the invention:
FIG. 1 is a perspective view of the optical system of a prior art imaging head;
FIG. 2-A is a plane view of a portion of a prior art color filter configuration;
FIG. 2-B is a plane view of a portion of another prior art color filter configuration;
FIG. 3-A is a schematic view of a light valve shown in relation to a substrate, depicting a step in an imaging method according to the present invention;
FIG. 3-B is a schematic view of a light valve shown in relation to a substrate, depicting another step in an imaging method according to the present invention; and
FIG. 4 is a perspective view of an embodiment of a light valve according to the present invention.
DESCRIPTION
A prior art light valve based imaging head is shown in FIG. 1 . A linear light valve 100 comprising a plurality of deformable mirror elements 101 is fabricated on a silicon substrate 102 . A laser 104 generates an illumination line 106 (shown as a broken line) using an anamorphic beam expander comprising cylindrical lenses 108 and 110 . U.S. Pat. No. 5,517,359 to Gelbart describes a method for forming illumination line 106 . The illumination line 106 is laterally spread across the plurality of elements 101 so that each of the elements 101 is illuminated by a portion of illumination line 106 .
When any particular element, for example element 122 , is un-actuated it forms a flat reflective surface and most of the light 124 reflected from the un-actuated element is blocked by aperture stop 116 . When an element is actuated it forms a curved mirror surface that focuses the light reflected from the actuated element through aperture 114 . A lens 118 images light valve 100 to form an imaging swath 120 comprising a plurality of individually modulated beams or channels 126 (corresponding to individual elements 101 ), which are scanned over the area of the substrate form an image. Further details of the operation of the light valve 100 of FIG. 1 are contained in commonly assigned U.S. Pat. No. 6,147,789 to Gelbart. The light valve may be fabricated to operate over a range of wavelengths from ultra violet, through the visible spectrum, and into the infrared spectrum.
When imaging rigid substrates, as is common in fabricating display panels, the scanner used is usually a flatbed scanner that secures a substrate in a flat orientation. The substrate or the imaging beams, or a combination of both are displaced relative to each other to effect the scan. U.S. patent application Ser. No. 10/440235 to Gelbart discloses an example of a high speed flatbed scanner suitable for display panel imaging. Alternatively, flexible substrates may be secured on either the external or the internal surface of a drum scanner to effect a scan. Even a substrate that is traditionally thought of as rigid, such as glass, may be scanned on a drum scanner provided that the substrate is sufficiently thin and the diameter of the drum is sufficiently large.
In general a light valve such as that shown in FIG. 1 has a separate driver channel for each element 101 . For many types of light valve, the drivers are a limiting factor in how many channels may be accommodated. While a particular light valve may be fabricated with more channels, the practical considerations of accommodating a large number of drivers, usually in close proximity to the light valve, dictates a maximum limit for the number of channels that can be individually driven. Furthermore, removing the heat generated by the switching of the driver circuitry also presents another particularly difficult challenge. Other practical considerations such as the vast number of electrical connections required between the drivers and the light valve elements may be another limiting factor.
Other light valve based imaging heads are well known in the art, employing a variety of techniques to provide a plurality of light beams. Specific examples include PLZT light valves (U.S. Pat. No. 5,517,359), TIR light valves (U.S. Pat. No. 6,169,565) and grating light valves (U.S. Pat. Nos. 5,311,360 and 5,661,592).
Several configurations of color-elements are used in color filters for LCD display panels. Stripe configurations, shown in FIG. 2-A , have alternating columns of red, green and blue color elements and are currently the most common color element configuration. Mosaic configurations, shown in FIG. 2-B , have color elements alternating in both directions and provide improved color mix. Delta configurations (not-shown) have red, green and blue filter elements in a triangular relationship to each other and provide the best color mix. The mosaic and delta configuration color filters are more difficult to fabricate, the mosaic configuration additionally requiring a more complex driving circuit.
FIG. 2-A shows a portion of a stripe configuration color filter 10 . The color filter 10 comprises a plurality of red, green and blue color elements 12 , 14 and 16 formed in alternating columns across a substrate 18 . Color elements 12 , 14 , 16 are outlined by a black matrix layer 20 , which divides the elements and prevents the backlight leaking between elements. The columns are commonly imaged in elongate stripes and then subdivided by the black matrix 20 into individual color-elements 12 , 14 , 16 . The TFT transistor on the associated LCD panel (not shown) is also masked by a portion of the black matrix at area 22 .
FIG. 2-B shows a color filter 24 in the mosaic configuration, the only difference from the stripe configuration filter shown in FIG. 1 being the layout of the color elements, 12 , 14 , 16 , which alternate in color down the columns as well as across the columns.
In an embodiment of the present invention a color filter is fabricated by the direct imaging of a dye donor element placed in close contact with a receiver substrate. The dye is imagewise transferred to the substrate using a multi-channel light valve imaging system. The red, green and blue portions of the filter are imaged in separate steps, each time replacing the dye donor element with the next color dye to be transferred. The light valve has a specially configured channel layout in accordance with the pattern being imaged. More specifically, the light valve, shown in FIG. 3-A at 30 , has low resolution channels 32 and high resolution channels 33 arranged in groups 34 according to the image pattern to be printed. Low resolution channels 32 correspond to the interior portion (distal to the edges) of the stripe being imaged (in this case the red stripes 36 on substrate 18 ). High resolution channels 33 correspond to the edges of the stripes 36 , ensuring that the stripes 36 have good edge definition. In this embodiment, the spacing between each group 34 further corresponds to a predetermined spacing between adjacent stripes 36 , but this is not mandated. Stripes 36 are formed on substrate 18 by scanning the beams produced by the light valve 30 in the main scan direction indicated by arrow 38 . After each scan in direction 38 , the light valve is displaced in the sub-scan direction 39 to start a new main scan in direction 38 thus eventually imaging the entire substrate. It should be understood that while light valve 30 is shown in FIG. 3-A at the same scale as the imaged pattern, the schematic illustration is only intended to show the correspondence between the light valve groups 34 and the pattern being written and not a physical relationship. In practice, as shown in FIG. 1 , the light valve may be imaged onto the substrate by a lens 118 , which may reformat the size and shape of the imaging swath at the plane of the substrate.
The inclusion of high resolution channels 33 allows the width of stripe 36 to be precisely adjusted to suit the media or other conditions that may affect the imaged stripe width on the substrate. In color filter fabrication is it very important to fabricate stripes within a tight width tolerance and hence some measure of adjustment is necessary. The combination of low resolution channels 32 and high resolution channels 33 allows the benefit of imaging with a fixed mask light valve while still providing the flexibility to adjust the resultant pattern within some range.
Similarly, in FIG. 3-B the imaging of the green stripes 40 on substrate 18 is depicted, red stripe 36 having been imaged in a previous step. The imaging start position of light valve 30 has been displaced in direction 39 to align with the intended location of the green stripes 40 . The blue stripes are imaged in a third step (not shown).
The non-uniform light valve configuration significantly reduces the number of drivers required by ganging together connections to low resolution channels 32 , thus enabling low resolution channel 32 to be addressed by a single driver via a single connection. Furthermore, for a given number of drivers, the optionally extended spacing between groups 34 in direction 39 allows a much wider swath to be scanned on each successive scan in direction 38 . The number of high and low resolution channels that can be fabricated on a light valve is limited only by the substrate size and not by a limit on the number of drivers.
A specific embodiment of a light valve according to the present invention is shown in FIG. 4 . The light valve comprises a plurality of silicon nitride ribbon elements 50 formed on a silicon substrate 52 . A plurality of slots are etched into the upper surface 54 of substrate 52 . The substrate material is also etched away under the ribbon elements 50 leaving each ribbon element suspended freely across surface 54 . Each ribbon element 50 has a metallic electrode 56 formed on its upper surface that also serves as a reflective layer. Electrodes 56 are connected to a driver 58 via wire-bonded connections 60 . Substrate 52 has a common electrode formed on its underside that is connected to a system ground shown at 62 . When a voltage is applied to an electrode 56 by driver 58 , an electrostatic force causes the associated ribbon element to deform downwardly towards the base of substrate 52 , essentially forming a curved mirror.
The light valve operates in the same manner as described in relation to FIG. 1 and further detailed in U.S. Pat. No. 6,147,789. On application of a voltage by driver 58 to a high resolution area 33 comprising a group of elements 50 , the connected elements all deform towards the substrate. A light beam incident on the high resolution area 33 is reflected through the aperture thus generating a spatially modulated beam. High resolution area 33 , in this embodiment, comprises four individual ribbon elements 50 . Alternatively, the high resolution area may be made up using any number of individual elements or even a single element.
Similarly a larger number of elements 50 are grouped to form low resolution area 32 , driven by a driver 64 . In contrast, prior art light valves have regular uniformly sized channels. Advantageously, groups of channels 34 may also be spaced apart on substrate 52 , further corresponding to the pattern being imaged. Such non-uniformity is contrary to convention, which to date has concentrated on producing more and more channels of a regular size and spacing.
The present invention, in recognizing the regularity of features in certain imaging patterns, improves the imaging system performance for a given number of channels and drivers. By identifying the presence of regularly spaced low resolution features in the pattern, a specialized light valve may be fabricated with corresponding low resolution channels flanked by high resolution channels. As can be seen in FIG. 4 , the total number of drivers required for such a light valve is significantly reduced. For the simple light valve shown, instead of the 12 drivers that would have been required to drive the channels only 6 drivers are required. In this example 3 drivers are saved for each of the low resolution channels by driving a large number of elements with a single driver. The invention enables a significant reduction in driver real estate, heat generation and connection difficulty.
While the present invention has been described in relation to a specific light valve, it is equally applicable to many other embodiments of multi-channel light valves known in the art. In fabricating the light valve of the present invention, the light valve may be fabricated with elements corresponding in number and location to the pattern. Alternatively, the light valve may be fabricated with a plurality of uniformly spaced elements that are then grouped and connected according to the required pattern. In practice many light valves are initially fabricated without connections, the connection being made in a separate wire-bonding step. The light valve of the present invention may thus be fabricated using a common substrate with fully formed elements. This is followed by a configuration step wherein the elements are connected according to a pattern, or range of similar patterns to be imaged.
While the present invention has been described in relation to display and electronic device fabrication the methods described herein are directly applicable to the imaging of any regular pattern including those used in biomedical imaging for Lab-on-a-chip fabrication.
As will be apparent to those skilled in the art in light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof.
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A light valve for use in an imaging head for imaging a regular pattern with relatively large imaged areas in a pre-determined orientation has low resolution channels and high resolution channels corresponding to the pattern to be imaged.
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BACKGROUND OF THE INVENTION
The present invention relates to a system of equipment for physical exercise.
At present, there are separate devices designed for the exercising of almost every muscle or group of muscles in the human body. Such devices have been specifically designed for the exercising of a given group of muscles and are therefore hardly usable for any other purposes in physical exercise. If an establishment for physical exercise is to be provided with a good variety of equipment, then it is necessary to acquire dozens of these separate devices, requiring large investments and plenty of room.
The object of the invention is to eliminate the drawbacks referred to. A specific object of the invention is to achieve a new system of equipment for physical exercise, allowing the use of modular exercising devices consisting of the same kind of parts as far as possible, simplifying the structural solutions employed in the exercising devices and reducing their space requirement.
SUMMARY OF THE INVENTION
According to the invention, the system of equipment for physical exercise consists of a number of separate frame modules having an essentially rectangular form and provided with suitable coupling elements enabling the modules to be detachably connected to each other when mounted side by side in a vertical position. In addition, these wall-like frame modules of the invention have no separate legs or equivalent supports and are provided with mounting elements permitting the attachment of separate exercising devices without frame structures, said devices only consisting of suitable benches, supports, levers and equivalent elements which, when mounted on and supported by the frame structure, form a usable assembly of equipment for physical exercise.
In a preferred embodiment of the invention, the wall-like frame modules are linked together by means of the coupling elements to form a freestanding ring-type upright assembly consisting of three or more frame modules, depending on the space available and the desired number of devices. This ring-type assembly may preferably have a circular or elliptical form or a form freely selectable according to the space available.
In another embodiment of the invention, the frame modules are connected to each other by means of the coupling elements to form an essentially straight wall, which can be attached to the walls of the room or held upright by means of separate supports. It is also possible to use separate brackets by means of which the frame modules are fastened to the walls either separately or as an assembly of modules coupled together.
The coupling elements provided on the frame modules preferably consist of suitable hinges or links enabling the angle between adjacent wall-like frame modules to be freely selected as required in each case.
In a preferred embodiment of the invention, the rectangular frame module is provided with a counterforce device, e.g. a pack of weight plates movable along guide rails and provided with a power transmission belt, said device being placed within the space delimited by the module walls, so that, using the mounting elements, suitable structures of levers and bars designed to actuate this pack of weights can be attached to the frame module.
A preferred embodiment of the invention comprises frame modules of two different widths but of the same height and depth, so that, when coupled together side by side, they will form an even wall structure. In this case, the wider frame modules, which are provided with weight plates, can be equipped with various exercising devices requiring a counterweight, while the narrower frame modules, which are simpler in construction, can be equipped with various benches and bars which do not require the use of a counterweight. The frame modules, regardless of width, are provided with suitable mounting elements placed at different locations and different heights, and the exercising devices to be attached to them are provided with corresponding fixtures matching the mounting elements, so that each exercising device can be mounted on an appropriate frame module at the required height and in the required position. The mounting elements on the frame modules and the corresponding fixtures on the exercising devices may consist of suitable mounting flanges and holes, and of bolts or other tightening means adapted to them, but it is also possible to use various latches or other quickaction fastening elements enabling the devices to be secured and released without the aid of tools.
Compared to previously known techniques, the invention provides the advantages of significant reductions in the space requirement and costs of physical exercise establishments, because the system of the invention allows the costs per exercising device to be considerably reduced. Moreover, since the frame modules of the invention have a wall-like construction and can be erected independently, the modules can be arranged so as to divide the exercising halls into quite different compartments and areas, thus obviating the need for erecting partitions in large halls while still offering the user more pleasure and privacy in exercising than is possible in large halls where all the equipment and activities are simultaneously exposed to the sight of all those present. A further advantage is that frame modules and execrsing devices can be so combined as to produce an assembly that suits the user's individual needs and resources as well as the space available.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, the invention is described in detail by referring to the appended drawings, in which FIG. 1 presents a general view of a system implemented as provided by the invention, FIG. 2 presents a schematic diagram of a system implemented as provided by the invention, FIGS. 3a, 3b, and 3c, illustrate a frame module structure, in FIGS. 4a and 4b illustrate another frame module structure, FIGS. 5 and 6 illustrate an exercising device designed to be mounted on a frame module, FIGS. 7 and 8 illustrate a mounting bracket designed for use in the system, and FIGS. 9 and 10 present another exercising device designed to be mounted on a frame module.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an embodiment of the system of exercising equipment of the invention, the body of which consists of eight rectangular frame modules 1 linked together so as to form an octagonal ring-like assembly. The embodiment illustrated uses two different types of frame module arranged alternately, so that the system comprises four wide frame modules 8 and four narrow frame modules 9.
The narrower frame module 9 is constructed as depicted in FIGS. 4a and 4b consisting of an enlongated rectangular wall with approximate dimensions of 2 m in height, 30 cm in width and 10 cm in depth. The front surface of this solid wall is provided with mounting elements 3, in this case suitable reinforcements with mounting holes placed at certain locations, permitting different exercising devices 4 to be mounted on the frame module at different heights as required in view of the practical purpose of the device in question. The rear side 10 of the narrower frame module 9 is an essentially straight and even surface. Attached to the rear corners of the module, close to the upper and lower ends of it, are socket-type coupling elements 2, by means of which the frame modules can be linked together by placing them so that the coupling elements of adjacent modules are aligned one on top of the other and inserting a hinge pin or equivalent through the coupling elements.
FIGS. 3a, 3b and 3c present a more detailed view of the wider frame module 8 used in the system. It consists of a skeleton which has the same height and depth as the narrower module but is about twice as wide, and whose side edges are provided with coupling elements 2 corresponding to those of frame module 9. In addition, the module skeleton is provided with various mounting elements 3, such as holes 11 in the front surface and openings and holes 12 of different sizes in the upper and lower end members. Various exercising devices, benches, bars and levers can be installed in these mounting elements 3. In the interior space delimited by the skeleton of the frame module are guides 12 carrying a pile of weight plates 13 constituting a counterforce device 6, which can be connected with a pulling means 14 to exercising devices installed in the mounting elements 3 of the frame module.
Like frame module 9, frame module 8, too, has an essentially straight rear surface 10. Thus, when linked together to form a larger wall, the frame modules form an essentially even surface. As shown in FIG. 1, the front surface of the wider frame module 8 can be provided with suitable boards 15, e.g. transparent plastic boards, hiding most of the counterforce device inside the module and leaving only a narrow gap 16 between them to provide access to the counterforce control means.
FIGS. 5 and 6 illustrate an exercising device 4 which can be mounted on a narrow or a wide frame module 9,8. It consists of a padded bench 17 and padded bolsters 18 for backing the user's thighs. In addition, the device is provided with fixtures 7, i.e. plates provided with holes, enabling the device to be attached to the frame module 9 by means of bolts inserted through the appropriate holes in the mounting elements 3 and the fixtures. If such a bench structure is mounted on the lower part of a wide frame module 8 and a suitable lever or bar connected to the counterweight is mounted on the upper part of the module, the resulting combination allows a person sitting on the bench to exercise by operating the counterweight in a manner known in itself.
FIGS. 9 and 10 illustrate another exercising device 4 designed for use in connection with the frame modules of the invention. In this case, too, the device 4 cannot be used independently, but when attached by means of fixtures 7 to the mounting elements 3 of a narrow frame module 9, it can be used in a known manner for the exercising of the dorsal extensors, with the user's pelvis resting on the cushion 19 and his legs pressed against the padded stopper 20. In the same way, various exercising devices which have no frame of their own and therefore cannot be used independently can be mounted on suitable frame modules of either width to form usable exercising devices.
FIG. 2 shows a diagrammatic top view of a system of exercising equipment similar to that in FIG. 1. This embodiment comprises three wide frame modules 8 and three narrow frame modules 9 linked together alternately to form a hexagonal frame in which each module accommodates a different exercising device.
FIGS. 7 and 8 illustrate an embodiment of the invention which enables the frame modules to be mounted separately on a wall. A frame module can be attached directly to a wall by using a mounting bracket as shown in FIGS. 7 and 8. The bracket consists of a plate 21 provided with two studs 22 with a socket 23 at the end, the studs being placed at a distance between them corresponding to the distance between the coupling elements 2 of the frame module. Thus, by means of the coupling elements 2 and corresponding sockets 23, the frame module can be installed on mounting brackets 5 fastened to the wall. In this way, a given exercising hall space can be utilized very effectively by using only modular structures as provided by the invention and arranging part of the equipment in ring-type assemblies as illustrated by FIGS. 1 and 2 and mounting the rest on the walls.
In the foregoing, the invention has been described in detail by referring to some of its structural solutions. However, its embodiments may vary within the scope of the idea of the invention as defined in the following claims.
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A modular system of equipment for physical exercise includes various devices designed for the exercising of different muscles. The system includes a number of separate frame modules, each having an essentially rectangular form and provided with coupling elements enabling the modules to be linked together, or mounted individually on a wall. In addition, the frame modules are provided with mounting elements enabling separate exercising devices without frame structures to be mounted on and supported by the modules.
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This application is a 35 U.S.C. §371 National Stage Application of PCT/EP2011/068566, filed on Oct. 24, 2011, which claims the benefit of priority to Serial No. DE 10 2010 064 114.6, filed on Dec. 23, 2010 in Germany, the disclosures of which are incorporated herein by reference in their entirety.
BACKGROUND
The disclosure relates to a pump having an outflow channel for discharging fluid out of the pump, the passage area thereof being determined by a throttle.
In the case of pumps, in particular piston pumps with pulsating hydraulic pressure generation, and especially in the case of pumps for use in motor vehicle brake systems, a throttle is often arranged in the outflow channel or discharge channel thereof. The throttle is intended to reduce the effect of pressure pulsations arising in the pump on the downstream hydraulic system and, in particular, to reduce the noise made by the pump. Throttles of this kind with a fixed passage area are known as a low-cost means of noise reduction.
Typical pumps for motor vehicle brake systems comprise a cylinder, in which a piston is movably mounted. As it moves, the piston pumps a fluid in the form of brake fluid into the outflow channel of the pump.
SUMMARY
According to the disclosure, a pump having an outflow channel for discharging fluid out of the pump is provided, the passage area thereof being determined by a throttle. The throttle is designed with a spring element which changes the size of the passage area of the outflow channel.
According to the disclosure, the passage area of the throttle in an outflow channel of a pump is of variable design. By varying or changing the size of the passage area, the throttling effect can be adapted to the operating situation of the pump. The variation in the size of the passage area is provided in a particularly simple way that can be produced at low cost by means of a deflectable spring element. The spring element is subjected to the hydraulic pressure produced by the pump and is pushed back accordingly. As it is pushed back, the spring element simultaneously increases the passage area, reducing the throttling effect. As a result, the throttling effect is reduced at a high delivery rate of the pump, whereas the throttling effect is greater at a low delivery rate.
In the case of known fixed throttle cross sections, in contrast, throttling is excessive at a high delivery rate of the pump and too little at a low delivery rate.
The passage area of the pump is preferably designed with a bypass area that cannot be closed by the spring element. The bypass area forms a passage area or cross-sectional area in the outflow channel, through which flow is always possible. It thereby ensures a minimum outflow from the pump.
The bypass area is preferably formed next to the spring element, along the direction of movement thereof. In this case, the bypass area is preferably designed as a gap, a slit or the like next to the spring element. This gap is not closed and therefore always allows free flow. Moreover, the gap serves to compensate for tolerances in the dimensions of the width of the spring element and the width of the outflow channel. As a result, the mounting of the spring element in the outflow channel is also simpler.
In the pump, the spring element is preferably formed by a leaf spring. The spring element designed in this way is particularly simple to arrange and fixed in position in the outflow channel. Moreover, the leaf spring has only a small installation space requirement.
As an alternative, a diaphragm spring can be chosen as a spring element. A diaphragm spring allows a greater range of variation as regards the size of the passage area when the passage is largely closed and when it is largely open.
The leaf spring is preferably designed and arranged in such a way that it projects in an arc shape into the outflow channel. The fluid flowing through the outflow channel can then flow against the arc shape of the leaf spring in a specifically intended manner, thereby making it possible to keep turbulence formation low. A leaf spring subjected to an incident flow in this way is thus pushed back in a defined manner by the pressure force of the incident flow. In this way, the size of the passage area and hence the throttling effect are varied in a precise manner. It is thus possible to produce a defined flow situation at the spring element, leading to a correspondingly defined throttling behavior of the throttle, which is variable according to the disclosure.
The leaf spring furthermore preferably rests by means of at least one section on a wall of the outflow channel and is of rounded design in this section. The leaf spring designed in this way can be positioned simply by being inserted or placed within the outflow channel. The at least one rounded section reduces the friction of a leaf spring placed against the wall of the outflow channel in this way. Consequently, the bending behavior of the leaf spring is improved when it is forced back and, in the process, deformed by the pressure force of the approaching hydraulic fluid.
At least one offset, by means of which the spring element is positioned in the longitudinal direction of the outflow channel, is preferably formed in the outflow channel. The offset prevents the spring element from shifting along the outflow channel. When designed in this way, the spring element can be positioned in a simple and, at the same time, precise way in the outflow channel.
A pump cap is preferably provided on the pump, acting as a cap element, in particular a disk-shaped cap element, for the cylinder of the pump and having an end face that faces the cylinder. The outflow channel with the spring element arranged therein is formed in the end of the pump cap. An outflow channel formed in this way in the end of a cap element and, in particular, also an offset, formed at the same time in the outflow channel, for the positioning of the spring element can be produced in a particularly simple and low-cost manner. The spring element can simply be inserted or fitted from the side in the outflow channel in the end face. In interaction with another component of the pump, in particular the cylinder, the flow channel formed in this way in the end face can be made to form a closed channel shape or tubular shape.
It is advantageous if the pump is formed along a cylinder axis, and the outflow channel with the spring element arranged therein is oriented radially with respect to the cylinder axis. With the radial flow path of this kind out of the center of the pump toward the outside thereof, a solution which is very space-saving overall and hence optimized in terms of installation space is formed.
The pump described is preferably used in a motor vehicle brake system. The variable throttling effect achieved according to the disclosure is particularly advantageous especially for use in the case of motor vehicle brake systems and the noise reduction that is aimed at there.
BRIEF DESCRIPTION OF THE DRAWINGS
An illustrative embodiment of the solution according to the disclosure is explained in greater detail below with reference to the attached schematic drawings, in which:
FIG. 1 shows a longitudinal section through a pump according to the disclosure, and
FIG. 2 shows the section II-II according to FIG. 1 on an enlarged scale.
DETAILED DESCRIPTION
The figures illustrate a pump 10 , in which a first piston element 12 and a second piston element 13 are mounted in such a way as to be movable in a substantially block-shaped housing 11 . The piston elements 12 and 13 are coupled to one another for the transmission of force, in particular being connected at the ends, and are driven by means of a drive 14 in the form of an eccentric. In this case, the piston element 13 is preloaded toward the drive 14 by a spring 16 in the form of a helical spring. The spring 16 is arranged in a pumping chamber 18 , which is surrounded by a cylinder 19 . Piston element 13 slides in a fluidtight manner in the cylinder 19 .
An inlet 20 is connected fluidically to an inlet opening 28 , which is formed centrally in the piston element 13 in relation to the longitudinal axis of the arrangement. This inlet opening 28 is part of an inlet valve 22 and, as such, interacts with a closure element 24 in order selectively to allow brake fluid to flow into the pumping chamber 18 . The inlet valve 22 is designed as a nonreturn valve, with the closure element being in the form of a ball which is preloaded toward the inlet opening 28 by means of a spring 26 .
There is furthermore a central outlet opening 36 at an end of the cylinder 19 remote from the inlet opening 28 . This outlet opening 36 is part of an outlet valve 30 and interacts with a ball-shaped closure element 32 . The closure element 32 is preloaded toward the outlet opening 36 by means of a spring 34 . The outlet valve 30 is thus likewise designed as a nonreturn valve.
A pump cap 37 is arranged on the end of the cylinder 19 , after the outlet opening 28 in the direction of flow of the outflowing brake fluid (and hence outside the pumping chamber 18 ). The pump cap 37 is mounted on the end of the cylinder 19 and supports the spring 34 . The pump cap 37 furthermore makes available sufficient installation space for an accumulator or damper (not shown), if appropriate.
An outflow channel 38 is formed, in particular milled, radially from the pump cap 37 , at the end facing the cylinder 19 , said outflow channel leading to an outlet 40 in the housing 11 . A spring element 42 in the form of a leaf spring acting as a throttle is arranged in the outflow channel 38 . The leaf spring is shaped in such a way that, in the rest position thereof, it substantially closes the outflow channel 38 and can be deformed by an incident flow of outflowing brake fluid so as then to provide an enlarged passage area in the outflow channel 38 in comparison with the rest position.
Overall, the leaf spring has an arc-shaped cross section (see FIG. 1 ) and is provided in the end regions thereof with respective oppositely bent or rounded sections 46 . In this arrangement, the sections 46 rest against one of the walls of the outflow channel 38 which are formed by the pump cap 37 . The leaf spring is thus bent in a manner similar to a Greek omega (Ω). The bent sections 46 reduce the friction of the leaf spring on the supporting or contact surfaces in the outflow channel 38 .
The width (measured in the circumferential direction of the pump cap 37 ) of the leaf spring is matched to the width of the outflow channel 38 in such a way that a gap 54 remains on both sides of the leaf spring. The gaps 54 thus extend along the direction of movement of the spring element 42 and form a bypass line or a minimum passage area for the outflow channel 38 , ensuring a resistance-free minimum outflow from the pump 10 . The gaps 54 also serve as a means of compensating for tolerances in respect of the width dimensions mentioned.
An offset 44 is furthermore formed as a kind of step in the outflow channel. A section 46 of the spring element 42 rests against this offset 44 , thereby preventing the spring element 42 from being able to shift or slip radially. In particular, this prevents the spring element 42 from being able to shift in the direction of the outlet valve 30 (owing to pressure pulsations in the outflow channel 44 ). Here, the outflow channel 38 is divided from the inside outward into a first radial subsection 48 , a second radial subsection 50 and a third, axial subsection 52 . The offset 44 is formed in subsection 48 , and the spring element 42 is formed in subsection 50 . The transition from subsection 50 to subsection 52 is of L-shaped configuration, thereby ensuring that the spring element 42 is restrained in the direction toward the outlet 40 . Subsection 48 is of slightly longer configuration than the leaf spring, thus allowing the latter sufficient space for the bending movement thereof.
The operation of the variable throttle provided by the spring element 42 is explained below: when there is a pumping operation triggered by the drive 14 , which pushes the coupled piston elements 12 and 13 into the pumping chamber 18 , fluid is forced under pressure into the outflow channel 38 through the outlet valve 30 .
As far as possible, the fluid can flow through the outflow channel 38 through the gaps 54 . Moreover, a backpressure builds up ahead of the spring element 42 , leading to the spring element 42 being moved out of the rest position thereof into a deformed position. In this deformed position, the shape of the spring element 42 is less arched, i.e. it is bent back. It then no longer blocks the outflow channel 38 to a substantial degree but exposes an enlarged passage area in said channel, through which fluid can pass to the outlet 40 .
The spring element 42 is thus deformed as long as a relatively large quantity of fluid is supplied from subsection 48 of the outflow channel 38 . The deformation begins only above a certain pressure value or above a certain force exerted by the fluid on the spring element 42 . The flow cross section through the outflow channel 38 , which was previously largely closed, is increased. The throttle thus regulates the flow of fluid through the outflow channel 38 in accordance with the delivery rate of the pump 10 .
The advantageous aspect of this embodiment is that the spring element 42 can be produced at low cost as a simple bent sheet-metal part by means of stamping. Moreover, only a small amount of space is required for the spring element 42 . In principle, just one outflow channel 38 with an associated variable throttle is necessary. However, it is also possible for a plurality of such outflow channels to be provided, in particular a plurality of outflow channels distributed around the circumference of the pump cap 37 .
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A pump includes an outflow channel configured for discharging fluid out of the pump. The outlet area thereof is formed by a throttle. The throttle includes a spring element configured to change the size of the outlet area of the outflow channel.
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FIELD
[0001] The present invention relates to elevator installations and particularly to the passive generation of electrical energy while such an elevator installation is in operation.
BACKGROUND
[0002] The use of piezoelectric elements has been proposed previously within the field of elevators to generate control signals, which are fed to an elevator controller enabling the controller to regulate operation of the elevator. For example, JP-A-2002068618 and U.S. Pat. No. 6,715,587 both describe the use of piezoelectric elements mounted either between or to one of an elevator car and its associated frame. The piezoelectric elements in these examples are provided as pressure sensors, which generate signals to an elevator controller enabling the controller to determine changes in the load within an elevator car. JP-A-2011213479 similarly describes the use of a pressure sensor which, on this occasion, is inserted at the bottom of a groove of a traction sheave to diagnose wear of the groove.
[0003] EP-A1-1780159 and EP-A2-0636569 describe elevator operating panels, which are generally provided on each landing to enable prospective passengers waiting on the landing to call an elevator. Similar panels may also be mounted within the elevator car to allow boarded passengers to enter their required destination floor. In both the arrangements, piezoelectric elements are used within the operating panels as buttons such that upon exertion of sufficient pressure by a passenger's finger, the elements generate the required signal to the elevator controller and can also illuminate an LED to indicate acceptance of the passenger's call.
[0004] Accordingly, piezoelectric elements have been used as pressure sensors within elevators to generate control signals either for determining the changes in the load within an elevator car or for diagnosing wear of a sheave groove or acting as call signals for transmission to the elevator controller.
[0005] However, since load changes within the elevator car occur rather intermittently, groove wear is gradual, and buttons on the operating panel have a small cross-sectional area and can be operated with relatively little pressure, none of these applications of piezoelectric elements within elevators is sufficient to generate a reliable supply of energy.
SUMMARY
[0006] The present invention has been developed to overcome the above-identified problems related to the described prior art.
[0007] An objective of the present invention is to provide an elevator and method to passively and reliably generate electrical energy while an elevator installation is in operation.
[0008] The elevator installation comprises an elevator car, a tension member for supporting and moving the elevator car and a pulley engaging with the tension member, wherein the pulley comprises a piezoelectric layer positioned such that any force imparted to the pulley during engagement with the tension member compresses the piezoelectric layer and further includes a power storage unit having an input electrically connected to an anode and a cathode of the piezoelectric layer. Thereby electrical energy generated by the piezoelectric layer can be harvested in the power storage unit.
[0009] As the tension member is driven to move the elevator car up and down along an elevator hoistway, it also engages with the rotating pulley. Force imparted to the pulley during this engagement with the tension member compresses the piezoelectric layer, which consequently generates electrical energy. Given, firstly, the relatively high rotational speed of elevator pulleys and, secondly, the substantial compressive force differentials exerted on the pulley during each rotation, a significant and reliable supply of electrical energy can be generated by the piezoelectric layer when the elevator is in operation.
[0010] Preferably, the piezoelectric layer is applied to an outer circumferential surface of the pulley and engages with the tension member. Accordingly, the tension member directly compresses the piezoelectric layer as it travels over the pulley.
[0011] The pulley can further comprise a shaft, which is rotatably supported by a bearing mounted in a support bracket. Consequently, the pulley and shaft rotate in unison and forces are transmitted from the tension member, through the pulley and its shaft and to the support bracket via the bearing.
[0012] In this arrangement, the piezoelectric layer can be provided on an outer circumferential surface of the shaft that is rotatably supported by the bearing. This can be used in addition or as an alternative to the previously described arrangement where the piezoelectric layer is applied to an outer circumferential surface of the pulley and engages with the tension member.
[0013] In another alternative arrangement, the pulley may have an inner circumferential surface and is supported by a bearing on a non-rotating axle. Here again the piezoelectric layer can be applied to the inner circumferential surface to generate electrical energy during rotation.
[0014] Although the power storage unit can be mounted on and thereby is rotated in unison with the pulley, it is envisaged that it would be more beneficial to mount the power storage unit remotely from the pulley. In such a case the anode and the cathode of the piezoelectric layer can be electrically connected to a first and a second conductive ring, respectively. The rings are mounted to either the pulley shaft or to a side face the pulley. Brushes can be used to slidably engage with the rotating conductive rings. Preferably the brushes are spring biased into engagement with the rings. The brushes can then be electrically connected to the input of the power storage unit. Thereby, electrical energy generated by the rotating pulley can be transmitted to the stationary power storage unit.
[0015] Energy generated can be transferred into an electrical energy bank within the power storage unit and can be stored for subsequent use. The electrical energy bank may comprise batteries, capacitors, fuel cells or any other form of DC electrical energy storage.
[0016] Depending on the respective voltage ratings of the piezoelectric layer and the electrical energy bank, it may be necessary to insert a DC to DC converter between the input of the power storage unit and the electrical energy bank.
[0017] Preferably, energy harvested within the power storage unit can be supplied to external electrical loads via one or more outputs. If the external load has the same voltage rating as the energy bank, it can be supplied from a DC output connected directly to the energy bank. Alternatively, the voltage from the energy bank can be bucked, boosted or otherwise transformed by a DC to DC converter to supply external electrical loads having different voltage ratings via a further DC output. Furthermore, a DC to AC inverter can be used to invert the DC power from the energy bank into AC power, which can be supplied to external electrical loads via an AC output.
[0018] The invention further provides a method for providing electrical energy within an elevator installation, wherein a tension member supports and moves an elevator car. The method comprises the steps of incorporating a piezoelectric layer in a pulley, compressing the piezoelectric layer when the tension member engages with the pulley and electrically connecting the piezoelectric layer to a power storage unit.
[0019] Subsequently, the electrical energy harvested can be supplied from the power storage unit to an electrical load.
DESCRIPTION OF THE DRAWINGS
[0020] The invention will be described herein with reference to the following drawings in which:
[0021] FIG. 1 is an exemplary schematic showing a conventional arrangement of components within an elevator installation according to the present invention;
[0022] FIG. 2 is an axial, plan view of a traction sheave arrangement according to an exemplary embodiment suitable for use in the elevator installation of FIG. 1 ;
[0023] FIG. 3 is a cross-sectional view of an exemplary embodiment of the support bracket of FIG. 2 ;
[0024] FIG. 4 is a cross-sectional view of an exemplary embodiment of the traction sheave of FIG. 2 ;
[0025] FIG. 5 is a perspective view of an exemplary embodiment of the traction sheave of FIGS. 2 and 4 ;
[0026] FIG. 6 is a schematic of an exemplary embodiment of a power storage unit in which energy generated by the piezoelectric layer of FIGS. 3 and 4 is harvested;
[0027] FIG. 7 is a cross-sectional view of an exemplary embodiment of one of the underslung, car mounted pulleys of FIG. 1 ; and
[0028] FIG. 8 is an axial, cross-section view showing the engagement the tension member with a pulley according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
[0029] FIG. 1 illustrates an exemplary embodiment of a conventional arrangement of components within an elevator installation 1 . An elevator car 2 and a counterweight 4 are supported on a traction member 6 by means of deflection pulleys 8 . In this example, the tension member 6 has a 2:1 roping ratio whereby it extends from one termination 10 in an elevator hoistway 12 under a deflection pulley 8 mounted to the top of the counterweight 4 , back up the hoistway 12 for engagement with a traction sheave 14 driven by a motor, down to a pair of underslung pulleys 8 mounted underneath the car 2 and finally back up to a further termination point 10 in the hoistway 12 . Naturally, the person skilled in the art will easily recognize that alternative roping arrangements are equally applicable and that the traction sheave 14 and its associated motor can be mounted within the shaft 12 to provide what is conventionally known as a machine-room-less (MRL) installation, as shown, or alternatively can be provided in a separate and dedicated machine room.
[0030] In operation, as the traction sheave 14 is rotated by the motor, it engages with the traction member 6 to vertically move the car 2 and counterweight 4 in opposing directions along guiderails (not shown) within the hoistway 12 .
[0031] FIG. 2 is an axial, plan view of an exemplary embodiment of a traction sheave 14 arrangement suitable for use in the elevator installation 1 of FIG. 1 . The traction sheave 14 has an inner circumferential surface 14 . 2 , which is splined to or otherwise fixed to a shaft 16 for concurrent rotation. The traction sheave shaft 14 can be integral with, or directly or indirectly coupled to the drive shaft of the motor. The shaft 16 is rotatably supported by bearings 18 mounted in support brackets 20 arranged at opposing sides of the traction sheave 14 . The brackets 20 are mounted on a structural beam 22 either in the hoistway 12 or in a machine room.
[0032] FIG. 3 is a cross-sectional view of an exemplary embodiment of the traction sheave of FIG. 2 . The outer circumferential surface 14 . 1 of the traction sheave 14 that engages with the tension member 6 is coated with a piezoelectric layer 30 . In operation, the tensions T 1 and T 2 exerted through the sections of the tension member 6 leading to the counterweight 4 and to the car 2 , respectively, will be transmitted through the piezoelectric layer 30 as distributed contact force over the wrap angle α through which the tension member 6 engages the traction sheave 14 . In the present example the wrap angle is 180°, forming the upper semi-circular segment of the traction sheave 14 . The traction sheave itself will naturally provide a counteracting and distributed normal force over the same wrap angle α. The interaction of the opposing contact and normal forces exerted on the piezoelectric layer 30 will generate electrical energy.
[0033] Accordingly, in operation as the piezoelectric layer 30 rotates, it will have minimal compression while located in the lower semi-circular travel segment of the traction sheave 14 . However, as the tension member enters into engagement with the traction sheave 14 , the compression exerted on the piezoelectric layer 30 progressively increases to a maximum compression in the upper travel region of the traction sheave 14 . Thereafter, the compression exerted on the piezoelectric layer 30 progressively decreases to the minimal compression once again when the tension member 6 disengages with the traction sheave 14 .
[0034] The rated speed of a traction sheave 14 will vary widely depending on application. Typical factors that are taken into consideration include sheave diameter, wrap angle α, rated load, travel height, roping ratio and tension member type. Consequently, the traction sheave 14 may have a rated speed ranging from the tens to the hundreds of revolutions per minute (rpm).
[0035] Given, firstly, the relatively high rotational speed of the traction sheave 14 and, secondly, the substantial compressive force differentials exerted on the piezoelectric layer 30 during each rotation of the traction sheave 14 , a significant and reliable supply of electrical energy can be generated by the piezoelectric layer 30 when the elevator 1 is in operation.
[0036] FIG. 4 is a cross-sectional view of an exemplary embodiment of the support bracket 20 of FIG. 2 and depicts an additional or alternative embodiment for generating electrical energy within an elevator 1 . In this example, a piezoelectric layer 30 is provided on the outer circumferential surface of the shaft 16 that is rotatably supported by bearing 18 mounted in the support brackets 20 . The vertical tensions T 1 and T 2 imparted on the traction sheave 14 by the tension member 6 are ultimately transmitted through the shaft 16 to the portions thereof which are supported on the brackets 20 and manifests as a downward contact force F. Each of the brackets 20 will exert a counteracting normal force through the bearing 18 . The interaction of the opposing contact and normal forces exerted on the piezoelectric layer 30 will generate electrical energy.
[0037] During operation of the elevator, the piezoelectric layer 30 will have minimal compression while located in the upper semi-circular segment of rotation. However, as the piezoelectric layer 30 travels through the lower semi-circular segment of rotation, its compression will increase progressively to a maximum compression and progressively decrease to the minimal compression once again.
[0038] As with the traction sheave 14 of FIG. 3 , the piezoelectric layer 30 mounted on the shaft 16 will experience a relatively high rotational speed and substantial compressive force differentials during rotation. Thereby, a significant and reliable supply of electrical energy can be generated by the when the elevator 1 is in operation.
[0039] FIG. 5 is a perspective view of an exemplary embodiment of the traction sheave of FIGS. 2 and 3 and provides an example of how the electrical energy generated by the piezoelectric layer 30 can be harvested. Anode(s) 32 and cathode(s) 34 of the piezoelectric layer 30 are connected by insulated wire 36 to a first and a second conductive ring 38 , respectively. The rings 38 are mounted over but insulated from the shaft 16 . Carbon brushes 40 , mounted to a stationary frame (not shown), are biased by compression springs 42 into engagement with the exposed surfaces of the conductive rings 38 . Power is drawn from the conductive rings 38 , through the carbon brushes 40 , through power cables 44 connected to the brushes 40 and supplied onto a power storage unit PSU, as shown in FIG. 2 . It will be appreciated that the same technique can be used to transmit the energy generated in the arrangement of FIG. 4 .
[0040] The DC voltages supplied along cables 44 are used as an input DC in to the power storage unit PSU, as shown in FIG. 6 . Within the power storage unit PSU, the electrical energy from the input DC in can be feed through a DC to DC converter 46 and is ultimately stored in an energy bank 48 , which in this instance comprises a plurality of rechargeable batteries 50 . Naturally, other forms of DC electrical energy storage such as capacitors, fuel cells etc. are equally feasible.
[0041] Power harvested in the DC energy bank 48 can be fed directly to a first DC output DC out 1 and supplied further to electrical loads operating with the same voltage rating as the energy bank 48 . Alternatively, the voltage from the energy bank 48 can be bucked, boosted or otherwise transformed by a further DC to DC converter 46 to supply external electrical loads having different voltage ratings via a second DC output DC out 2 . Furthermore, a DC to AC inverter 52 can be used to invert the DC power from the energy bank 48 into AC power, which is supplied to external electrical loads via an AC output AC out .
[0042] Although the above description relates to the generation of electrical energy from a traction sheave 14 and its associated shaft 16 , it will be appreciated that the same principles can be applied to any pulley used within the elevator installation 1 that engages with the tension member 6 .
[0043] For example, FIG. 7 is a cross-sectional view of an exemplary embodiment of one of the underslung, car mounted pulleys 8 of FIG. 1 . As with the traction sheave 14 from the preceding embodiments, an outer circumferential surface 8 . 1 of the deflection pulley 8 that engages with the tension member 6 is coated with a piezoelectric layer 30 . However, contrary to the earlier embodiments, the pulley 8 is not fixed to a shaft for concurrent rotation but instead is rotatably mounted via bearing 18 on a non-rotating axle 54 which in turn is mounted to the elevator car 2 . A further piezoelectric layer 30 is applied to the inner circumferential surface 8 . 2 of the deflection pulley 8 .
[0044] The distributed contact force imparted to the deflection pulley 8 as it engages with the tension member 6 over the wrap angle α and the counteracting normal force exerted by the non-rotating axle 54 through the bearing 18 will substantially compress both piezoelectric layers 30 and thereby generate electrical energy.
[0045] Although the wrap angle α at 90° is considerably smaller than in the previous examples and the force exerted by the tension member 6 on the pulley 8 is also smaller, the deflection pulley 8 generally has a much smaller diameter and therefore its rotational speed is considerably greater than that of the traction sheave 14 . Accordingly, a significant and reliable supply of electrical energy can still be generated by the piezoelectric layer 30 when the elevator 1 is in operation.
[0046] Preferably, using the same principle as described with reference to FIG. 5 , the power generated by the piezoelectric layer 30 is transmitted to conductive rings, this time provided on a side face of the pulley 8 , through carbon brushes and onto a power storage unit PSU mounted to the elevator car 2 . Accordingly the power harvested within the power storage unit PSU can be supplied to electrical loads within the car 2 such as lighting, ventilation, operating panels etc.
[0047] FIG. 8 is an axial, cross-section view showing the engagement the tension member 6 with a pulley according to an exemplary embodiment of the present invention. The form of the pulley can be applied to either a traction sheave 14 in accordance with FIGS. 1-5 or to a deflection pulley 8 in accordance with FIGS. 1 and 7 . The tension member 6 is in the form a ribbed belt and the outer circumferential surface of the pulley 14 or 8 has corresponding grooves. The piezoelectric layer 30 is provided between the grooves of the pulley 14 or 8 and the tension member 6 . The anode 32 and cathode 34 of the piezoelectric layer 30 are extended to one side of the layer 30 and can be subsequently connected electrically as outlined above with reference to FIG. 5 .
[0048] Having illustrated and described the principles of the disclosed technologies, it will be apparent to those skilled in the art that the disclosed embodiments can be modified in arrangement and detail without departing from such principles. In view of the many possible embodiments to which the principles of the disclosed technologies can be applied, it should be recognized that the illustrated embodiments are only examples of the technologies and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims and their equivalents.
[0049] In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.
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An elevator installation and method to passively and reliably generate electrical energy while the elevator installation is in operation utilizes piezoelectric layers. The elevator installation includes an elevator car, a tension member for supporting and moving the elevator car, and a pulley engaging with the tension member wherein the pulley has a piezoelectric layer positioned such that any force imparted to the pulley during engagement with the tension member compresses the piezoelectric layer. As the tension member is driven to move the elevator car up and down along an elevator hoistway it also engages with the rotating pulley. Force imparted to the pulley during this engagement with the tension member compresses the piezoelectric layer which consequently generates electrical energy.
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BACKGROUND OF THE INVENTION AND PRIOR ART
This invention relates generally to sanitary valves and particularly to precision flow control valves adapted for use with fluids that are extremely sensitive to environmental exposure.
The advances of technology, especially in the area of the biological sciences such as those concerned with producing genetically altered bacteria and the like, has given rise to a need for valves that are capable of precision flow control under highly sterile conditions. In addition, the valves must be rugged, reliable, minimize the possibility of build-up of flow deposits therein and permit thorough cleaning without dismantling. Such stringent requirements gave rise to the valve constructions of the invention.
The requirements of cleanability and minimum build-up of deposits are satisfied by the straight-through cylindrical valve chamber. The valve element, which is cylindrical and has a hemispherical tip, is supported in a cylindrical supporting means that intersects the valve chamber in a right angle. This permits a continuous seal to be maintained between the valve element and its support at all times, even during cleaning. This continuous seal condition obtains both the rotary configuration and the slidable configuration of the valve of the invention. The flanges that terminate the cylindrical valve chamber permit intimate mating with a pipeline and avoid non-smooth threaded surfaces, contributing to valve flow characteristics and minimizing the build-up of deposits.
U.S. Pat. No. 2,420,849, issued May 20, 1947, describes a valve that is transversely actuated and includes a generally T-shaped resilient sealing element for closing off the walls of the valve chamber when the barrier (valve plug) is moved to its closed position. That construction is not a straight-through valve chamber design, has threaded port openings and has a split valve body in which the seal between the valve plug and the valve chamber is broken during actuation of the valve.
U.S. Pat. No. 3,536,296, issued Oct. 27, 1970, discloses a precision flow valve that includes a spherical plug element with a tapered groove extending substantially completely around the ball. The valve chamber is not a straight-through design and presents many obstructions that would pose significant problems in cleaning.
The valve construction of the invention permits the pipeline to be drained completely for in-place sterilization. It is also simple in construction, easy to operate, and lends itself to either rotary or sliding actuation.
OBJECTS OF THE INVENTION
A principal object of the invention is to provide a novel sanitary valve.
Another object of the invention is to provide a sanitary valve that is easily cleaned and safe from environmental contamination.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects of the invention will be apparent upon reading the following description in conjunction with the drawings in which:
FIG. 1 is a partially sectioned view of a rotary sanitary valve constructed in accordance with the invention;
FIG. 2 is a cross section of the portion of the valve of FIG. 1 taken along line 2--2;
FIG. 3 is a plan view of the portion of the valve shown in FIG. 2;
FIG. 4 is a partially sectioned view of a slidable sanitary valve constructed in accordance with another aspect of the invention;
FIG. 5 is a section of FIG. 4 taken along the line 5--5;
FIG. 6 is a similar section with the valve element in the open position;
FIGS. 7 and 8 illustrate different constructions of the valve element; and
FIG. 9 is a partial cross section illustrating a preferred installation position for the valve of FIG 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Throughout the description, like reference characters are used to indicate like elements and primed reference characters to illustrate parts that are similar, but not identical, to their unprimed counterparts. Referring to FIGS. 1-3, reference numeral 10 illustrates a rotary type sanitary valve of the invention. By rotary type is meant that valve 10 has a valve element that controls flow in the valve chamber as a function of its rotation. Valve 10 includes a valve body 11 that is fabricated as a unitary structure with an actuator mount 28 that intersects valve body 11 in a right angle. Actuator mount 28 is also sometimes referred to herein as supporting means for the valve element. A pair of flanges 12 are formed at opposite ends of valve body 11 for enabling connection of the valve into a pipeline (not shown) by any suitable, well-known means. A valve chamber 14 is formed in valve body 11 and comprises a highly finished, cylindrical passageway. Actuator mount 28 similarly defines a cylindrical cavity 25 that supports a valve element 16 for rotational movement. Valve element 16 is cylindrical and includes a hemispherical tip 18 and a pair of cutout portions 20 that permit a variable passageway to be formed in valve chamber 14 to permit flow therein to be controlled as a function of valve element rotation. Valve element 16 supports a U-shaped seal member 22 that extends over tip 18 and a circular seal member 24 that extends around the circumference of valve element 16. Seal member 22 forms a seal with the inner periphery of chamber 14 when valve element 16 is in its closed position. Circular seal member 24 is connected to, or integrally formed with, seal member 22 and forms a continuous seal with the surface of cylindrical cavity 25 of stem 28 for all conditions of valve operation. This is important to prevent the possibility of environmental contamination of valve chamber 14.
Valve element 16 is attached to, or integrally formed with, a cylindrical stem 26 that is formed into a drive end 32, of square cross section, with the transition between square drive end 32 and cylindrical stem 26 occurring at a beveled surface 33. An actuator drive 36, of mating square cross section, extends from actuator 13 and is coupled in driving engagement with the drive end 32 by means of a collar 34 that has a square hole, of appropriate dimension, formed therethrough.
A bearing 30 is suitably journaled to permit rotation of cylindrical stem 26 and may be secured in actuator mount 28 by any suitable means. Actuator mount 28 extends into a flange 35 which is designed to mate with a flange 29, coupled to actuator 13. An antirotation disk 38 is positioned between flanges 28 and 29 and includes a pair of flat sections 39 that engage with similarly shaped flattened areas on the outer surface of bearing 30 to prevent bearing 30 from rotating. It will be appreciated that the particular arrangement for preventing rotation of bearing 30 is a matter of choice and the invention is not to be limited to the construction shown. An inspection vent 31 is provided to permit verification of the integrity of the seal formed by seal member 24.
In operation, actuator 13 is energized by means (not shown) to move actuator drive 36 in a clockwise or counter clockwise direction which, by means of collar 34, imparts a similar rotation to valve element 16 by means of stem 26. With valve element 16 in its closed position, the seal member 22 prevents flow in valve chamber 14. In response to rotation of actuator drive 36, cutout portions 20 in valve member 16 form a passageway in valve chamber 14 for flow. Seal member 22 is disengaged from the inner periphery of valve chamber 14. It will be noted, however, that the seal formed by seal member 24 and the inner surface of cavity 25 in stem mount 28 is never broken. This is of critical importance to the suitability of the valve operation for this service application. As mentioned, it is important to preclude environmental contamination of the valve chamber and throughout valve operation seal member 24 maintains a continuous seal with actuator mount 28.
Referring to FIGS. 4, 5 and 6, a sliding stem movement version of the valve is shown. Valve 10' includes a similar valve body 11' having flanges 12 and defining a cylindrical valve chamber 14 with an actuator mount 28' perpendicularly disposed to valve body 11'. Valve element 16' differs in that it does not include any cutout portions. Actuator mount 28' defines a polished inner cylindrical surface 40 within which valve element 16 is slidably movable. A stem 26' of generally cylindrical configuration extends into an actuator 13' which functions in response to means (not shown) to slide valve element 16' into and out of valve chamber 14 to control flow therein. As best illustrated in FIG. 6, when the valve is fully opened, valve element 16' is positioned high in actuator mount 28' and completely out of valve chamber 14. At no time does circular seal member 24 break its sealing contact with the polished cylindrical surface 40 in actuator mount 28'. Thus valve chamber 14 is never exposed to the outside environment.
In FIGS. 7 and 8, two different forms of construction of the valve element are shown. FIG. 7 shows an undercut or grooved configuration for valve element 16' with a horizontal circumferential groove 24' and a vertical U-shaped groove 22' formed therein. It will be appreciated that these grooves are configured such that appropriately shaped circular and U-shaped seal members 24 and 22 may be positioned and maintained therein. In practice, the seal material is molded in one piece and, due to its resilient nature, may be slightly distended and slipped into position in grooves 22' and 24'.
The configuration in FIG. 8 illustrates a valve element 16" that may be coated overall with a somewhat resilient material but have raised sections to form circumferential seal element 24" and U-shaped seal element 22'. It will be further appreciated that the valve element configuration of both FIGS. 7 and 8 may include the cutout portions 20 shown in FIGS. 1 and 2 and further that the valve elements 16, 16' and 16" may be molded out of any suitable material commensurate with the service application of the valve. Also, the seal members are preferably integrally formed.
During cleaning and sterilizing of pipelines, the straight-through cylindrical design of the valve chamber enables complete draining. As illustrated in FIG. 9, in the rotary version of the valve which has cutout portions for flow control, the valve element is mounted in a horizontal position such that the passageway 46 formed by the lower cutout portion 20 is positioned with a low point to permit complete draining of the valve chamber (and associated pipeline). In the sliding version of the valve, the entire valve chamber is readily opened to permit thorough cleaning by any suitable technique. The absence of threaded surfaces and the like in the valve chamber also materially assists resistance to build-up of deposits and contributes to thorough cleaning.
The integral stem and hemispherical plug design of the valve of the invention provide positive sealing and a readily cleanable design. The elastomeric bond has no crevices to trap the process or cleaning solution.
What has been described is a novel control valve suitable for sanitary installations where cleanliness and immunity from outside contaminants are extremely desirable. The valve is simple, readily cleanable, and economical to manufacture and operate. It is recognized that numerous modifications in the described embodiments of the invention will be apparent to those skilled in the art without departing from its true spirit and scope. The invention is to be limited only as defined in the claims.
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A sanitary valve includes a valve body having a straight-through cylindrical valve chamber terminating in flanges with a valve element support intersecting the valve chamber at a right angle. The valve element is cylindrically shaped with a hemispherical tip that is covered with an elastomeric material which includes a raised circular seal that extends around the circumference of the valve element and a raised U-shaped seal that extends over the tip. The circular seal always engages the supporting means in both the rotatable and sliding versions of the valve to preclude any environmental exposure of the valve chamber.
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This invention relates to improved modular frames for buildings and buildings constructed from such frames, and more particularly to high quality buildings that can be erected quickly and at low cost from tubular steel modular frame units that are fabricated off site and trucked to the building site where they are bolted together into a building frame by a small work crew without the use of heavy equipment.
BACKGROUND OF THE INVENTION
Conventional building practice for residence housing and small commercial buildings relies primarily on wood frame construction in which the building frame is constructed on site from framing lumber cut to fit piece-by-piece individually. It is a labor intensive process and demands considerable skill from the carpenters to produce a structure that has level floors, perfectly upright walls, square corners and parallel door and window openings. Even when the building frame is constructed with the requisite care and skill, it can become skewed by warping of the lumber, especially modern low grade lumber produced on tree farms with hybrid fast-growth trees.
Although conventional wood frame buildings require very little equipment for construction, they have become quite costly to build. The labor component of the cost is substantial, partly because of the wages that must be paid for the laborious process of constructing the frame, and partly because of the many government mandated extra costs such as workman's compensation and liability insurance, social security payments, medical insurance premiums, and the host of reports that must be made to the Government by employers. Accordingly, employers now seek to minimize their work force by whatever means is available to minimize these burdensome costs.
Steel frame construction, usually referred to as “red iron” construction, is commonly used on commercial buildings because of its greater strength, fire resistance and architectural design flexibility. The parts of such a steel frame are typically cut and drilled to order in accordance with the architect's plans, then trucked to the building site and assembled piece-by-piece with the use of a portable crane. The building can be made precisely and as strong as needed, but the cost is relatively high because of the costly materials and the skilled crew and expensive equipment need to assemble the building. It is a construction technique generally considered unsuitable for single family residence building because the cost is high and the building walls are substantially thicker than those made using standard frame construction, so standard door and window units do not fit properly and must be modified with special trim that rarely produces the desired aesthetic appearance.
Earthquake damage is becoming a matter of increasing concern among homeowners because of the publicity given to damage and loss of life in recent earthquakes in the U.S. and abroad. Earthquake preparedness stories and advice abound, but an underlying unresolved concern is that conventional wood frame homes in the past were not built to tolerate the effects of an earthquake, neither in its ultimate load-bearing capability nor its post-quake serviceability limits. Modern building codes attempt to address this concern, but the measures they require merely add to the already high cost of a new home and may not always provide significantly improved resistance to earthquake damage, particularly with respect to after-quake serviceability.
Fire often follows an earthquake, as happened in the disastrous Kobe earthquake of 1994, and of course fire is a major threat to homes independent of earthquake. When fire breaks out in a conventional home, the wood frame fuels the fire and reduces the chances of successfully extinguishing it before the entire structure is destroyed. The major life saving advance in the recent past is the fire alarm which detects the fire and alerts the occupants that a fire has started so they may escape before burning up with the house, but significant improvements to the fire resistance of the home itself that would retard the spread of the fire would be desirable.
The other major catastrophic threat to homes is wind. Wind loads on wood frame homes have destroyed many homes, primarily because the roof is usually attached so weakly to the walls that the combination of lift, exerted upward on the roof by the Bernoulli effect of the wind flowing over the roof, and pressure under the eves tending to lift the roof off the walls, wrenches the roof off the walls and allows the wind to carry the roof away like a big umbrella. Without the roof, the walls of the house collapse readily under the wind load, completing the total destruction of the house.
Termite and carpenter ant damage to wood frame homes is a major form of damage, costing many millions of dollars per year. Although the damage done by insects is rarely life threatening, it is actually more extensive in total than the combined effects of wind and earthquake, and it is an ever-present danger in many parts of the country.
Thus, there has existed an increasing need for a home building frame design that would enable the inexpensive construction of homes that are highly tolerant of the effects of earthquakes, do not support combustion, are capable of withstanding high winds, are immune to damage from insects, and can use standard building components such as door and window units. Such a building frame concept would be even more commercially valuable if it were possible to erect the building in a short time with a small crew and without heavy equipment, and the frame could be adapted to produce buildings of attractive building styles desired locally. Such a building frame is disclosed in U.S. Pat. No. 6,003,280 issued to Orie Wells on Dec. 21, 1999 and assigned to the assignee of this application. However, numerous improvements were found to be desirable in the building frame system shown in that patent for improved design flexibility, fabrication economy, ease of assembly and improved structural strength and resistance to adverse environmental conditions.
SUMMARY OF THE INVENTION
Accordingly, this invention provides an improved building frame, ideally suited for single story and multi-story buildings, that can be assembled rapidly at the building site by bolting together metal frame modules fabricated off site and attaching sheet metal elements that simplify the finishing of the building with exterior sheathing and interior wall board. This invention also provides an improved metal frame for a building having integral internal diamond bracing that enables the building to withstand the racking of severe earthquakes and high winds yet be cost competitive with comparable wood frame buildings. This invention provides an improved process for constructing a building frame that uses low cost standard frame modules for the majority of the frame and shorter or lower versions of the standard modules to adjust the length or height of the frame walls to accommodate any desired building size and joist height for floors between stories, to produce a building frame that is cost competitive with conventional wood frame buildings and substantially more resistant to damage from wind, fire and earthquakes. A further object of this invention is to provide an improved steel frame building having walls the same thickness as conventional wood frame buildings, so that standard door and window units can be used with normal appearance, but the building has the strength of a steel frame building and superior fire resistant benefits, while remaining cost-competitive with conventional wood frame buildings. This invention also provides an improved steel building frame that can be erected quickly in multiple stories using standard frame and anchor brackets. The invention provides a roof frame system using rectangular steel tubing that can accommodate virtually all desired roof designs, including hips and gables.
These and other features of the invention are attained in a building frame having side walls made of side wall frame modules bolted together along adjacent edges and end walls made of end wall frame modules bolted together along adjacent edges. The frame modules are constructed of rectangular steel tubing, typically 2″×2″, welded together in a welding jig to ensure exact 90° angles. The gauge or thickness of the tubing walls is selected for the desired strength. The wall frame modules, other than the window and door modules, have diagonal diamond bracing to provide rigidity against folding or wracking wind loads and forces experienced during earthquakes. The end walls are each bolted at their ends to ends of the side walls to form a peripheral wall of the building. Trusses for supporting a roof on the peripheral wall are bolted into pockets on top of the side walls between structural members at the top of the wall to secure the roof of the building on the peripheral wall, and structural tubing elements are connected diagonally to the trusses, coplanar with the top chords of those trusses, for supporting purlins adjacent the ridges of a hip roof. The peripheral wall is secured to a concrete foundation by attachment of the frame modules to special anchor brackets bolted to anchors set in a concrete foundation. The same anchor brackets can be arranged in pairs, oriented bottom-to-bottom, clamping between them the second story floor panels, to secure the frame wall of the second and subsequent stories to the supporting story below it and to establish high strength tensile load path between the foundation and the frame modules and the roof trusses. Light gauge metal elements are fastened on the inside and outside surfaces of the wall frame modules for speedy attachment of interior wall board and exterior siding. The roof is supported by longitudinally extending purlins that are attached to the trusses by the use of U-shaped brackets that are pre-welded to the top of the trusses. A canted eve strut is supported atop the side and/or end wall modules at the same angle as the top chord of the trusses to provide a flush support for the roof sheathing, parallel and in the same plane with the purlins. A high strength tensile load path is thus established through steel structure from the foundation through the frame to the roof for resisting high wing loading and shaking forces of earthquakes.
DESCRIPTION OF THE DRAWINGS
The invention and its many attendant objects and advantages will become better understood upon reading the following description of the preferred embodiment in conjunction with the following drawings, wherein:
FIG. 1 is a perspective view of one end of a two-story building frame made in accordance with this invention;
FIG. 2 is a cross sectional elevation from the inside of the building frame shown in FIG. 1;
FIG. 3 is a perspective view of a top story building frame wall module for use in buildings made in accordance with this invention;
FIG. 4 is a sectional perspective of a portion of the building frame shown in FIG. 1 from the inside with only the first story modules erected;
FIG. 5 is a sectional perspective of a portion of the building frame shown in FIG. 1 from the inside, with the first and second story modules erected;
FIGS. 6 and 7 are perspective views of the outside and inside, respectively, of a window wall frame module used in the building frame shown in FIG. 1;
FIGS. 8 and 9 are perspective views of a door wall frame module for a building frame in accordance with this invention;
FIG. 10 is a perspective view of an anchor bracket holding the base of two adjacent wall modules in accordance with this invention;
FIG. 11 is a perspective view of the anchor bracket shown in FIG. 10;
FIG. 12 is a sectional elevation of a second story joist and bottom-to-bottom anchor bracket arrangement in accordance with this invention;
FIG. 13 is a plan view of structural corner connection for a building frame in accordance with this invention;
FIG. 14 is a plan view of an alternative structural corner connection for a building frame in accordance with this invention;
FIG. 15 is a perspective view of a portion of a building frame in accordance with this invention showing the details of the hip roof supporting structure;
FIG. 16 is a perspective view of the structure shown in FIG. 15, with the purlins and ridge cap attached; and
FIG. 17 is a schematic elevation of a portion of a modification of the frame module shown in FIG. 3, showing how welding plates can be used to reduce cutting and welding time.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the drawings, wherein like reference numerals designate identical or corresponding parts, and more particularly to FIGS. 1 and 2 thereof, one end corner of a two-story building frame 20 is shown having a peripheral wall (shown only partially) supporting a roof truss structure. The peripheral wall is made of two end walls 22 (only one of which is shown in FIG. 1) connected at their ends to ends of two side walls 26 (a portion of only one of which is shown in FIG. 1 ). The upper portions of the side walls 26 support opposite ends of a plurality of main trusses 28 spaced apart along the side walls at regular intervals, and the end walls 22 support one end of a plurality of hip roof jack trusses 30 , the other ends of which are supported on the main trusses 28 as will be described in more detail below. A plurality of purlins 32 are attached to the trusses 28 and 30 for supporting roof sheathing 34 . The peripheral wall may be secured to a building foundation 36 by anchor brackets 38 bolted to the foundation by anchor bolts 40 or the like, described in detail below.
The top story of the end walls 22 and the side walls 26 are assembled from a plurality of top wall modules 44 T, shown in FIG. 3, which are fabricated off site and trucked to the building site where they are bolted together as the top story of the building frame, shown in FIG. 1 . The lower story of the end walls and sides walls are likewise assembled from a plurality of lower story wall modules 44 L as shown in FIG. 4 . The modules 44 are made in a welding shop from lengths of rectangular metal tubing, welded together at precisely 90° corners so that the assembled building frame is perfectly true and square when bolted together. The tubing is preferably commercially available 2″×2″ square steel tubing having a wall thickness of 14 gauge, or 0.083″, ASTM-A-500 with a yield strength of about 50 KSI and a tensile strength of about 55 KSI. Naturally, other materials could be used, but this material is preferred because it is widely available from many sources at low cost and in various wall thicknesses and dimensions for different strength requirements. The gauge is selected based on the strength requirements of the building frame and will normally be within the range of 7-16 gauge.
The modules are preferably welded together on a welding jig that holds the lengths of tubing at the desired 90° within about 2°, or preferably with about 1° tolerance. Care should be taken to tack weld the entire module before completely welding the junctions to avoid heat distortion of the assembly. TIG welding has been found to produce clean welds that do not require de-slagging and also minimize heat input into the junction. If enough welding jigs are not available for the desired production rate, the first module may be made on the welding jig and the other identical modules may be made on top of the first as a pattern.
The preferred standard wall modules 44 , are exactly eight feet square, although the dimensions can conveniently be varied for different house designs if desired. The modules may be dimensioned to use standard interior wall board, such as that commonly sold in 4′×8′ panels, so the interior may be finished without extensive cutting of the wall board. The top story wall module 44 T shown in FIG. 3 includes two upright end members 40 and three longitudinal or girt members 42 u , 42 m and 42 b welded between and spanning the end members 40 . The upper girt member 42 u is welded atop the ends of the two upright end members 40 ; the lower girt member 42 b is welded flush with the bottom of the end members 40 ; the middle girt member 42 m is welded between the upright end members 40 intermediate the upper and bottom girt members 42 u and 42 b , all at 90° corners.
As shown in detail in FIG. 3, an internal diamond shear brace is provided, having a 45° brace 43 welded to an upright end member 40 and the upper or bottom girt members 42 u or 42 b , across each corner. The internal placement of the diagonal braces 43 , within the frame defined by the two upright end members 40 and the upper and bottom girt members 42 u and 42 b , ensures that light gauge elements, to be described below, can be attached to the inside and outside faces of the frame module 44 without special cutting or other costly operations. A third upright member 41 may be welded midway between the two upright end members 40 at the apex of the upper and lower diagonal braces 43 for additional vertical load bearing capacity if the building design requires the additional strength. The diamond shear module shown in FIG. 3 is used in the peripheral wall 20 in all modules that do not have a window or door opening to provide strength and stiffness in the plane of the wall section for resistance against deflection toward a parallelogram shape under wind loads or lateral shaking during an earthquake. Because this invention can be used in buildings as high as six stories, shear bracing is added for resistance to shear distortion as well as flexural distortion due to bending as a cantilever, so this strengthening minimizes not only threats to the safety of the occupants but also to the serviceability of the building after the windstorm or earthquake.
Two upstanding stub members 45 , made of 4″ lengths of the same 2″×2″ steel tubing, are welded to the upper girt member 42 u of the wall modules 44 , and an eve strut 46 is welded between them about 2″ above and parallel to the upper girt member 42 u . The stub members are each off-set from the outer edge of the end members 40 by about 1″, leaving a pocket 48 , shown in FIGS. 1 and 5, between adjacent stub members 45 on adjacent wall modules 44 for receiving end portions of the trusses 28 and 30 , as will be described in more detail below. The eve strut 46 stiffens the connection of the trusses 30 to the wall modules 36 in the pocket 48 and allows shear stresses exerted by the trusses on the stub members 45 to flow through the modules 44 from one side to the other.
The pocket 48 may be made deeper by using longer stub members 45 , for example, by using 6″ long stub members 45 instead of the 4″ long ones. The longer stubs 45 raise the eve strut 46 to about the height of the roof sheathing, allowing the sheathing to be attached directly into the eve strut. Attachment of the roof sheathing to the eve strut 46 as shown in FIG. 1 adds to the diaphragm shear strength of the roof system.
To facilitate attachment of the roof sheathing 34 to the eve strut 46 , the eve strut 46 is attached to the stubs 45 at an angle canted to correspond to the angle that the upper chord of the roof trusses lies. The depth of the pocket 48 is selected to allow the under surface of the eve strut to lie flush with the top surface of the top chord of the roof trusses, so the eve strut lies in the same plane as the purlins 32 attached to the trusses 28 . Attachment of the roof sheathing to the eve struts 46 by self-drilling/tapping screws or the like is then the same as attaching the sheathing to the purlins 32 . The attachment of the roof sheathing 34 directly to the eve struts 46 also increases the shear coupling between the roof and the building walls.
For buildings that do not have a hip roof, the wall modules for the end wall are identical to the side wall modules 36 except that the stub members 45 and the eve strut 46 are not used, so the upper girt member 42 u is the topmost structural member on the end wall modules. This enables the lower chord of the end trusses to lie directly atop and be fastened to the upper girt members 42 u of the end walls.
The lower story wall modules 44 L shown in FIGS. 1 and 4 use the same basic welded tubing design described above in conjunction with FIGS. 3 and 6 - 9 , but instead of the eve strut and truss pocket arrangement atop the upper girt member 42 u , a wall extension 50 is welded for attachment of the second and higher story floor joists 52 , as shown in FIGS. 2, 4 and 5 . The wall extension 50 includes several vertical risers 52 welded atop the upper girt member 42 u , and a top tube 54 welded to the top of the vertical risers 52 . A series of joist hangers 56 is welded between the top tube 54 and the upper girt member 42 u for supporting floor joists 58 , as shown in FIG. 5 . The hard attachment of the joists 58 between opposite walls of the building frame stiffens the frame against “oil can” diaphragm flexing of the side and end walls of the building frame.
Typical door and window wall modules, shown in FIGS. 6-9, do not normally include the diagonal shear bracing shown in the wall panel shown in FIG. 3 because the assembled wall frame with one or more diamond shear bracing modules as shown in FIG. 3 provides the shear stiffness for the entire wall.
Light gauge elements are welded to the frame modules 44 for attachment of exterior siding and interior finishing such as wallboard, paneling or the like. The light gauge elements include inside studs 60 , exterior furring or stringers 62 , bottom track 64 , and interior top angle 66 and, for the top story modules 44 T, exterior top angle 68 . The inside studs 60 and the inside flange 61 i of the bottom track 64 provide light gauge metal supports to which the interior wallboard can be attached by wallboard screws or the like. The ceiling wallboard and the top of the wall wallboard are attached to the interior top angle 66 . The exterior furring 62 and the exterior flange 61 e of the bottom track 64 provides attachment surfaces for attachment of exterior siding to the modules 44 . On the top story module 44 T, the exterior siding is attached at the top to the flange of the exterior top angle 68 . The angle surface of the exterior top angle 68 provides an attachment surface for the soffit. The interior sheet metal elements are typically about 22 gauge, on the order of 0.034″. The exterior sheet metal elements are typically about 20 gauge, on the order of 0.040″. These gauges provide the desired stiffness and ease of welding to the tubing of the frame modules while allowing ready penetration by drilling screws during attachment of the interior wallboard and exterior siding.
The anchor brackets 38 by which the wall modules 44 are fastened to the building foundation 36 are shown in detail in FIGS. 10 and 11. Each anchor bracket 38 includes two side plates 70 having a square cut-out 72 at the bottom outside corner. The two side plates 70 are welded to opposite ends of a short length of angle iron 74 having a round or elongated hole 76 in the horizontal leg of the angle iron 74 . The square cut-outs 72 form a step that allows the bracket to sit on the bottom track 64 adjacent the bottom girt member 42 b with the two side plates bracketing adjacent upright members 40 of adjacent modules 44 . A pair of bolts 80 extends through two holes 82 in each of the side plates 70 and corresponding holes in the adjacent upright members 40 of the adjacent modules 44 to secure the modules 44 together. An anchor bolt extends from the foundation through a hole in the bottom track 64 and through the hole 76 , and a nut secures the anchor bracket to the anchor bolt and the foundation 36 .
The anchor brackets 38 are also used in a bottom-to-bottom arrangement, shown in FIG. 12, to secure vertically adjacent wall modules 44 together through the base floor deck 85 of the floor between the two wall modules 44 . A bolt 88 extends through the holes 76 in the two anchor brackets 38 to clamp the base floor deck between the upper and lower wall modules 44
The corners at the junction of the end wall frames 22 and the side wall frames 26 are formed by a corner structure 90 , shown in FIG. 13 . The corner structure 90 includes a base plate 92 and a top plate 94 (not shown), and two vertical tubes 96 and 98 arranged edge-to-edge and welded in that position to the top and bottom plates 92 and 94 . The adjacent edges of the vertical tubes 96 and 98 are stitch-welded along their length. The adjacent ends of the adjacent end and side wall frames 22 and 26 are attached to the tubes 96 and 98 , respectively to provide a strong rigid corner structure.
A flanged right-angle exterior light gauge element 100 is attached around the outside of the corner structure 90 to provide an attachment structure for the exterior siding at the corner. The flanges 102 provide a stand-off for the attachment surface of the element 100 equal to the stand-off of the exterior light gauge furring 62 , so the exterior siding lies perfectly flat along the outside of the building. An interior W-shaped light gauge sheet metal element 110 attaches to the inside surfaces of the adjacent modules of the adjacent end and side wall frames 22 and 26 . Attachment surfaces 115 for attachment of the interior wallboard are off-set from the surfaces of the tubing by stand-off portions 117 that are the same width as the interior studs 60 , so the wallboard is supported perfectly flat at its junction at the corner.
Another version of the corner structure is shown in FIG. 14 . In this form, the corner structure 120 has a length of heavy angle iron 122 welded between the top and bottom plates 92 and 94 instead of the two edge-to-edge tubes 96 and 98 as shown in FIG. 13 . In all other respects, the corner structures 90 and 120 are structurally identical.
The wall modules 44 can be made different sizes for different building designs, but it is most economical to use the same wall modules and adjust the wall lengths by adding short end modules 125 to provide the added increment of wall length to satisfy the exact wall length desired. The short wall end modules 125 shown in FIGS. 1 and 2 are structurally alike the standard wall modules 44 except, of course, they are shorter. The diagonal bracing 43 is preferably designed to lie aligned with and at the same angle as the shear bracing 43 in the adjacent module to provide continuous shear bracing to the corner, but shear bracing will not always be needed in the short end modules 125 .
After the wall modules 44 and trusses 28 and 30 have been fabricated in the shop and the foundation has cured, the wall modules and trusses are trucked to the building site and unloaded around the foundation at about the positions they will occupy on the foundation. The lower story modules 44 L can be tipped up with a small crew and bolted together with bolts 80 extending through aligned holes in the upright end members 40 at the top and at the bottom adjacent the lower longitudinal member 42 b through the side plates 70 of the anchor bracket, with an additional bolt 80 at about the mid-level height of the end members 40 . The corner modules are first fastened together to the corner structure 90 or 120 , and then and the anchor brackets are fastened to anchor bolts in the foundation. The intermediate modules are then added and secured with bolts. When all the wall modules have been erected and connected together, the bolts 106 are tightened.
When all the lower story wall modules 44 L have been bolted together to complete the peripheral wall 20 for the first story, second story floor joists 58 are lifted into place and bolted to the joist hangers 56 . Base floor deck 85 is laid on and attached to the joists 58 out to the outer periphery of the wall frame 20 . Now the second story wall modules 44 U are lifted into place and attached together in the same manner as the ground story wall modules 44 L were attached. In the case of the building shown in FIG. 1, the second story frame modules have the joist pockets 48 and eve struts since that will be the top story. If the building were a three story or higher building, additional stories of modules 44 L would be installed.
The anchor brackets 38 are attached to the adjacent upright frame members 40 of adjacent frame modules 44 u and the vertically adjacent upright frame members 40 of adjacent frame modules 44 L, and the bolt 88 is inserted through the aligned holes 76 in the anchor bracket and a hole drilled in the base floor deck 85 . The bolts 88 of all the installed anchor brackets 38 are tightened by torquing the nuts 89 on the bolts 88 when the modules have all been erected and bolted together.
After the wall frame is erected, the trusses 28 are lifted onto the top of the peripheral wall 20 for attachment thereto. The center trusses 28 are attached first by laying the opposite ends of the bottom chord in the chosen truss pocket 48 . The other center trusses 28 are likewise fitted into the pockets 48 between the upstanding stub members between adjacent side wall modules 36 . A bolt is inserted through a hole that was pre-drilled in the shop through the upstanding stub members 44 and preferably also through the lower chord of the trusses 28 , and the bolt 107 is tightened to secure the trusses to the peripheral wall 20 . Alternatively, the upright stub members 44 could be predrilled and the truss lower chord 96 back drilled when it is in place to avoid the possibility of slight misalignment of the holes when the parts come together. The bolting of the trusses into the pockets 48 through the upright stub members 44 secures the roof to the peripheral wall 20 and, together with the anchoring of the peripheral wall 20 to the foundation, anchors the roof to the foundation against displacement due to wind loads or differential movement of the foundation and the building during an earthquake.
The hip roof trusses, shown in FIG. 15, are designed to support a roof lying at an angle to the crest of the “main” roof supported by the lateral trusses 28 . The hip roof supports roof purlins that extend out to the junction with the main roof along a hip ridge. A series of jack trusses 30 lying perpendicular to the planes of the main trusses 28 are supported at one end on the end wall frame 22 , and are supported at their other ends at intermediate positions along a lateral girder truss 29 . The center jack truss 30 has an extension 31 that spans the distance between the lateral girder truss 29 and the last main lateral truss 28 adjacent the junction with the hip roof.
Two hip beams 130 and 132 are provided for supporting ends of the main roof purlins and the hip roof purlins at the hip ridge. Each hip beam 130 and 132 lies generally adjacent and parallel to the hip ridge. The hip beam 130 has an upper surface lying in the plane of the main roof and the hip roof beam 132 has an upper surface lying in the hip roof plane. The hip beams are each attached adjacent one end thereof to the underside of the eve strut 46 , and are attached adjacent the other end thereof to a truss.
The hip beam 132 is made of two pieces, each supported at adjacent inner ends thereof on the outermost jack truss by way of attachment bars spanning top and bottom surfaces of an upper chord of the jack truss 30 at the inner ends of the hip beam pieces. In this way, the hip beam is supported at the same angle as the jack truss for flush attachment of the purlins to the hip beams and the jack trusses. The hip beam 130 also has two parts, each having an inner end. The inner ends of the two parts are supported on the girder truss with upper surfaces of the hip beam 130 flush with upper surfaces of the girder truss so the purlins supported at their ends by the hip beam 130 lie in the plane of the main roof.
After all the trusses 28 and 30 have been bolted into the pockets 48 , the purlins 32 are inserted between and fastened to pairs of L-shaped brackets 122 prewelded onto the upper chord 94 of the trusses, and are fastened thereto by nuts and bolts or by self-drilling/tapping screws through each bracket. The purlins 32 lie atop the trusses 30 and connect them together. A sheet metal ridge angle piece 135 is attached to the adjacent ends of the purlins at the hip ridge, as shown in FIG. 16 . Roof sheathing 124 is laid over and screwed to the purlins, as shown in FIG. 1, and the roof is sealed and shingled in the usual manner.
A foaming insulating material is applied against the inside surface of the exterior siding and is allowed to expand around the wall frame, sealing and insulating the wall. After setting, the foam is sawed off flush with the surface of the interior studs 60 providing sound dampening as well as thermal insulation. The spacing of the wallboard and the extersiding away from the structural frame provides excellent thermal insulation. The wall, with a double layer of wallboard on both sides, was tested in accordance with the Standard Fire Tests of Building Construction and Materials, ANSI/UL263. After three and one half hours the test was terminated with the wall still intact.
The invention thus enables the low cost construction of a house with design capabilities of meeting the design needs of multiple requirements without major redesign. In areas where heavy snow loads can be expected, the pitch angle of the trusses can be increased to any desired angle to increase the load bearing strength and the snow shedding capability of the roof. In earthquake prone areas, the diagonal shear panels give redundant load sharing capability. The roofing material may be selected for minimum weight to minimize the inertial forces so the house moves more like a rigid unit rather than a flexible vertical cantilever. This will minimize the damage to the building caused by differential movement of the foundation and the roof so that the building will remain serviceable after the earthquake. The metal frame building is inherently immune to attacks by termites and carpenter ants as well as mold and mildew, and is inherently resistant to fire damage.
Obviously, numerous modifications and variations of the preferred embodiment described above are possible and will become apparent to those skilled in the art in light of this specification. For example, the welding of the diagonal braces 43 can be by way of weld plates 140 instead of cutting the ends of the tubes 43 to fit flush against the inside surface of the frame members 40 , 42 u and 42 b , thereby saving cutting and welding time and producing a product that is as good or better. Many functions and advantages are described for the preferred embodiment, but in some uses of the invention, not all of these functions and advantages would be needed. Therefore, we contemplate the use of the invention using fewer than the complete set of noted functions and advantages. Moreover, several species and embodiments of the invention are disclosed herein, but not all are specifically claimed, although all are covered by generic claims. Nevertheless, it is our intention that each and every one of these species and embodiments, and the equivalents thereof, be encompassed and protected within the scope of the following claims, and no dedication to the public is intended by virtue of the lack of claims specific to any individual species. Accordingly, we expressly intend that all these embodiments, species, modifications and variations, and the equivalents thereof, are to be considered within the spirit and scope of the invention as defined in the following claims, wherein we claim.
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A building frame resistant to earthquakes, gale-force wind loads, fire, insects and rot includes a peripheral frame wall constructed of rectangular steel tubing. Side wall frame modules bolted together along adjacent edges, and end wall modules bolted together along adjacent edges and to the ends of the connected side wall modules form the peripheral frame wall. Diagonal bracing is built into selected side and end wall modules as required for the desired degree of wind resistance. Trusses made of various size tube such as 2×3 inch rectangular steel tubing for supporting a roof, including a hip roof, on the peripheral wall, are assembled and welded in a welding shop and the prefabricated trusses and wall modules are trucked to the building site. Multiple stories may be erected and fastened together by anchor brackets arranged bottom-to-bottom above and below the second and higher floors. The building frame is secured to a foundation by attaching the anchor brackets to anchor bolts set in the foundation.
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BACKGROUND OF THE INVENTION
The present invention relates to a new and improved method of using a controlled or controllable magnetic bearing arrangement in a textile winding device. The present invention also relates to a new and improved construction of a winding device for use with a spinning machine and equipped with such controlled or controllable magnetic bearing arrangement.
In its more particular aspects the present invention specifically relates to a new and improved method of using a controlled magnetic bearing arrangement which is intended for use with a rotatable shaft in a textile winding device. The controlled magnetic bearing arrangement contains a predetermined number of stationary electromagnets arranged in a substantially circular annular relationship. An electronic control means or circuit is provided for appropriately controlling the electric currents flowing through the stationary electromagnets.
A controlled magnetic bearing arrangement as described, for example, in a brochure published by Societe de Mechanique Magnetique, BP 431,27204 Vernon Cedex, France and commercialized under the trademark "ACTIDYNE", can be utilized for supporting shafts which rotate at variable rotational speeds. The shaft is floatingly supported and can pass through critical rotational speeds without the excitation or generation of dangerous resonance vibrations.
Known winding devices for use during spinning operations contain a plurality of packages which are located on a common support shaft and which are simultaneously wound. When the packages reach their fully-wound condition, the weight of each individual package may amount to more than 20 kg. It is desirable during the winding operation to select the winding speed in such a manner that the related threads are wound up on each package at a rate of up to 6,000 meters per minute.
These requirements cannot be satisfied by the currently available means or expedients or can be satisfied only inadequately. The encountered difficulties include bending of the package supporting or support shaft in dependence upon the weight of the packages, and more particularly the presence of critical rotational speeds, that is to say, rotational speeds associated with different orders of the resonance vibrations of the package support shaft. These critical rotational speeds are caused by the occurrence of resonance at the natural vibrational frequencies of the package support shaft. The package support shaft can be destroyed at such critical rotational speeds and this can be extremely dangerous considering the high rotational speeds and the weights of the processed packages.
Attempts have been made to adapt the currently used winding devices to the spinning machines by immediately winding up the thread or the like which is delivered by the spinning machine, and adapting the rotational speed of the package to the thread delivery speed, see, for example, U.S. Pat. No. 4,394,985, granted July 26, 1983. This requires a continuous adaptation to the continually increasing weights of the packages and to the continually decreasing rotational speed during the winding operations. During such adaptation, operation at or near the critical rotational speeds can arise of necessity. Due to the previously mentioned considerable danger, operation in the region of the critical rotational speeds during such adaptation cannot be tolerated. Thus, optimal rotational speeds cannot be maintained under certain conditions which necessarily arise during the previously mentioned continuous variations, and thus the spinning machine or installation cannot be operated or used at full capacity.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind, it is a primary object of the present invention to provide a new and improved method of using a controlled magnetic bearing arrangement in a manner which is not afflicted with the drawbacks and limitations of the prior art discussed hereinbefore.
It is a further significant object of the present invention to provide a new and improved construction of a winding device for use with a spinning machine and which winding device is not afflicted with the drawbacks and limitations of the prior art constructions discussed hereinbefore.
Another important object of the present invention is directed to a new and improved construction of a winding device for use with a spinning machine and which winding device can be operated at variable rotational speeds and at full capacity of the spinning machine without being endangered by resonance vibrations.
In order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the method of the present development is manifested by the features that, the controlled magnetic bearing arrangement is used for rotatably supporting the package support shaft of a winding device operatively associated with a spinning machine or installation.
The package support shaft serves, by means of bobbin tubes placed thereat, for winding-up threads or the like, particularly endless synthetic filaments, in order to form packages. The support package shaft is provided with at least one free end. The bobbin tubes are axially slid or inserted upon the at least one free end and the completed packages are axially removed from the at least one free end of the package support shaft.
As already alluded to above, the invention is not only concerned with the aforementioned method aspects but also relates to an improved construction of a winding device for use with a spinning machine.
In its more particular aspects, the inventive package winding device comprises:
a rotatable package support shaft supporting a predetermined number of bobbin tubes which are exchangeably mounted in an end-on manner at the rotatable package support shaft i.e. these bobbin tubes are inserted onto the shaft from at least one free end thereof and supported thereupon;
drive means for rotatably driving the package support shaft in order to thereby wind-up threads delivered by the spinning machine on related ones of the predetermined number of bobbin tubes in order to thereby form related packages from the threads;
a controlled magnetic bearing arrangement containing a predetermined number of stationary electromagnets for rotatably supporting the package support shaft;
control means controlling the electric current flowing through said predetermined number of electromagnets; and
the control means controlling the electric current flowing through the predetermined number of electromagnets such that the package support shaft is floatingly arranged in the controlled magnetic bearing arrangement and the electric current is regulated as a function of the position of the package support shaft in the magnetic bearing arrangement.
It is a main advantage which is achieved by the invention that the stiffness as well as the damping of vibrations of the package support shaft can be adjusted by regulating the degree of magnetization such that it is not necessary to perform the winding operation at or immediately close to a critical rotational speed. Passage through the regions of critical rotational speeds is carried out during the regulating operation. In other words, in the event of an approach to a critical rotational speed, the passage through the region of the critical rotational speed can be accomplished within a very short time duration by varying the stiffness of the package support shaft simultaneously with the variation in the rotational speed of the package support shaft, so that in practice there does not arise any build-up of vibrations caused by resonance. This enables complete adaptation to the spinning machine or installation, to the different occurring winding conditions of the packages and to the various types of threads as concerns the thread material and thread density, that is to the different package weights.
This is a decisive advantage for the spinning mill operation, particularly since varying package weights cause different degrees of bending in the package support shaft and thus varying critical rotational speeds. Therefore, the use of the controlled magnetic bearing arrangement offers very specific advantages for different winding operations and winding devices used in combination with spinning machines or installations.
In this connection, it is mentioned as a matter of completeness that the material density in cross-wound packages can have values in the range of 0.35 to 0.55 g/cm 3 for texturized yarns and 0.7 to 0.95 g/cm 3 for smooth yarns. These values are, for example, dependent upon the thread tension, the angle of lay in the package or the yarn count. In general, values lying between approximately 0.3 and 1.0 g/cm 3 and thus considerable variations must be anticipated.
In accordance with the invention, there is obtained the additional advantage that the package support shaft rotates in a frictionless manner and thus no bearing lubrication is required. This is especially important in connection with textile materials because soiling thereof cannot be tolerated.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein throughout the various figures of the drawings there have been generally used the same reference characters to denote the same or analogous components and wherein:
FIG. 1 is a partially sectional schematic top plan view of an exemplary embodiment of a winding device constructed in accordance with the present invention; and
FIG. 2 is a schematic illustration of a further embodiment of the inventive winding device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, it is to be understood that to simplify the showing thereof, only enough of the structure of the inventive winding device has been illustrated therein as is needed to enable one skilled in the art to readily understand the underlying principles and concepts of the present invention. Turning now specifically to FIG. 1 of the drawings, there is shown a package support shaft or chuck 11 which supports four packages 12. The packages 12 are formed by winding not specifically illustrated threads or the like onto bobbin tubes 12a which are mounted on the package support shaft 11. A drive roll 13 is pressed against the packages 12 and serves to set into rotation these packages 12 along with the package support shaft 11. Drive means 14 constituting an electric motor are provided to rotatably drive the package support shaft 11 via the drive roll 13 and the packages 12. Since the diameter of the packages 12 continuously increases during winding-up of the threads, the drive roll 13 and the electric motor 14 are appropriately movable as a unit along support rails 15 as is known in this technology. A thread traversing guide 16 or equivalent structure is provided for guiding the threads to be wound and is movable in the directions indicated by the double-headed arrow 17.
In the illustrated embodiment shown in FIG. 1 of the drawings the rotatably driven package support shaft 11 contains a free shaft end 11a which supports a predetermined number, in the illustrated embodiment, namely for instance four packages 12 which are exchangeably mounted at the free end 11a in an end-on manner i.e. the bobbin tubes 12a upon which the thread packages 12 are formed are doffed or inserted onto the package support shaft 11 from such free end 11a . As just explained, the bobbin tubes 12a are axially placed on the free end 11a of the package support shaft 11 and, at the end of the winding operation and after completion of the wound packages 12, these wound packages 12 are axially again removed from the free end 11a.
The inventive winding device is specifically suited for winding up packages 12 from endless synthetic filaments delivered by a not specifically illustrated spinning machine with which the inventive winding device is operatively associated.
A controlled magnetic bearing arrangement containing a predetermined number of stationary electromagnets 23, 24, 25 and 26 is generally designated by the reference numeral 18 and constitutes a bearing which rotatably supports the rotatable package support shaft 11. In the specific illustrated embodiment, the controlled magnetic bearing arrangement 18 comprises two radial magnetic bearings 19 and 20 and one axial magnetic bearing 21; however, the controlled magnetic bearing arrangement 18 may contain any other number of radial and axial magnetic bearings as required for the purposes of the momentary winding operations. At least in the region of the radial magnetic bearings 19 and 20, the package support shaft 11 contains a predetermined region 11b which is made of a suitable magnetic or magnetizable material for a purpose to be described further hereinbelow.
The radial magnetic bearings 19 and 20 contain a preselected number of the aforementioned stationary electromagnets, namely the electromagnets 23 and 24, each of which is formed by a plurality of individual, laterally abutting electromagnets arranged in a substantially circular annular relationship or configuration around the package support shaft 11. The end faces of the pole shoes or pole pieces, generally indicated by reference numeral 40, of the individual electromagnets are directed towards the package support shaft 11 and lie on a substantially cylindrical surface which is separated by a small spacing or intermediate gap 37 from the rotatable package support shaft 11. During operation, the package support shaft 11 is floatingly arranged or supported by the magnetic fields of the stationary electromagnets 23 and 24 which form the two radial magnetic bearings 19 and 20 of the controlled or controllable magnetic bearing arrangement 18.
In order to prevent displacement of the package support shaft 11 in its axial direction, there are provided the axial magnetic bearing 21 and a disk 22 which is made of a suitable magnetic or magnetizable material and which is mounted at and extends essentially perpendicular to the package support shaft 11. A further preselected number of the aforementioned stationary electromagnets, namely in this case the electromagnets 25 and 26, are arranged on both sides of the disk 22 and annularly surround the package support shaft 11. The pole shoes or pole pieces 42 of the electromagnets 25 and 26 are directed towards the disk 22. During operation the electromagnets 25 and 26 are energized or magnetized such that a narrow intervening gap 38 is formed between these electromagnets 25 and 26 and the disk 22 on both sides of the disk 22.
The electromagnets 23, 24, 25 and 26 of the magnetic bearings 19, 20 and 21 are energized or magnetized via related electrical cables or lines 27, 28, 29 and 30. The magnetization of the electromagnets 23 to 26 is variable and is appropriately regulated by any suitable control means or circuit 31.
In the case of the stationary electromagnets 23 and 24 of the respective radial magnetic bearings 19 and 20, this regulation is carried out by regulating the electric current flowing through the stationary electromagnets 23 and 24 in dependence upon the centering of the package support shaft 11 with respect to the individual magnets arranged in the aforementioned circular annular manner or configuration around the package support shaft 11. In the case of the stationary electromagnets 25 and 26 of the axial magnetic bearing 20 this regulation is carried out by regulating the electric current flowing through the stationary electromagnets 25 and 26 such that the spacings of the disk 22 from the stationary electromagnets 25 and 26 are of equal magnitude.
The accuracy of the centering of the package support shaft 11 and of the central positioning of the disk 22 is continually monitored by means of suitable sensors 44, 46, and 48 generating signals which indicate deviations from the desired positions of the package support shaft 11 and the disk 22 and which are fed via the electrical cables or lines 32, 33 and 34 to the control means or circuit 31.
During operation of the illustrated embodiment of the inventive winding device, the electric motor 14 sets into rotation the drive roll 13. The packages 12 engaging the drive roll 13 are thereby entrained and set into rotation conjointly with the package support shaft 11. During this operation related threads are wound up on the packages 12.
The thread traversing guide 16 guides the aforementioned threads in known manner such as to produce the desired type of thread winding. During the winding operation, the diameter of the packages 12 increases continually. Therefore, the unit encompassing the drive roll 13 and the electric motor 14 is displaceably mounted at horizontal support rails 15 and the drive roll 13 continually engages the packages 12. Since the length of thread delivered by the spinning machine per unit time is constant, the rotational speed of the packages 12 and thus the rotational speed of the package support shaft 11 continually decreases with increasing package diameter and at constant rotational speed of the drive roll 13.
The package support shaft 11 is continuously held in a centered and floating position by means of the electromagnets 23 and 24. Every deviation from this centered position which is continuously monitored by the aforementioned sensors 44 and 46, is indicated at the control means or circuit 31 by means of the electrical sensor output signals transmitted via the electrical leads 32 and 33. The control means or circuit 31 processes these signals and thereby generates control signals for individually regulating the electric current fed to the individual magnets of the stationary electromagnets 23 and 24 forming the radial magnetic bearings 19 and 20, such that deviations of the package support shaft 11 from a set or reference position are instantaneously and continually corrected.
In analogous manner, the package support shaft 11 is maintained in its predetermined position in axial direction. The sensors 48 monitor the intervening gaps or spaces 38 between the disk 22 and the stationary electromagnets 25 and 26 which form the axial magnetic bearing 21. Deviations from predetermined set or reference values of these intervening gaps or spaces 38 are indicated to the control means or circuit 31 by electrical sensor output signals transmitted via the electrical lead 34. In the control means or circuit 31, these sensor output signals serve for regulating the magnetizing current fed to the stationary electromagnets 25 and 26 via the related cables 29 and 30. Deviations in the position of the disk 22 from the set or reference value are thus instantaneously and continually corrected.
The package support shaft 11 rotates in a freely floating manner in the controlled magnetic bearing arrangement 18 without coming into contact with any one of the members of this bearing arrangement. Thus, there is no mechanical friction and no mechanical wear. Since no lubrication is required, there is no soiling of the thread material due to lubrication.
The package support shaft 11 possesses the aforementioned predetermined region 11b which is made of magnetizable material. By varying the degree of magnetization of this region 11b of the package support shaft 11, the stiffness of the package support shaft 11 can be varied in order to change or shift the critical rotational speeds associated with the different orders of resonance vibrations of the package support shaft 11. This is of decisive significance because there thus results the possibility of realizing the following mode of operation:
During the previously mentioned continual reduction of the rotational speed of the package support shaft 11 during the course of a winding operation, the necessity may arise for a passage of the package support shaft 11 through one of its critical rotational speeds. It will be assumed that, under the given operating conditions, this critical rotational speed lies at n 1 revolutions per minute. In order to pass through the rotational speed having this value n 1 and in accordance with the teachings of the invention, the stiffness of the package support shaft 11 is varied by varying the degree of magnetization in the predetermined region 11b of the package support shaft 11. There is thereby changed the critical rotational speed of the package support shaft 11, for example, to a value corresponding to n 2 revolutions per minute. In this manner, it is possible to operate, if desired, at the rotational speed corresponding to n 2 revolutions per minute which is not critical in view of the altered degree of magnetization. If, however, it is desired to pass through the critical rotational speed corresponding to n 1 revolutions per minute, then the degree of magnetization in the predetermined region 11b of the package support shaft 11 is returned to its original value after the value corresponding to n 1 revolutions per minute has been passed and before the value corresponding to n 2 revolutions per minute is reached. This takes place in an extremely short period of time. Thus, the passage through the critical rotational speed which is now located between the values n 1 and n 2 , during this return operation is of extremely short duration.
Thus there is no time for the formation of resonance vibrations and the passage through the critical rotational speed between the values n 1 and n 2 occurs in a completely safe manner during the return magnetization of the predetermined region 11b of the package support shaft 11.
In accordance with FIG. 1, two radial magnetic bearings 19 and 20 and one axial magnetic bearing 21 are provided. The mutual spacing of the two radial magnetic bearings 19 and 20 is matched to correspond to the portion of the package support shaft 11 at which portion the packages 12 are placed, and to the thickness of the package support shaft 11 and other suitably selected parameters, if desired, taking into account the package weight. Likewise, the number of radial magnetic bearings is selected in dependence upon the momentary circumstances, but in general there will be selected two such radial magnetic bearings.
It can be advantageous to provide conditions which are balanced in terms of weight with respect to the controlled magnetic bearing arrangement 18. For this purpose and as illustrated for a further embodiment of the inventive winding device in FIG. 2, the same number of packages 12 can be mounted on both sides of the controlled magnetic bearing arrangement 18 at related free ends 35a and 35b of a package support shaft 35. In such arrangement, a single radial magnetic bearing is sufficient. In such a case, the provision of two thread traversing guides 36 was found useful.
In a further development of the inventive winding device, the drive of the package support shaft 11 and the packages 12 is not effected, as shown in FIG. 1, by means of the separately installed conventional electric motor 14, but by means of an electric motor which is incorporated into the controlled magnetic bearing arrangement 18.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims.
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The controlled magnetic bearing arrangement supports a rotatable shaft and contains an electronic control circuit. The shaft is floatingly supported in the bearing arrangement by magnets controlled by the electronic control circuit and the stiffness of the shaft is thereby adjustable. The shaft may constitute a package support shaft in a winding device of a spinning machine and has a free end for permitting the axial exchange of bobbin tubes and packages. This arrangement provides the advantages of attaining very high rotational speeds for the package support shaft and the possibility of varying the stiffness of such package support shaft and thus the critical rotational speeds. The regions of the critical rotational speeds can be passed through in a safe manner.
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BACKGROUND OF THE INVENTION
This invention relates to cleaning methods and apparatus, and more particularly relates to methods and means for cleaning interior surfaces of railroad tank cars and the like, and also stripping rubber linings and the like affixed to these interior surfaces.
It is well known in the prior art that a diversity of commodities are transported by land in railroad tank cars, truck trailers, transport tankers, etc. It is also well known in the prior art that there are special purpose railroad tank cars and the like which are lined with rubber and the like, to prevent contamination, chemical reactions, etc.
Prior to being filled or loaded with a particular commodity, a tank car and the like must be thoroughly cleaned for health and safety reasons. Tank cars with linings must, of course, also be cleaned and, indeed, such linings may be stripped and replaced prior to being filled or loaded with another commodity. Such cleaning and stripping have heretofore conventionally been both labor-intensive and time-consuming.
During typical manual cleaning, the flow of liquid through hand-held hoses is limited to volumes of less than approximately 7 gallons per minute. This throughput is not only limited by a worker's handling ability, but also is limited by the unstable standing conditions in a slippery, conventional rounded-bottom tank car. Indeed, considering that typical manual car-wash volumes of water are only 2 gallons per minute at low pressures of 1,500 psi, a 7 gallon per minute flow presents a considerable challenge to a worker, particularly within the confines of a tank car and the like. Furthermore, there are hazards to workmen from splashing chemicals, debris, fumes, and even explosions. Thus, in addition to being an inherently hazardous and slow method of cleaning tank cars, such manual methods are inherently nonuniform and unreliable.
Accordingly, there have been several attempts in the art to automate the cleaning and stripping of tank cars and the like. To clean the interior of a tank car with reduced human intervention. However, requires that a suitable apparatus either be a permanent member thereof or be inserted and then assembled therein. As should be evident to those conversant with the art, entry into a railroad tank car is routinely available through a narrow manway located on top thereof or could be rendered expedient through a specially designed wall or side panel or door. But, of course, a tank car with such a specially designed panel or door would necessitate structural modifications and would be susceptible to contamination and leakage.
An apparatus designed to eliminate or minimize such danger to workmen is illustrated by Hulbert in U.S. Pat. No. 3,571,985. Specifically intended to clean tank car linings with an abrasive material like sand, Hulbert discloses an apparatus consisting of a support structure affixed to the ends of a tank car using hydraulics and pneumatics. A pneumatic pump provides for longitudinal movement of a carnage along the support structure, while another pneumatic pump simultaneously provides for independent rotational movement of a plurality nozzles. Drive means are also provided for the manual control of linear carriage advancement and rotational nozzle spray pattern. A vacuum pump removes debris from the floor of the tank car. Since considerable time appears to be prerequisite to assembling the Hulbert apparatus, it is probably intended not to be portable, but to be a relatively permanent fixture in a tank car.
As another example, Saxonmeyer, in U.S. Pat. No. 3,461,889, teaches an apparatus for washing railway tank car interiors which provides for the entry through a side door in the tank car of a platform movably mounted by a base and a carriage movably mounted with respect to the platform. A boom assembly mounted on the carriage controls the spray of liquid about a vertical axis through plurality of nozzles. The Saxonmeyer apparatus includes sensing axis to provide semi-automatic operation by limiting its washing operation only to times when a side edge of the tank car door opening is not contacted.
While improving the prior railway tank car cleaning art, the Hulbert and Saxonmeyer devices have provided only limited arcuate manipulation of the spray nozzles and require structural modifications to a railroad tank car. Guigon et al., in U.S. Pat. No. 3,444,869, disclose a jet cleaning device which attempts to improve the effectiveness and nature of the spray for cleaning purposes. Based upon a complicated plurality of oscillatable nozzles, this device has a corresponding plurality of streams of cleaning liquid which is directed to the internal surfaces of a tank car. The sizes of these streams depends upon the distances of the plurality of nozzles from tile internal surfaces therefrom.
Another improvement in the nozzle manipulation art is disclosed by Jaeger in U.S. Pat. No. 3,895.756. In particular, there is disclosed a method and apparatus for cleaning vessels which not only enables presetting control means to accommodate a vessel's dimensions, but also enables programming a sequence of nozzle movements. The Jaeger apparatus is lowered into a tank car through its manway and the assembly connected by liquid pressure lines to a control device and to a source of pressurized cleaning fluid. A high pressure spray nozzle is mounted for universal movement relative to two perpendicular axes. Separate hydraulic actuators are connected to and activated from a remote control device, which is air operated and with means for adjusting the speed and degree of sweep of the spray nozzle, thereby enabling a spray of any configuration to be generated. Thus, in addition to providing more versatile manipulation and control of spray nozzles, the Jaeger apparatus is portable and is inserted into a tank car through its manway.
Similarly, in U.S. Pat. No. 3,001,534, Grant teaches a portable apparatus for cleaning a tank car by being inserted thereinto. A baseplate temporarily replaces a tank car's dome cover and supports an assembly extending into the interior of the car and carrying rotating spray heads. These spray heads are driven by an electric motor and rotate about two orthogonal axes, thereby permitting water spray throughout a tank car's interior. Thus, in addition to improving the prior art with a portable top-insertable apparatus, the Grant apparatus is easily positioned within the tank car and directs a controllable, compound water spray pattern throughout the interior thereof using swivel means. The number of revolutions of the swivel means is determined by the relative ratios of two sets of pinions and gears.
Further improvements in the prior art are disclosed by Looper and Maton. In U.S. Pat. No. 4,244,523, Looper teaches a top-inserting apparatus for conveniently and inexpensively cleaning rubber-lined tank cars. This apparatus consists of a fixed frame for supporting a tiltable frame from which extends a pivotally mounted wash nozzle assembly containing a cleaning liquid tube at the end of which is connected spray nozzles. The spray jets operate simultaneously on longitudinal and transverse axes of the tank car promoting thorough cleaning thereof. Similarly, in U.S. Pat. No. 4,341,232, Maton discloses a tank cleaning apparatus which limits the rotation of top-insertable spray arms to 180° instead of the conventional 360°. By only rotating spray arms through 180° during the washing cycle, matter dislodged from the interior of a tank car is prevented from being forced upon already cleaned surfaces because a spray pattern is formed which directs such dislodged material to one end of the car or to its bottom.
Notwithstanding these improvements in the tank cleaning and stripping art, there is still not available an automatic and reliable apparatus and method cleaning tank cars and the like and for stripping the linings therein contained. It would be advantageous for an apparatus to be sufficiently portable to be completely inserted through an existing manway and then be conveniently and quickly assembled therein. It would also be advantageous for such an apparatus to be readily configured so as to accommodate tank cars of various lengths and diameters, and having various size thermal wells.
Those skilled in the art would also appreciate the utility of an apparatus capable of generating and accurately controlling a high pressure and high volume liquid spray such that the entire interior surfaces of a tank car and the like would be effectively treated, even containing a lining thereon. Such effective liquid spray would preclude the present conventional use of abrasive cleaning of linings, thereby significantly prolonging the longevity thereof. It would be further advantageous if such apparatus were driven within the tank car by a nonelectrical motor to avoid a potential safety hazard due to sparks causing combustion or explosion.
Accordingly, these limitations and disadvantages of the prior art are overcome with the present invention, and improved means and techniques are provided which are useful for cleaning and stripping residue, contaminants, debris, etc. from all of the interior surfaces in a railway tank car and the like, such that the means may be conveniently lowered into a tank car through its manway and, after quick assembly thereof, pneumatically configured to accommodate the particular physical dimensions of the tank car, and then be preset for automatic cleaning and/or stripping operation.
SUMMARY OF THE INVENTION
The present invention provides an improved apparatus and method cleaning and stripping residue, contaminants, debris, etc. from all of the interior surfaces in a railway tank car and the like, with minimal prerequisites heretofore unknown in the prior art. The present invention discloses means which may be conveniently lowered into a tank car through its manway and, after quick assembly thereof, pneumatically configured to accommodate the particular physical dimensions of the tank car, and then be preset for automatic cleaning and/or stripping operation.
In accordance with the present invention, means and methods are provided which enable half of a tank car and the like to be effectively cleaned without worker intervention. As will be described in detail, the present invention teaches a synergistic means which inherently coordinates and synchronizes the cleaning and stripping of virtually every internal surface contained in a tank car and the like.
The preferred embodiment of the present invention comprises an X-frame assembly having a pair of corresponding X-members which are attached by an axle disposed therebetween. Pivotally attached to this X-frame assembly is a swivel support assembly which houses a swivel, drive means and a hydraulic pump, and also receives a K-fame assembly. The K-flame assembly comprises a plurality of arm means, linkage means and spray means for spraying all of the interior surfaces of a tank car and the like. In accordance with the teachings of the present invention, the end walls or bulkheads of a tank car are cleaned and stripped while the preferred embodiment is situated in a "hold" or "stationary" mode; the sidewalls, ceiling and floor of a tank car are cleaned and stripped while the preferred embodiment is situated in a "tracking" mode. The transition from such hold mode to tracking mode is accomplished automatically by the present invention, whereby substantially longitudinal half of a tank car may be cleaned or stripped without human intervention. In addition, such tank car treatment is typically accomplished with speed and reliability heretofore unknown in the prior art.
It is feature and advantage of the present invention that its linear tracking along the floor of a tank car and the like is synchronized with the rotational movement of its spraying means. Nevertheless, as will be described in detail, the tracking speed of the present invention via its pneumatically controlled tire assemblies may be changed independently of the rotational speed of its spray means. In accordance with the preferred embodiment, a high pressure spiral spray pattern is delivered to the internal surfaces of a tank car and the like, through a novel linkage of a plurality of arm means comprising a K-frame assembly. Rotational motion of a swivel is effected by a hydraulically driven motor. Thus, under the present invention, sources of power are limited to air and water, thereby avoiding electrical hazards and other dangers common in wet, chemical environments.
Accordingly, in accordance with the present invention, methods and means are provided to enable a tank car and the like to be effectively and quickly cleaned with minimal worker intervention. It is also within the teachings of the present invention that lined tank cars and the like may be effectively and quickly cleaned and stripped with minimal worker intervention.
It is an object of the present invention to provide means and method for effectively and safely cleaning and stripping tank cars and the like.
It is also an object of the present invention to provide a means and method for cleaning and stripping tank cars and the like which requires only minimal worker intervention.
It is a further object of the present invention to provide an apparatus for cleaning and stripping tank cars and the like which may be remotely adapted to accommodate all interior surfaces thereof.
It is a feature and advantage of the present invention that an entire half of a tank car and the like may be automatically cleaned and stripped before any worker intervention is required for similarly cleaning and stripping the other half thereof. Thus, worker intervention associated with the present invention limited to only a few minutes of initial set up time and then its positioning for treating the remainder of a tank car and the like has heretofore unknown in the prior art. It is accordingly an object of the present invention to provide an improved means which may conveniently be lowered thereto through a manway, quickly assembled and positioned, and then automatically clean and strip at least an entire half of a tank car and the like.
It is a further object of the present invention to provide a means for cleaning tank cars and the like which operates in the absence of electric power therein.
It is also an object and feature of the present invention that an apparatus and method are provided which enables those skilled in the art to strip liners contained in tank cars and the like by exercising accurate control of the distance between spray nozzles and the lining's surfaces. Hence, it is an advantage of the present invention that the longevity of tank car liners is sustained by the nozzle location precision heretofore unknown in the art.
It is another object of the present invention to provide a means which inherently synchronizes its linear tracking longitudinally along the floor of a tank car and the like, with the rotational movement of a swivel assembly.
It is an object and feature of the present invention to provide a means which automatically adapts to the dimensions of a tank car and the like.
It is a specific object of the present invention to provide, in a tank car having a plurality of interior surfaces including a floor, side walls, end walls and a ceiling having a manway for access of a worker thereinto, a cleaning and stripping apparatus comprising: a X-frame assembly comprising: a first X-member fixedly attached to a second X-member by an axle disposed therebetween, and having a swivel support assembly rotatably attached thereto; a first sleeve member fixedly attached to said first X-member and to said second X-member; a second sleeve member fixedly attached to said second X-member and to said first X-member; a first sprocketed sleeve member fixedly attached to said first X-member and to said second X-member, and disposed oppositely of said first sleeve member; a second sprocketed sleeve member fixedly attached to said second X-member and to said second X-member, and disposed oppositely of said second sleeve member; first sprocket means disposed concentrically of said first sprocketed sleeve member for receiving roller chain means; and second sprocket means disposed concentrically of said second sprocketed sleeve member for receiving said roller chain means; said first X-member and said second X-member pivotally attached at their longitudinal midpoints by said axle disposed perpendicularly of each of said first and second X-member; said X-frame assembly configured to be insertable into said manway when arranged in a compressed position and further configured to receive a plurality of pneumatic tire assemblies mad to support a K-frame assembly when said X-frame assembly is arranged in an extended position; said K-frame assembly releasably and rotatably attached to said swivel support assembly and having swivel means: fluid supply conduit means connected to said swivel support assembly for operating hydraulic motor means for rotating said swivel means; spray means fixedly attached to said swivel means for forming a fluid spray pattern upon said plurality of interior surfaces of said tank car; and air supply conduit means connected to a plurality of air cylinder means hingedly connected to said X-frame assembly for pneumatically controlling said compressed or extended configuration of said X-frame assembly, connected to drive means for pneumatically controlling linear movement of said X-frame assembly independently of movement of said rotation of said swivel means and for synchronizing said rotational movement of said swivel means with said linear movement of said X-frame assembly.
It is another specific object of the present invention to provide a method for cleaning and stripping a plurality of interior surfaces of a tank car, including a floor, a pair of side walls, a pair of end walls and a ceiling, said tank car having a manaway for access of a worker thereinto, said method comprising the steps of: inserting a compressed X-frame assembly having a swivel support assembly rotatably attached thereto into said manway; affixing the axles of four corresponding pneumatic tire drive assemblies to said X-frame assembly; positioning said pneumatic tire drive assemblies on said floor of said tank car: further affixing the axles of four corresponding pneumatic tire stabilizing assemblies to said X-flame assembly; connecting air conduits to a pair of air cylinders hingedly attached to said X-frame assembly; pneumatically configuring said X-frame assembly so that said pneumatic tire drive assemblies contact said floor of said tank car and said pneumatic tire stabilizer assemblies simultaneously contact said ceiling thereof: pivoting said swivel support assembly from a position substantially perpendicular of said floor of said tank car to a position substantially parallel to said floor and pointed toward one of said pair of end walls; further inserting an extended K-frame assembly having swivel means into said manway: attaching said K-frame assembly to said swivel support assembly: further connecting fluid conduits to said swivel support assembly, for communicating fluid to spray means contained in said swivel means and for operating a hydraulic pump contained in said swivel support assembly: further positioning said spray means proximal to said one of said pair of end walls; initiating fluid flow through said fluid conduits, for activating said hydraulic pump and said spray means; engaging clutch means contained in said swivel support assembly, for cleaning and stripping said one of said pair of end walls; holding said X-frame assembly in position with said spray means proximal to said one of said pair of end walls: disengaging said clutch means and releasing said X-frame assembly, for cleaning and stripping said pair of side walls, said ceiling and said floor of substantially a longitudinal half of said tank car; driving said pair of pneumatic tire drive assemblies linearly and longitudinally along said floor of said tank car and synchronizing simultaneous rotating of said swivel means for producing a spiral spray pattern from said spray means; detaching said K-frame assembly from said swivel support assembly: further pivoting said swivel support assembly through substantially 180° maintaining its position substantially parallel to said floor and pointed toward the opposite one of said pair of end walls; and repeating said attaching, engaging and disengaging steps for cleaning and stripping said plurality of interior surfaces of substantially the remaining longitudinal half of said tank car.
These and other objects and features of the present invention will become apparent from the following detailed description, wherein reference is made to the figures in the accompanying drawings.
IN THE DRAWINGS
FIG. 1 depicts a right side view of a portion of an apparatus embodying the present invention, with this apparatus being lowered into a railroad tank car.
FIG. 2 depicts a front view of an apparatus embodying the present invention, with this apparatus being disposed in a railroad tank car.
FIG. 3A depicts an enlarged view of the apparatus depicted in FIG. 1.
FIG. 3B depicts a front view of the apparatus depicted in FIG. 3A.
FIG. 4A depicts an enlarged front view of a portion of the apparatus depicted in FIG. 2.
FIG. 4B depicts an enlarged front view of a portion of the apparatus depicted in FIG. 2.
FIG. 5 depicts a enlarged front view of the apparatus depicted in FIG. 2.
FIG. 6 depicts an enlarged front view of a portion of the apparatus depicted in FIG. 5, with said apparatus rotated counterclockwise through 90° and depicted in a partially spread position.
FIG. 7 depicts the apparatus depicted in FIG. 6 in a compressed position.
FIG. 8 depicts the apparatus depicted in FIG. 6 in a full spread position.
FIG. 9 depicts an enlarged partial cut-away front view of a portion of the apparatus depicted in FIG. 5.
FIG. 10 depicts a left side view of the apparatus depicted in FIG. 9, along line 10--10.
FIG. 11 depicts an enlarged front view of a portion of the apparatus depicted in FIGS. 6-8.
FIG. 12 depicts an enlarged front view of a portion of the apparatus depicted in FIG. 5.
FIG. 13 depicts an enlarged view of a portion of the apparatus depicted in FIG. 15.
FIG. 14 depicts an enlarged view of a portion of the apparatus depicted in FIGS. 6-8.
FIG. 15 depicts an enlarged partial cut-away view of a portion of the apparatus depicted in FIG. 5.
DETAILED DESCRIPTION
Referring to FIG. 1, there is depicted a simplified frontal view of railroad tank car 200 with X-frame assembly 68 (as will be described in detail, each of a pair of corresponding members are configured essentially in the shape of a letter "X" and, accordingly, attachment 68 is referred to herein as "X-frame assembly" and each of its pair of such members as "X-members") of the present invention being lowered by hoist 300 through manway 205 into tank car 200. More particularly, there is shown a right side view of X-frame assembly 68 configured in a folded position to enable easy entry thereof into tank car 200 through manway 205. Also shown is debris film or layer 215 disposed upon the interior surfaces of tank car 200.
Now referring to FIG. 2, there is depicted a similar simplified frontal view of railroad tank car 200 as depicted in FIG. 1, but with X-frame assembly 68 configured in an extended position. In particular, X-frame assembly 68 is shown with a first X-member comprising channel frame 59A and flat frame 60A substantially perpendicular of each other. Also depicted is swivel support bracket 61 which is rotatably attached to shaft 19 of X-frame assembly 68. As shown, channel frame 59A and flat frame 60A are preferably secured to shaft 19, at the intersection thereof, by a suitably sized bolt.
Referring now to FIGS. 2 and 3A-B, there is seen K-frame assembly 140 releasably interconnected with swivel support bracket 61 by quick-connect member 11. Pneumatic tires 70A and 70C are affixed to lower drive sleeves 290A and B, respectively. As will be hereinafter explained in detail, pneumatic tires 170B and 70D (not shown) are affixed to upper, dead sleeves 240A and B, respectively. Pneumatic tires 70A, B, C and D are preferably identical.
Referring now to FIGS. 3A and 3B, there is depicted corresponding right side and frontal enlarged views, respectively, of X-frame assembly 68 depicted in its extended position as in FIG. 2. It is seen that X-frame assembly 68 comprises two sets of X-members: first X-member comprising channel frame 59A and flat frame 60A, and corresponding second X-member comprising channel frame 59B and flat frame 60B. Channel frames 59A and B are preferably constructed from conventional angle-iron containing channels 250A and B, respectively, to impart strength to X-frame assembly 68. In particular, channel frame 59A is shown having longitudinal channel 250A throughout its length; similarly, channel frame 59B is shown having longitudinal channel 250B throughout its length. On the other hand, frames 60A and B are constructed from conventional flat iron to enable their being folded together with paired frames 59A and B to form a substantially linear arrangement thereof. As shown in FIG. 1, this linear arrangement enables the convenient entry of X-frame assembly 68 through a railway tank car hatch or manway.
The first set of frames depicted in FIGS. 3A-B comprise channel frame 59A and flat frame 60A. Channel frame 59A has socket 63B at one end and socket 63D at the other opposite end thereof. Flat frame 60A has socket 63A at one end and socket 63C at the other opposite end thereof. The second set of frames depicted in FIG. 3A comprise channel frame 59B has socket 63D at one end and socket 63B sprocket 57D at the other opposite end thereof; flat frame 60B has socket 63C at one end and socket 63B sprocket 57C at the other opposite end thereof. Channel frame 59A and flat frame 60B are fixedly interconnected at the top portion thereof by sleeve 240A and at the bottom portion thereof by sprocketed sleeve 290A. Sprocketed sleeve 290A contains sprocket 57A disposed transversely thereon and sprocketed sleeve 290B contains sprocket 57B disposed transversely thereon.
As shown in FIG. 3A, "folding" of channel frames 59A and B together with flat flames 60A and B is accomplished by pivoting the respective socketed ends 63A, B, C, D of each pair of channel and flat frames together, thereby juxtaposing flat frame 60A upon channel frame 59A and simultaneously juxtaposing flat frame 60B upon channel frame 59B. In such a compressed or folded configuration, the present invention may be inserted through manways as small as 171/2 inches in diameter.
Now referring to FIGS. 3A-B and 4A-B and C, channel frame 59A is seen to have a pair of sleeves 240A and 290A disposed at each opposite end thereof. More particularly, sleeve 240A is disposed at the end portion of channel frame 59A perpendicularly of socket 63B and is configured to receive pneumatic tire assembly 225A as will hereinafter be described in detail. Similarly, sprocketed sleeve 290A is disposed at the other opposite end portion of channel frame 59A perpendicularly of socket 63D and is configured to receive pneumatic tire assembly 275A as will hereinafter be described in detail. Likewise, flat frame 60A is seen to have a pair of sleeves 240B and 290B disposed at each opposite end thereof. Sleeve 240B is disposed at the end portion of channel frame 59B perpendicularly of socket 63D and is configured to receive pneumatic tire assembly 225A. Similarly, sprocketed sleeve 290B is disposed perpendicularly of socket 63D and is configured to receive pneumatic tire assembly 275A.
Referring specifically to FIGS. 3A-B, there is also depicted air cylinder 65 hingedly attached to channel frame 59A at hinge 260 and to flat frame 60A at hinge bracket 265. Air line 42 provides air to air cylinder 65 from air supply 170 (not shown). Water line 335 carries water from water supply 330 (not shown) through elbow 340 to water swivel support 61.
In accordance with the present invention, as depicted in FIGS. 3A-B and 4A-B, once X-frame assembly 68 is placed upon the floor of a railroad tank car, four pneumatic tire stabilizer assemblies, each configured as shown by pneumatic tire assembly 225A, are inserted into corresponding sockets 63A and B, and 63A' and B' (not shown), respectively. Similarly, four pneumatic the drive assemblies, each configured as shown by pneumatic tire assembly 275A, are inserted into corresponding sockets 63C and D, and 63A' and B' (not shown), respectively. In particular, axle 67A of a first pneumatic tire stabilizer assembly 225A is inserted into socket 63A and, in turn, received by the portion of sleeve 240A adjacent socket 63A. Similarly, axle 67A of a second pneumatic tire stabilizer assembly 225A (not shown) is inserted into socket 63B and, in turn, received by the portion of sleeve 240B adjacent socket 63B. Also, axle 67A of a third pneumatic tire stabilizer assembly 225A is inserted into socket 63A' (not shown) and, in turn, received by the end portion of sleeve 240A disposed remotely and oppositely of socket 63A. Similarly, axle 67A of a fourth pneumatic tire stabilizer assembly 225A is inserted into socket 63B' (not shown) and, in turn, received by the end portion of sleeve 240A disposed remotely and oppositely of socket 63B.
Similarly, axle 66A of a first pneumatic tire drive assembly 275A is inserted into socket 63C and, in turn, received by the portion of sleeve 290A adjacent socket 63C. Similarly, axle 66A of a second pneumatic tire drive assembly 275A (not shown) is inserted into socket 63D and, in turn, received by the portion of sleeve 290B adjacent socket 63D. Also, axle 66A of a third pneumatic tire drive assembly 275A is inserted into socket 63C' (not shown) and, in turn, received by the end portion of sleeve 290A disposed remotely and oppositely of socket 63C'. Similarly, axle 66A of a fourth pneumatic tire drive assembly 275A is inserted into socket 63D' (not shown) and, in turn, received by the end portion of sleeve 290A disposed remotely and oppositely of socket 63D.
Air pressure is then applied to air cylinder 65 through air line 42, thereby retracting piston rod 82 and reducing equal vertical angles α and β, which are formed by the intersection of channel frame 59A and flat frame 60A, as these flames are caused to cooperatively pivot about shaft 19. Simultaneously, as the top portions of each channel and flat frame are pneumatically arched toward the ceiling of a railroad tank car, preferably four identical pneumatic tires 70E, F, G and H (not shown), rotatably attached to respective ends of sleeves 240A and B are caused to establish contact with the ceiling thereof. Similarly, as the bottom portions of each channel and flat fame are pneumatically arched toward the floor of a railroad tank car, preferably four identical pneumatic tires 70A, B, C (not shown) and D (not shown), rotatably attached to respective ends of sleeves 290A and B, are caused to establish contact with the floor thereof. Thus, once X-frame assembly 68 is properly installed within a tank car and the like, each of its eight tires preferably contact an upper or lower surface thereof. In accordance with the present invention, sustained air pressure in cylinders 65A and B maintain pneumatic tire contact on each of eight points on these surfaces.
In accordance with the present invention, since each of the axles about which each pair of pneumatic tires rotate are substantially of equal length, pivot pin 19 will remain substantially at the centroid of a tank car's interior. It should be clear to those skilled in the art that the instant X-frame assembly design is a novel and important aspect of the present invention, wherein ease of access and simplicity of set-up are provided. As shown in FIGS. 4A-B, depicting pneumatic tire stabilizer and drive assemblies 225A and 275A, respectively, axles 67A and 66A are provided with threaded shafts 230A and 280A, respectively, to allow adjustment in axle length to accommodate wider or shorter diameter tank cars. Thus, in pneumatic tire stabilizer assembly 225A, axle 67A may be screwed toward threaded shaft 230A, i.e., screwed clockwise, to reduce the length thereof. Contrariwise, axle 67A may be screwed away from threaded shaft 230A, i.e., screwed counter-clockwise, to increase the length thereof. Jam nut 235A enables such adjustments to be made quickly and conveniently. Alternatively, a sliding adjustment or telescopic spring-loaded mechanism may be used to adjust axle length.
As will be hereinafter described in detail, referring to FIGS. 2, 3A-B, and 4A-B, sprockets 57A and B cooperate with respective drive axles 66A of said first and second pneumatic tire drive assemblies 275, and sprockets 57A' and B' (not shown) cooperate with respective drive axles 66A of said third and fourth pneumatic tire drive assemblies 275A to linearly move the present invention along the floor of tank car 200. Specifically referring to FIGS. 4B, axle 66A is configured with notch 295A to enable corresponding pair of pneumatic tire drive assemblies 275A to be joined together and secured with bolt 297A. In accordance with the present invention, when corresponding sprockets 57A-A' are caused to rotate, the joined axle-pair 66A, formed as hereinbefore described via matching notches 295A, is, in turn, caused to rotate simultaneously with its respective tires 70C and D (not shown). Lug 298 is mounted on tire assembly 275A to assure that axle 66A and tires 70C and D (not shown) rotate together. Thus, lower tire drive assemblies enable the instant apparatus to traverse the floor of a tank car functioning like a positive 4-wheel drive vehicle.
The set of four tires contacting the tank car ceiling, 70E, F, G and H, rotate freely upon conventional bearings about their respective axles 67A. Sleeves 240A and B, in turn, cooperate with dead axles 67A of each pneumatic tire stabilizer assembly 225A to stabilize the position of the present invention along the ceiling of tank car 200.
As depicted in FIGS. 4-B, while drive axle 66A of pneumatic tire assembly 275A should preferably be constructed with a larger diameter than dead axle 67A of pneumatic tire stabilizer assembly 225A, in applications involving smaller vehicles like truck trailers and transport tankers, axles 66A and 67A may be substantially the same diameter. This, of course, is due to the particular embodiment of the present invention being adapted to a smaller-sized vehicle.
Referring now to FIG. 5, in accordance with the present invention, K-frame assembly 140 is releasably connected to swivel support 61 of X-frame assembly 68 by hammer-on quick connect 11. More particularly, hammer-on connector 11 is preferably a pipe fixture that serves as a support and a conduit for high pressure water. As depicted in FIG. 6, K-frame assembly 140 is configured essentially in the shape of a letter "K" formed by frame 9, flying arms 7 and 8, and link arms 5 and 6. Accordingly, attachment 140 is referred to herein as "K-frame assembly." As will be hereinafter described in detail, in accordance with the present invention, to perform cleaning and stripping heretofore unknown in the prior art, this K-frame assembly is caused to vary its configuration of this plurality of arm means from the K-formation shown in FIG. 6 to the extended configuration shown in FIG. 8 to the compressed configuration shown in FIG. 7.
Referring to FIGS. 5-8, during all cleaning and stripping operations, K-frame assembly 140 rotates about an axis defined by water conduit 10. As will become evident to those skilled in the art, when engaged to process the bulkheads or end walls of a tank car, K-flame assembly 140 starts in its compressed configuration shown in FIGS. 5 and 7, and rotates horizontally about this axis. Included in this rotation action is water conduit 10 and attached connector 11, but excluded therefrom is actuator drive gear assembly 1. Under the present invention, drive gear assembly 1 remains engaged to swivel support 61 as K-frame assembly 140 rotates about its transverse axis. Thus, every member comprising K-frame assembly 140 depicted in FIGS. 6-8 rotates about water conduit 10 except drive gear assembly 1.
As specifically shown in FIG. 14, an enlarged frontal view of actuator drive gear assembly 1 which is depicted in FIGS. 5-8, this drive gear assembly comprises drive gear 156 and drive arm 154. In accordance with the present invention, and now referring to FIGS. 6-8 and 14, when actuator driven gear 2 is meshed with stationary drive gear 156 of drive gear assembly 1, actuator screw 3 is caused to turn, thereby advancing actuator yoke 4. As will become clear to those skilled in the art, through a linkage provided by actuator drive gear assembly 1 and clutch 46 (see FIG. 11 ), every revolution of K-frame assembly 140 incrementally propels yoke 4, thereby gradually increasing or decreasing the radius of water spray emanating from nozzles 160A and B. For example, if yoke 4 is propelled toward the end portion of actuator screw 3 adjacent hinge 15A, as depicted in FIG. 7, then the radius of water spray is a gradually decreasing spiral pattern. On the other hand, if yoke 4 is propelled toward the end portion of actuator screw 3 adjacent hinge 15B, as depicted in FIG. 6, then the radius of water spray is a gradually increasing spiral pattern. The engagement of stationary drive gear 156 to X-frame assembly 68 via clutch 46 causes driven gear 2 to turn from its posterior side. That is, driven gear 2 is engaged with and tracks over drive gear 156 based upon the hereinbefore referenced linkage.
As will be described in detail, advancing yoke 4 along actuator screw 3 causes a plurality of interconnected arm means to be either pushed or pulled, in coordinated fashion, whereby the spiral spray emanating from nozzles 160 A-B is regulated. In particular, advancing yoke 4 along actuator screw 3 pushes or pulls lead link arm 6, which, in turn, corresponding pulls or pushes lead flying arm 7, which, in turn, causes corresponding movements in drag link ann 5 and drag flying arm 8. In accordance with preferred embodiment of the present invention, flying arm 7 leads the movement of K-frame assembly 140 wherein the spray coverage emanating from pair of nozzles 160A-B is regulated. Flying arm 8, which is preferably configured to be smaller than flying arm 7, follows the lead thereof. Flying arm 8 is preferably welded to drag link arm 5 by transversal 13. Flying arm 7 is pivotally attached to drag link arm 5 by hinge 17 and also pivotally attached to lead link arm 6 by pivot pin 6b. Drag link arm 5 remains a set length serving as a retractor of lead flying arm 7. On the other hand, the length of lead link arm 6 and the point of its connection 6b lead flying arm 7 can be either shortened to speed up the cycle or lengthened to slow down the cycle. More particularly, lead link ann 6 is pivotally attached to lead flying arm 7 at 6b and is pivotally attached to actuator yoke 4 at 6a. Thus, by controlling the length of lead link arm 6, the width of a pattern of spiral lines described by spray emanating from nozzles 160A-B may be regulated.
It is also within the teachings of the present invention that the inherent speed of movement of flying arm 8 in response to the movement of flying arm 7 may be controlled by the placement of pivot pin 6b along flying arm 7. Thus, in an alternate embodiment of the present invention, flying arm 7 may be constructed with a plurality of holes or the like to pivotally receive link arm 6. For example, if link ann 6 is rotatably attached to flying arm 7 by moving 6b closer to the nozzle-end thereof, the movements of K-frame assembly 140 are reduced. As another example, if link arm 6 is rotatably linked to flying arm 7 by moving 6b closer to pivot pin 16B, the movements of the K-frame assembly are accelerated.
K-frame assembly 140, when positioned near the bulkhead of a tank car, preferably produces a water spray with a spiral coverage of approximately 200°, corresponding to overlapping 90° coverage of each nozzle. Actuator yoke 4 preferably includes split nut 158 that can be loosened for quick adjustment of the position of flying arm 7 and 8.
As shown in FIG. 8, retracting flying arms 7 and 8 into the full spread position makes it possible to clean and strip the side walls of a tank car and the like. The versatility of the design inherent in the present invention provides several advantages heretofore unknown in the art. Since the preferred axis of rotation of the present invention is the theoretical center of a cylinder or tank car, it should be set up at a predetermined distance from the bulkhead or end wall thereof. After X-frame assembly 68 is properly installed therein with eight pneumatic tire assemblies and K-frame assembly attached thereto, split nut 158 of actuator yoke 4 is loosened and yoke 4 is repositioned at a point on actuator screw 3 that holds flying arms 7 and 8 in the position aiming their nozzles 160A and B, respectively, at the center of the bulkhead or end wall. In accordance with the present invention, the stream of water emanating from nozzles 160A and B converge at this point. Then, once cleaning and counter-clockwise rotation of K-frame assembly 140 begin, this water spray describes a path of ever-increasing spiral from the center configuration (see FIG. 7) to the full spread configuration (see FIG. 8), covering every square inch of the end wall. Nozzle supports 14A and B are manually adjustable to accommodate different diameter tank cars and the like.
When the full spread position depicted in FIG. 8 is reached, the meshing of drive gear 156 and driven gear 2 is disengaged and control mechanism 36 (FIG. 11) is engaged as will be hereinafter described in detail, thereby changing the mode of operation of the present invention from the stationary brake mode to the tracking mode. Under the present invention, once the treatment of the bulkhead is completed, with a concentrated water spray, the K-frame is configured in its extended configuration, as depicted in FIG. 8, whereby it commences to linearly track toward the middle of the tank car, treating the interior side wall and concomitant top and bottom surfaces thereof. Thus, it is an advantage and feature of the present invention that a longitudinal half of a tank car can be processed automatically, once properly positioned therein, as has hereinbefore been described in detail.
In accordance with the teachings of the present invention and referring to FIGS. 2, 5 and 11, during cleaning and stripping of a tank car's end walls or bulkheads, the functions performed by actuating K-frame assembly 140 are preferably accomplished by engaging clutch 46 with actuator drive gear assembly 1. This engagement is typically set manually at the beginning of the cleaning and stripping process. Clutch base 55 is mounted over swivel 62 on swivel support bracket 61. Flying arms 7 and 8 of K-frame assembly 140 are also manually adjusted to point to the center of the bulkhead, actuator yoke 4 is locked in place and clutch 46 is engaged with actuator drive gear assembly 1. Actuating K-frame assembly 140 by rotating counter-clock,vise changes its configuration from a compressed center position depicted in FIG. 7 through an intermediate position depicted in FIG. 6 into a full spread position depicted in FIG. 8. In accordance with the teachings of the present invention, as has been explained hereinbefore, this configuration change can be accomplished by varying the speed of rotation of the K-frame or by varying the rate of actuation. For stripping rubber off the interior lining of a railroad tank car for example, 300 to 400 revolutions are typically required. As another example, to clean such linings typically takes from 150 to 300 revolutions. It is an advantage of the present invention that such operations, even at the lowest speed of rotation, nominally consume only about one hours' time. For comparable stripping and/or cleaning in the prior art, typically one man-day is required to complete this demanding task. Furthermore, using the methodology and apparatus known to those skilled in the art produces less reliable cleaning and stripping results. This, of course, is due to the absence of inherent regularity provided by an automatic procedure like the present invention.
Referring again to FIG. 11, once actuator yoke 4 contacts release arm 49, it causes ann 49 to turn, which thereby causes associated release pawl 52 to be dislodged from pawl post 53. Release arm spring 48 then pulls release arm 49 through release arm slide mount 51. As should be understood by those skilled in the art, the impact of release actuator 54 upon eccentric striker 56, in turn, releases eccentric grab member 50 imposed on clutch 46. Clutch return spring 47 disengages clutch 46 from actuator drive gear assembly 1 and engages air supply mode valve 36, thereby transferring air supply from brake caliper 23 to air valve alternator 43. This, of course, releases the static hold on the present invention and then distributes air in sequence as the tracking mode taught by the present invention begins. This fulfills the unique "head-to-half" process provided by the present invention wherein substantially a longitudinal half of a tank car or the like is cleaned and stripped automatically once it is properly installed therein.
Referring now to FIGS. 9 and 10, the structure and function of swivel assembly 62 may be described in detail. In particular, in FIG. 9 there is shown a partial cut-away frontal view of swivel assembly 62. FIG. 10 is a cut-away left side view, along line 9--9, of swivel assembly 62 depicted in FIG. 9. Swivel assembly 62 comprises swivel shaft 72 disposed axially of swivel cylinder 76, contained within bore hole 168 and supported by end plates 73A and B, which are fixedly attached by four elongated bolts 71A, B, C and D. In accordance with the present invention, swivel assembly 62 rotates under high pressure and discharges high water volume during cleaning and stripping. For example, swivel assembly 62 typically operates as will be hereinafter described, at pressures of 10,000 psi at water volumes exceeding 100 gallons per minute. Water enters swivel cylinder 76 through induction hole 80 which is drilled normally into shaft 72 which is axially contained within bore hole 168. The water then passes along shaft 72 to end portion thereof 164. Opposite end 166 of swivel cylinder 76, contrary to end 164, contains no bore hole and thus is inherently sealed.
Swivel shaft 72 is turned by hydraulic motor 45 (see FIG. 12). As should be apparent to those skilled in the art, subject to water pressures and volumes as hereinbefore described, swivel assembly 62 must withstand significant forces, and, indeed, must operate reliably and automatically within a tank car and the like. As should be clear to those skilled in the art, there are equal forces on each longitudinal side of induction hole 80, which tend to neutralize each other. To neutralize the intense thrust exerted particularly on swivel shaft 72, swivel assembly 62 includes packing 75 positioned on all sides of induction hole 80. Packing 75 may be Chevron-shaped sealant material which is commonly used in the hydraulics art. Another suitable material is UTEX non-adjustable plunger packing. In addition, especially in the absence of conventional thrust bearings, swivel assembly 62 is constructed with bushings 74A and B which preferably comprise solid brass rotation bearings to provide advantageous wear capabilities. Specifically referring to FIG. 9, it is seen that swivel support plates 73A and B are preferably configured squarely to provide adequate mounting surface within swivel support bracket 61.
Now referring to FIG. 12, there is seen reciprocating drive 150 which, in accordance with the present invention, enables X-frame assembly 68 with eight tire assemblies attached thereto as hereinbefore described, to track or move horizontally and longitudinally along a tank car's interior at suitable speeds without using a multitude of gears as is common in the art. In addition, reciprocating drive 150 enables tracking speed to be changed without concomitant changes of the speed of rotation of sprayer nozzles 160. Thus, by simply loosening and sliding eccentric adjust 28 (see FIGS. 5, 12 and 15) to provide a longer or shorter throw, i.e., longer or shorter advancement of the present invention along the bottom of a tank car and the like, concomitant with a given rate of rotation, tracking speed is conveniently changed.
As shown in FIGS. 5 and 12, rotation of sprayer nozzles 160 is effectuated by hydraulic motor 45 which is fixedly connected to swivel shaft 72. The tracking of the present invention, heretofore unknown in the prior art, is accomplished by inherently synchronizing its rotation and linear tracking. As particularly shown in FIGS. 13 and 15, this synchronization is provided through 1-to-1 meshing of power take-off gear 30 with accessory drive gear 29.
During the usual initial phase of cleaning and stripping of a tank car, tracking is suspended while the bulkhead is being cleaned and stripped. Hence, it is necessary to maintain the speed of rotation of sprayer nozzles 160, but without altering the established location of supporting X-frame assembly 68 on the tank car floor. It is an advantage and feature of the present invention that it affords controls providing the prerequisite capability to quickly and effectively switch from a rotation, non-tracking mode, i.e., holding mode, to a rotation, tracking mode without any pause in rotation.
Referring to FIGS. 3A-B and 12, drive disc 18 is positioned in the center of the preferred embodiment of the present invention disposed on the same rotational axis, pivot pin or axle 19, as X-frame assembly 68. It is an important feature and advantage of the present invention that drive disc 18 is independent and can spin relative to pivot pin 19, from within the confines of the frame assembly. Attached fixedly on each side of drive disc 18 and parallel thereto are drive sprockets 20A and B (not shown). Roller chains 24 run from sprockets 20A and B to corresponding sprockets 57A and B disposed normally on sleeves 290A and B, which in turn cooperate with pneumatic tire drive axles 66A and B as hereinbefore described. Thus, rotating drive disc 18 causes drive axles 66A and B to rotate.
Under the present invention, drive disk 18 is preferably rotated using air calipers as will be described in detail. Air calipers 21 and 23 have built-in air cylinders which, when supplied with air, clutch or grasp drive disc 18. More particularly, drive caliper 21 and brake caliper 23, in conjunction with built-in air cylinders 22A and B, are designed to be independent of both pivot shaft 19 and drive disc 18, but nevertheless pivot about the same axis thereof. Brake caliper 23 is anchored to X-frame assembly 68 through anchor point 25.
As will become clear to those skilled in the art, brake caliper 23 provides stability to the present invention not only during air-feed through air line 39, but also during air-feed through alternating air line 40. In particular, with a constant flow of air through air line 39, brake caliper 23 holds the present invention against the nozzle thrust encountered during cleaning and/or stripping of tank bulkheads and the like. On the other hand, with an alternating flow of air through air lines 41 and 42, brake caliper 23 holds the present invention during the tracking mode while the reciprocating action of drive caliper 21 is retracting. Conversely, brake caliper 23 releases to allow charged caliper 21 to advance drive disc 18. As should be evident to those skilled in the art, the length of this advancement is preselected at eccentric adjust 28. Ergo, while brake caliper 23 functions in a static hold-mode, drive caliper 21 functions in a dynamic rotation-mode.
In accordance with the present invention, during a typical cleaning and stripping operation, referring specifically to FIGS. 13 and 15, there occurs a constant reciprocating motion orchestrated through drive push rod 26 depending from drive eccentric base 27 and associated eccentric adjust 28. Preferably, during the fixed mode of the present invention, air supply is held constant onto brake caliper 23, thereby preventing its motion. K-flame assembly 140 retracting into full spread position, as depicted in FIG. 8, will mechanically shift air supply mode valve 36 into the tracking mode, releasing air from brake caliper 23 and simultaneously redirecting air to air valve alternator 43 which senses the direction of motion of drive push rod 26, thereby alternately sending air to the appropriate caliper. As should be clear to those skilled in the art, this alternating air flow provides a pull-hold-pull-hold action. Similarly, by sending air through sequence reversing valve 35, the same alternating impulses from air alternator valve 43 are sent to the opposite caliper. This air flow effects a reversal of the direction of tracking from a pull-hold action to a hold-push action.
Referring now to FIGS. 12 and 15, in accordance with the present invention, sensing the direction of the motion of reciprocating push rod 26 is achieved by alternating air valve 43 in conjunction with resistor lever 34. The resistance force provided by lever 34 compels sliding rods 32 and 33 to engage the plunger of valve 43, one way under push mode and the opposite way under pull mode. As will be understood by those skilled in the art, the resistance of lever 34 cannot be spring-loaded, but must be applied by friction thereby providing uniform resistance at any position thereof. As will also be understood by those skilled in the art, this quantum of resistance should preferably only exceed the resistance inherent in the actuation of the said plunger of alternating air valve 43 under normal air pressure therein.
It should be apparent to those skilled in the art that a particular advantage of reciprocating drive 150 is the ability to track in the same direction independently of the direction of rotation. Obstructions which interfere with the current direction of rotation can be overcome by simply reversing the rotation, without disturbing the linear tracking of the present invention along the tank car floor. By applying a series of reversals of rotation, such obstruction can be conveniently circumvented and, of course, with the present invention simply tracking in the same direction. Thus, it is a feature of the present invention that by translating rotational motion to reciprocating motion, as hereinbefore described in detail, directional tracking in is inherently negatived; the push-pull behavior characterizing the present invention is independent of the direction rotation.
This synchronous relationship between rotation and tracking has been heretofore unknown in the tank car cleaning and stripping art. With conventional cleaning and stripping apparatus, unforeseen interference or cessation of nozzle rotation, has no affect upon tracking, because rotation and tracking are unsynchronized. Accordingly, under such adverse circumstances, an attendant must stop the apparatus' operation and back-up the apparatus due to ineffective cleaning or stripping which has transpired during the erratic rotation. On the other hand, in accordance with the present invention, when such anomaly with rotation occurs, changing the direction of rotation is typically sufficient remedial action. For example, during rubber-stripping occasionally rubber remnants hang down from the ceiling or accumulate on the floor of a tank car. It is observed in practice that a nozzle that is hung-up because of accumulation of debris or the like, is usually freed therefrom by a mere change in rotational direction. If, however, an obstruction is caused by a fixture inside a tank car, and particularly if the nozzle-surface distance must be sustained for effective cleaning and/or stripping, using the present invention, reversing the direction of rotation will at least partially free-up its nozzles, so that tracking will continue provided partial rotation achieves the length of the synchronized push or pull cycle, namely 180°.
It should be evident to those skilled in the art that partial tracking can nevertheless occur under the present invention even if rotation is less than 180°, depending upon the nozzle positions relative to the push rod. Furthermore, it is an advantage of the present invention that even if the nozzles cease rotation on both sides of such a fixture/obstacle, reversing direction of rotation sustains uniform cleaning and stripping in the vicinity thereof. Of course, once the present invention traverses the fixture/obstacle, normal single-directional rotation resumes. It is another advantage of the present invention that its synchronized rotation-tracking relationship uniquely requires tracking to await (reversal of) rotation whenever interference or cessation of rotation occurs.
Other variations and modifications will, of course, become apparent from a consideration of the structures and techniques hereinbefore described and depicted. Accordingly, it should be clearly understood that the present invention is not intended to be limited by the particular features and structures hereinbefore described and depicted in the accompanying drawings, but that the concept of the present invention is to measured by the scope of the appended claims herein.
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An improved apparatus and method for cleaning and stripping residue, contaminants, debris. etc. from all of the interior spaces in a railway tank car and the like. The present invention may be conveniently lowered into a tank car through its manway and, after quick assembly thereof, pneumatically configured to accommodate the physical dimensions of the tank car, and then be preset for automatic cleaning and/or stripping operation. A means is provided which inherently coordinates and synchronizes the cleaning and stripping of virtually every internal surface contained in a tank car. The preferred embodiment comprises a X-frame assembly having a pair of corresponding X-members which are attached by an axle disposed therebetween. Pivotally attached to this X-fame assembly is a swivel support assembly which receives a K-frame assembly comprising a plurality of arm means, linkage means and spray means spraying all of the interior surfaces of a tank car.
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BACKGROUND OF THE INVENTION
This invention relates generally to digital display apparatus, and particularly relates to such apparatus having means for minimizing the jitter which may otherwise occur in the last digit.
A digital speedometer has certain obvious advantages over a conventional instrument with a pointer because it presents data to the observer in a form which is easily read and which is unambigious. Thus instead of having to estimate the precise speed it can now be read in exact numbers. This applies to any digital display whether it is a speedometer, a frequency counter, an event counter or the like. In other words, it applies to any apparatus which digitally displays pulses having a variable repetition rate.
The digital speedometer may, for example, form part of a digital speed control system. Such speed control systems have become well known in the art, an example being the patent to Carol, Jr. et al., U.S. Pat. No. 3,599,154.
The jitter in a digital speedometer may be caused by the fact that the speed pulses representative of the speed of the vehicle are by necessity not synchronized with the clock pulses which control the operation of the system. Even if the speed pulses were synchronized with the clock pulses, this would only apply to one particular speed. The result is that even if the speed is constant the last digit is subject to jitter, that is the last number may vary at random between say three and four or two and three.
The jitter may also be caused by a backlash in the gear drive train which acts as the speed pulse generator. This may cause variations in the pulse rate even if the speed is constant.
Even if the actual speed of the vehicle is not actually constant, minimizing of jitter or rapid change of the last displayed digit would be useful. This is particularly true when an automobile, for example, accelerates or decelerates.
It is accordingly an object of the present invention to provide an improved digital display apparatus having means for minimizing the jitter of the last displayed digit which may otherwise occur.
SUMMARY OF THE INVENTION
A digital display apparatus in accordance with the present invention includes means for generating pulses indicative of a characteristic to be measured. These pulses which may, for example, be speed pulses in the case of a digital speedometer, are fed to a counter. After a predetermined period of time which is controlled by a time base and logic means, the number stored in the counter is transferred by transfer means or gates to a storage register. Finally, a digital display is coupled to the storage register for displaying the number transferred into the storage register.
So far the system described is entirely conventional. In order to minimize the jitter additional means are provided between the pulse generator and the counter. Preferably, this means consists of a precounter which may consist of one or more flip-flops. There may further be provided an AND gate having an input coupled to one of the outputs of the flip-flop and to the logic means for controlling the transfer means. This is so arranged that the transfer means can only transfer the number stored in the counter into the storage register when the precounter flip-flop is in the zero state where Q is false and Q is true.
In some cases it may be desirable to provide a larger precounter in the form of two slip-flops in series. This will provide an even larger control of the jitter. In other words, the last digit will only change if the variation of the input pulses is greater than a predetermined amount as will be more fully explained hereinafter.
The novel features that are considered 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, as well as additional objects and advantages thereof, will best be understood from the following description when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing in block form of a digital speedometer embodying the present invention;
FIG. 2 is a sectional view on enlarged scale of a magnetic pickup device for generating speed pulses representative of the speed of a vehicle; and
FIG. 3 is a schematic drawing similar to that of FIG. 1 and illustrating another embodiment of the present invention permitting even greater control of the jitter of the display device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like elements are designated by the same reference characters and particularly to FIG. 1, there is illustrated in block form a digital display apparatus including means for minimizing the effects of jitter in accordance with the present invention. The digital display of FIG. 1 may form part of a digital speed control as mentioned before. However, FIG. 1 only illustrates a digital speed display.
The apparatus of FIG. 1 includes means for generating speed pulses indicative of the speed of the vehicle or in general of the number of events to be counted or a frequency to be determined. The mechanism for generating speed pulses is generally shown at 10 and may include a gear 11 connected to the drive train of the car. There may also be provided a pickup such as a magnetic pickup having a magnetic shaft 14. The details of an exemplary pickup will be more fully explained hereinafter in connection with FIG. 2. However, it will be realized that such speed pulse generating means are old in the art. The speed pulses are developed by the pickup 12 and may be amplified by an amplifier 15.
Conventionally the speed pulses are now applied through a lead 16 to a counter 17 into which they are fed in serial fashion. The counter is controlled by a time base or clock 18 through a control logic 20 connected thereto. After a period of time which may be referred to as a clock period the counter 17 is reset by applying a pulse through a lead 21 to its reset input.
By means of gates 23 the number of pulses stored in the counter 17 are transferred to a storage register 24. The transfer from counter 17 to storage register 24 by the gates 23 is controlled by a lead 25 from the control logic 20. Thus an instant before the counter 17 is reset the number stored in the counter 17 is transferred in a parallel fashion through the gates 23 to the storage register 24.
This process repeats periodically, once during each clock period. The number stored in the storage register 24 is then displayed by a suitable display device 26 which will permit a digital readout of the speed. Such displays are well known in the art and may consist of light emitting diodes or other well known light emitting elements which can be controlled by the display 26. An example of these is found in any electronic calculator.
What has been described so far is a conventional digital speed display. As explained previously, such a speed display may have a certain amount of jitter. Thus, the speed pulses are not synchronized with the clock pulses which are controlled by the time base 18. Accordingly, the last digit of the display may constantly vary by one unit up or by one unit down from the real value.
Thus, assuming that the speed is 60 mph the variation may be 60 ± X, where X is 1. As previously explained, this may also be caused by a backlash in the gear train represented by the gear 11.
In accordance with the present invention this jitter is minimized by the provision of a precounter flip-flop 30 having an input terminal 31 connected to the lead 16. In other words, the speed pulses are impressed on the input of the flip-flop 30. The flip-flop 30 has a true output Q which is connected by lead 32 to the counter 17. This will clock the counter.
In accordance with the present invention there is further provided an AND circuit 34 having one input connected to the lead 25, that is one input is controlled by the control logic 20 to transfer the number in the counter 17 to the storage register 24. The AND circuit 34 has a second input connected by lead 35 to the false or Q output of the flip-flop 30. As a result the AND gate 34 is only opened when the total number of speed pulses during the clock period is even so that the Q output becomes 1. This will enable the AND gate 34 to cause a transfer of the numbers stored in the counter 17 to the storage register 24 at the time the control logic 20 places a signal representation of a 1 on transfer control line 25.
It will be realized that this requires either a larger number of speed pulses or a longer clock period to provide the desired display. Thus assuming again a speed of 60 mph which normally requires say 60 speed pulses during each clock pulse period, due to the provision of the flip-flop 30, the number of speed pulses in a clock pulse period must now be 120. The jitter at 60 mph which is 60 ± X is now reduced because X is 0.5 mph. An extra speed pulse during the clock period will inhibit transfer of data to the storage register and the display will not jitter.
Referring now to FIG. 2, there is shown by way of example a pickup suitable for the system of FIG. 1. The magnetic shaft 14 cooperates with the teeth of the gear 11. The shaft 14 is surrounded by a cup-shaped housing 37 of magnetic material. The lines of force are shown at 38 and issue from the cup-shaped housing 37 through the gear 11 back into the shaft 14 which closes the magnetic circuit. The magnetic circuit is periodically interrupted every time a tooth moves away from the shaft 13. This magnetic discontinuity is picked up by the coil 40 surrounding shaft 14 to derive an output pulse between the output leads 41 which may be connected to the amplifier 15. The pulse generator of FIG. 2 is only shown as an example, such generators being known in the art.
In some cases it may not be sufficient for minimizing the effects of jitter to have only a single flip-flop 30. This may, for example, be due to random variations in the times between successive pulses. This in turn may be due to drive train backlash or the like. In such a case the embodiment of the invention illustrated in FIG. 3 may be used. Here a second flip-flop 45 has been provided ahead of the flip-flop 30 to form a two bit precounter. The speed pulses are impressed by lead 16 on the input of the flip-flop 45. Its Q output is impressed by lead 46 on the flip-flop 30. Additionally, the Q output of flip-flop 45 is impressed by lead 47 on the AND circuit 34 which now has three inputs.
The circuit of FIG. 3 operates generally in the same manner as does that of FIG. 1. However, the number of speed pulses obtained from lead 16 is now divided by 4. Therefore, in the example previously discussed of a speed of 60 mph, the number of speed pulses per clock pulse period must be 240. As explained before this can either be effected by increasing the number of the teeth of the gear 11 or by increasing the clock pulse period. In any case the gates 23 can only be energized to transfer the number in counter 17 to the storage register 24 when both Q outputs of the two flip-flops 45 and 30 are 1 and if the transfer pulse is present. In this case the jitter is minimized because if the jitter is now 60 ± X, X can be as great as 0.75 mph without affecting the display 26. In other words, if the number of speed pulses during the clock period varies anywhere between 237 and 243, the speedometer will consistently display 60 mph and the storage register will be refreshed only when the number of speed pulses equals 240.
There has thus been disclosed a digital display apparatus such as a digital speedometer having means for minimizing the effects of jitter on the last display digit. This is accomplished by the provision of a precounter ahead of the counter of the digital display. The precounter may consist of one or more flip-flops in series. This will in effect divide the number of incoming pulses by a factor of 2 N , where N is the number of flip-flops in the precounter so that in conjunction with appropriate gating jitter is minimized even if the speed varies slightly or if the nonsynchronism between the pulses to be displayed and the time base becomes large.
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A digital speedometer, frequency or event counter with digital display. The speedometer conventionally receives speed pulses representative of the speed of the vehicle. Due to the lack of synchronization between speed pulses and clock pulses the last display digit exhibits undesirable jitter. This may also be caused by backlash in the drive train or the like. This jitter is minimized by the provision of a precounter between the counter and the gate transfer to a storage register. This will permit transfer of the number generated in the counter only if the precounter is in the zero state, thus minimizing the jitter due to random occurrences of the last pulse.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] The present application derives priority from U.S. provisional application Ser. No. 61/214,448 filed Apr. 23, 2009.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention generally relates to fishing products and, more specifically, to a free spool controller for a fishing reel.
[0004] 2. Description of the Background
[0005] Sailfish and marlin are among the most prized sport fishing trophy fish in existence, largely because they fight aggressively, launching themselves out of the water over and over again. However, catching a sailfish and/or marlin is no simple task. It takes great finesse. Typically, a heavy duty lever-drag reel is spooled with over 400 yards of 20-30 pound test monofilament, and ballyhoo, pilchards, threadfin herring or goggle eyes are used as bait. The bait may be drifted, slow trolled or fished from a kite, and in all such cases the reel is generally kept in a normal drag position until a fish strikes. Both sailfish and marlin are notoriously sensitive when they first take the bait. Just the slightest tug on the line when the fish comes upon the bait can result in them mouthing it, and then dropping it. For this reason, most anglers immediately release the reel drag to free spool with the clickers on, or with the bail open. The fish will pull the line in free spool as it runs with the bait, and it will not be pulled out of its mouth. However, within 5-10 seconds of the strike, the drag lever must be returned to the strike position and the hook set, or chances are that the fish will escape. This precisely-choreographed sequence sounds easy, but is very difficult to implement in practice. Sailfish and marlin tend to strike when the anglers are sitting around relaxing, and many are lost because the anglers are slow to the rod. This problem is especially acute for elderly anglers who are not as spry and cannot always jump to the rod within seconds of a strike. It would be helpful to automate the process of switching modes from drag to free spool and back, within a set interval after the fish strikes. While there have been prior efforts to electrically-control a fishing reel, none are for the foregoing purpose.
[0006] U.S. Pat. No. 7,188,793 to Takeshi Ikuta issued Mar. 13, 2007, shows an electric circuit for controlling a fishing reel spool, primarily to prevent backlash. A rotor having four magnets is disposed on the spool's shaft, and surrounding the rotor are coils. This rotor assembly is used to both generate electricity and brake the spool.
[0007] U.S. Pat. No. 6,045,076 to John J. Daniels issued Apr. 4, 2000, shows an anti-backlashing fishing reel. A line sensor generates a signal based upon the tension in the line to control the electronically variable brake. Depending upon the signal, the variable brake will apply a force to the spool to resist rotation to prevent an overrun.
[0008] U.S. Pat. No. 5,831,417 to John Wun-Sing Chu issued Nov. 3, 1998, shows electronic circuitry that takes input data, such as the outside diameter of the spool, the tension in the line, and the length of the released line, to determine whether the drag should be increased or decreased. The drag mechanism is engaged through constricting forces created by SMA wire that is controlled by the electronic circuitry.
[0009] U.S. Pat. No. 4,940,194 to John N. Young issued Jul. 10, 1990, shows casting reel with a dynamically controlled variable casting drag. A magnetic disc is connected to the spool shaft, and when the disc rotates with the shaft, an electrical coil produces an output signal. An electric circuit receives the signal and produces a drag signal based on the output signal, and the drag signal is used to control an electronic brake.
[0010] U.S. Pat. No. 4,790,492 to Takashi Atobe issued Dec. 13, 1988, shows a reel having a revolution sensor device. The device includes magnets located on the spool and Hall effect sensors opposing the magnets. An on-board microcomputer uses the generated signal to calculate line length.
[0011] U.S. Pat. No. 5,219,131 to Furomoto issued Jun. 15, 1993 shows a fishing reel with electronic drag measurement for notifying the user of the exact braking force of a drag mechanism.
[0012] U.S. Pat. No. 6,412,722 to Christopher K. Kreuser et al. issued Jul. 2, 2002, shows a bait cast fishing reel having a sensor to generate signals representing rotation of the spool. The sensor is coupled to a controller. Using the spool rotation signals, the controller generates a control signal that is transmitted to the breaking mechanism. The breaking mechanism comprises an electric solenoid that engages a brake pad with the spool when casting to prevent backlash.
[0013] None of the foregoing references nor any other known prior art suggests an automatic electronic drag/free spool control system that is capable of incorporation into an otherwise conventional lever-drag reel to selectively release, and then reapply drag a predetermined interval after a fish strike. FIG. 1 is an illustration of a conventional “big water” lever drag reel, and FIG. 2 details the internal spool, spindle and brake washer of FIG. 1 .
[0014] Such reels typically seat a rotatable spool 2 inside a unitary open frame 3 . The spool 2 is rotatably carried on a spindle 6 , and a hand crank 4 turns the spool 2 on the spindle 6 via an internal gear mechanism. A lever 5 allows preset of the desired drag from far left (0% drag) to far right (100% drag). As seen in FIG. 2 , the lever 5 extends and/or retracts the internal spindle 6 which in turn moves a brake washer 7 located at the opposing side of the reel, the brake washer 7 acting as a disc brake against the side of spool 2 . The brake washer 7 may be pre-biased toward the spool 2 by a spring or Belleview washer. When more drag is required, moving lever 5 clockwise retracts spindle 6 , thereby compressing the Belleview washer and biasing brake washer 7 harder against the spool 2 and requiring more pull to release line. When less drag is required, moving lever 5 counterclockwise extends spindle 6 , thereby easing off the brake washer 7 and requiring less pull to release line. The reel is set to free spool when the lever 5 is pulled all the way counterclockwise and all drag on the spool 2 is released. The reel is set to maximum drag when the lever 5 is moved fully clockwise from free spool position. Typically there is a spring-loaded (detent) button two thirds along the path of travel of the lever 5 , known as a strike button 9 . In addition, a stationary screw-post 8 acts as a stop demarcating the full free spool position. The reel is set to strike or “normal drag” when the lever 5 is moved clockwise from free spool position 8 and hits the strike button 9 . This is where anglers fight fish, and is designed to demarcate a drag setting equal to 33% of the line rating. If desired, the strike stop button 9 can be depressed allowing the angler to move the lever 5 forward to maximum drag, although max drag is typically higher than the line rating and results in broken fishing line. This is the basic footprint of a conventional lever drag fishing reel as referred to herein, although some conventional reels have equivalent free spool buttons in place of lever 5 . In practice, anglers will keep the lever 5 at the strike button 9 while trolling, kite fishing, or jigging. If a fish strikes, the angler must immediately place the lever 5 in free spool position 8 allowing the fish to run with the bait in free spool so as not to pull the bait out of its mouth. Then, within 5-10 seconds of the strike, the drag lever 5 must be returned to the strike position 9 and the hook set, or the fish will escape. This precisely-choreographed sequence is very difficult to implement in practice, especially if the anglers are seated at a distance and not as spry as they once were, or deep in conversation when the fish strikes.
SUMMARY OF THE INVENTION
[0015] It is, therefore, the primary object of the present invention to provide a free spool controller for a fishing reel that senses a fish strike, automatically places the reel in free spool mode, and then affords the angler a predetermined interval of free-spooling with a manual switch to free spool mode before automatically applying drag, thereby providing a safeguard if the anglers are not quick enough to jump up and manually set the drag.
[0016] It is another object to provide a free spool controller as above that can easily be incorporated into the footprint of a conventional lever drag fishing reel.
[0017] These and other objects are accomplished by an electronic drag/free spool controller incorporated into a fishing reel that has a transducer attached to the spool. When the spool spins the transducer generates a signal which is fed to a controller, and the controller determines if the spooling corresponds to a fish strike. When the transducer signal indicates a fish strike, an actuator automatically disengages the drag mechanism, placing the reel into a free spool position. This action allows the fish to run with the bait while the angler repositions himself to manually engage the drag to set the hook. If after a pre-determined interval the angler fails to manually engage the drag, the actuator will do so automatically.
BRIEF DESCRIPTION OF THE DRAWING
[0018] Other objects, features, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments and certain modifications thereof when taken together with the accompanying drawings in which:
[0019] FIG. 1 illustrates a conventional lever drag fishing reel (prior art).
[0020] FIG. 2 details the spool, spindle and brake washer of FIG. 1 (prior art).
[0021] FIG. 3 illustrates the entire reel assembly 1 in assembled form.
[0022] FIG. 4 is an exploded perspective view illustrating all the components of the fishing reel 1 with enlarged insets of individual components.
[0023] FIG. 5 is a block diagram of an exemplary control circuit for spool control circuit board 30 .
[0024] FIG. 6 is a diagram of the control scheme and switches S 1 , S 2 , S 3 and LEDs L 1 -L 3 mounted external to the reel 1 in master sleeve 13 for implementing the control scheme.
[0025] FIG. 7 is a side view of the master sleeve 13 A.
[0026] FIG. 8 is a composite drawing illustrating various views of the non-ferrous magnet disk 22 with a plurality of magnets 28 mounted in the non-ferrous disk 22 .
[0027] FIG. 9 is a close up view of an alternative motor-based braking mechanism.
[0028] FIG. 10 is a close up view of yet another alternative motor-based braking mechanism.
[0029] FIG. 11 illustrates yet another embodiment in which an electronic brake 200 operates directly on spool 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] The present invention is a fishing reel incorporating an automatic free spool control system. The free spool control system has at least two separate controls, one being ON or OFF, and one being AUTOMATIC or MANUAL Modes. When turned OFF, the reel functions as an ordinary reel. Thus, after a strike, the user will need to manually put the reel into free spool by moving the drag lever (ref 5 in FIG. 1 ) to free spool position 8 , or in case of some other control (e,g, a free spool button) by pushing down on that button or otherwise operating the free spool control. The reel will remain in free spool as long as the momentary free spool button or lever 5 is held in the free spool position. When the user releases the momentary free spool button or moves the drag lever towards drag, the reel returns to normal drag operation. Thus, when in OFF Mode the fishing reel of the present invention functions as a conventional big water lever drag fishing reel.
[0031] When the ON/OFF control is turned ON, the AUTOMATIC or MANUAL Modes offer two choices. When in ON/AUTOMATIC mode, the reel senses revolution of the spool when a fish strikes. It waits (in normal drag, typically at the strike stop button 9 of FIG. 1 ) until the reel has turned a programmable distance, and then the reel automatically enters free spool. The reel remains in free spool a programmable number of revolutions and, assuming the angler does not enter ON/MANUAL Mode, ON/AUTOMATIC mode automatically returns the reel to normal drag. This automates the entire process of switching modes from drag to free spool and back when a fish strikes.
[0032] This ON/AUTOMATIC Mode is interruptible by the ON/MANUAL Mode, which is essentially a manual override that momentarily prevents return of the reel to normal drag. Though various physical control schemes are envisioned for switching between these modes (as described below), three electronic switches accessible on the reel will suffice: a two position ON/OFF switch, a two-position AUTOMATIC Mode switch, and a momentary MANUAL Mode switch. This way, anytime the angler picks up the rod during the programmed free spooling time period in ON/AUTOMATIC Mode and depresses the momentary ON/MANUAL mode button, the reel enters ON/MANUAL Mode, which interrupts the ON/AUTOMATIC MODE countdown and maintains free spool for a longer duration of time. If the angler picks up the rod after the ON/AUTOMATIC Mode countdown when the reel has been returned to normal drag, and depresses the momentary ON/MANUAL mode button, the reel immediately enters free spool for as long the ON/MANUAL Mode button is depressed, thereafter returning to ON/AUTOMATIC Mode when the angler releases the ON/MANUAL Mode switch. In addition to the electronic modes the angler can manually go in and out of free spool anytime simply by depressing or releasing the existing reel free spool button/lever supplied with the reel.
[0033] Effectively, the combination of ON/AUTOMATIC MODE and ON/MANUAL modes afford a predetermined interval of free-spooling time for the angler to reach the reel and manually switch to drag mode, before the reel itself automatically switches to drag mode. This provides a safeguard in case no angler is quick enough to jump up and manually set the drag.
[0034] FIG. 3 illustrates the entire reel assembly 10 in assembled form, and FIG. 4 is an exploded perspective view illustrating all the components of the fishing reel 10 with enlarged insets of individual components. As seen in FIG. 3 , the reel assembly comprises certain components in common with typical big water lever drag spinning reels, and like components seen in FIGS. 1-2 are similarly numbered. These components include a unitary open frame 3 , a rotatable spool 2 inside the frame 3 , hand crank 4 and opposing side plate 11 with internal gear mechanism for turning the spool 2 about a spindle 17 . The spindle 17 is inserted through the center of the spool 2 and serves as a stationery axle. A gear wheel 18 is inserted onto the end of spindle 17 , and the gear wheel 18 is keyed to the spool 2 . The gear wheel 18 is a conventional component that engages an internal spring (not shown) simply to create a clicking noise and a minute but efficient amount of drag for indexing the position of the spool 2 . Turning the crank 4 one way rotates the spool 2 in a conventional manner similar to other existing fishing reels. Turning the crank 4 in the opposite direction is inoperative on the internal gear mechanism and has no effect. A brake washer 7 is mounted adjacent the spool 2 on spindle 17 . The brake washer 7 rotates with spool 2 , and applies a braking (drag) force to it as per the drag lever 5 described with reference to FIG. 1 . When the user wants more drag, they move drag lever 5 clockwise which biases spindle 17 , thereby forcing brake washer 7 harder against the spool 2 and increasing the braking drag. When the user wants less drag, they ease off drag lever 5 which biases spindle 17 thereby removing pressure. One skilled in the art will understand that additional components and slightly different components may be incorporated in side plate 11 . For example, many reels have clicking mechanisms to index rotation, etc. The present invention would not affect their operation. Indeed, one skilled in the art will recognize that everything to the left of line A-A′ may be considered conventional components found on conventional reels.
[0035] In accordance with the present invention, the reel assembly 10 also comprises a position disc 22 mounted on the spindle 17 and adapted to rotate with the spool 2 (enclosed between frame 3 and spool 2 ), and a drag/free spool controller circuit board 30 adjacent the position disc 22 but fixedly mounted within frame 3 and stationery relative to position disc 22 . The spindle 17 protrudes through spool controller circuit board 30 and terminates at the far end of a solenoid 34 . A metal hub 32 is slidably inserted between spool 2 and solenoid 34 . Solenoid 34 is commercially-available plunger solenoid with the metal hub 32 forming the longitudinally movable plunger and a toroidal coil body operable to move the plunger. The metal hub 32 may be spring-biased as is known with plunger solenoids, to bias the hub 32 back into the solenoid 32 . With this configuration, electrical activation of solenoid 34 pushes hub 32 and spindle 17 outward slightly (0.060″, though this distance may vary with different reels). This pushes the brake washer 7 , which is likewise attached to the spindle 17 on the other side of the spool 2 , out of its normal preset drag engagement with the spool 2 into free spool. The current system operates from a 12VDC power supply derived from the boats power main, though it is envisioned that a 12 VDC battery could be used for portability. The solenoid 34 is one exemplary mechanism for controlled shifting of spindle 17 along its axis in order to disengage the brake washer 7 , but other suitable linear positioning actuators exist. Alternative motorized embodiments are described below.
[0036] Given the linear actuator and mechanism for axially shifting spindle 17 , the present system adds the capability of knowing when to shift in and out of free spool. This is accomplished with the position disc 22 and the way that it interfaces the drag/free spool controller circuit board 30 . Position disc 20 forms a Hall-effect sensor with controller circuit board 30 . Specifically, position disc 22 is a flat circular washer having a particular pattern of very small permanent magnets 28 embedded therein. The position disc 22 faces the controller circuit board 30 which, in addition to power regulation and control circuitry (to be described), also provides a plurality of Hall sensors 27 on its backside in facing relationship with position disc 22 . The Hall sensors 27 are aligned with the rotation paths of the magnets 28 embedded in position disc 22 , and can thereby sense when a corresponding magnet 28 passes there beneath. Using a pattern of magnets 28 and Hall sensors 27 , the relative angular position of position disc 22 and hence the spool 2 can be accurately determined, and the rotation of the spool 2 can be tracked by controller circuit board 30 . Thus, the spool controller circuit board 30 is essentially an electronically-actuated automatic free spool controller that reads the position disc 22 and switches modes from normal drag to free spool and back dependent on its angular position and/or rotation. More specifically, the spool controller circuit board 30 senses the angular position and rotation of position disc 22 (and hence spool 2 ) and selectively activates solenoid 34 to disengage the brake washer 7 . The spool controller circuit board 30 includes control circuitry to do this in a predetermined sequence dependent on the selected one of three above-described modes. When OFF, no electronic control is exerted. When in ON/AUTOMATIC MODE, the spool controller circuit board 30 initially leaves the brake washer 7 in normal engagement as set manually using the drag lever 5 (see FIG. 1 ). However, when a fish strikes and peels away line, the spool 2 begins to rotate as does position disc 22 , and spool controller circuit board 30 counts a programmable first number of tics of revolution (for example, three full revolutions) and then automatically activates solenoid 34 to disengage the brake washer 7 , thereby entering free spool. The fish, which typically only mouths the bait and swims away, peels away line without drag (which would otherwise cause the fish to disgorge the bait). The spool controller circuit board 30 continues to monitor, counting a programmable second number of tics of revolution in free spool mode (for example, fifty full revolutions), and then automatically deactivates solenoid 34 to engage the brake washer 7 , thereby returning to normal drag. This automates the process of switching from drag to free spool and back, within set intervals after a fish strikes. The user always has the option of interrupting ON/AUTOMATIC MODE if they can reach the reel in time to extend the free spool duration before the reel itself automatically switches to normal drag, or if too late to switch back to free spool. This is done simply by depressing an ON/MANUAL mode switch, which interrupts the ON/AUTOMATIC MODE counting and, if necessary, immediately activates solenoid 34 to disengage the brake washer 7 , thereby returning to free spool for a longer duration. Again the ON/MANUAL mode control is preferably a momentary switch and when released the reel returns to ON/AUTOMATIC MODE counting. Consequently, the ON/AUTOMATIC MODE affords a predetermined interval of free-spooling time for the anglers and provides a safeguard in case no angler is quick enough to jump up and manually set the drag.
[0037] The system components which are not existing parts of the conventional lever drag reel are the position disc 22 , spool control circuit board 30 , hub 32 , solenoid 34 , master sleeve 13 and end cap 19 . In addition, the spindle 17 is elongated slightly to extend hub 32 into solenoid 34 , but is otherwise a conventional fishing reel spindle with rounded cross-section that serves as an axle for spool 2 .
[0038] The master sleeve 13 is custom manufactured to replace the existing reel side plate which is screwed onto frame 3 . The master sleeve 13 is a hollow cylindrical cover slightly longer than the existing manufacturer-supplied side plate in order to accommodate the position disc 22 , spool control circuit board 30 and solenoid 34 . The master sleeve 13 accepts a screw-on cap 19 to completely enclose the components. Note also the master sleeve 13 is machined with a plurality of side apertures for access to the mode control switches and viewing of mode-indicator LEDs (indicating the current operating mode) all resident on the spool control circuit board 30 . As described below, the number and function of the physical switches and LEDs may vary as a matter of design choice, and three switches S 1 -S 3 are shown in FIG. 4 along with three LEDs L 1 -L 3 according to one exemplary control scheme suitable for implementation of the embodiment of FIGS. 3-4 .
[0039] FIG. 5 is a block diagram of an exemplary control circuit for spool control circuit board 30 . The circuit board 30 includes at least one Hall Effect sensor 27 with outputs connected to a processor 110 . The Hall Effect sensor 27 in the illustrated embodiment may be an AH182 Low power Hall Effect Switch manufactured by Diodes Incorporated. If desired, two or more such Hall Effect sensors 27 may be used, and indeed in the presently preferred embodiment three Hall Effect sensors 27 are used to provide three separate pickups because this is necessary to determine spooling direction. The AH182 is a three-terminal Hall effect sensor device with a output driver, mainly designed for battery-operation. Power is supplied from a remote 12 VDC power source connected by a DC input connector to the circuit board 30 , and through an on/off power switch S 1 . An on-board voltage regulator supplies 3 VDC regulated power to the Hall Effect sensor(s) 27 and processor 110 . One skilled in the art will understand that voltage requirements may be adjusted as a matter of design choice. A surface mount power ON LED L 1 is also provided on circuit board 30 , and a connector for external power is provided. A PC-board mounted AUTO Mode ON switch S 2 is provided to set the controller to ON/AUTOMATIC mode, and a surface mount AUTO ON LED L 2 is also provided on circuit board 30 for indicating same. In addition, a PC-mounted MANUAL Mode ON switch S 3 is provided to set the controller back to ON/MANUAL mode, and a surface mount MANUAL ON LED L 3 is also provided on circuit board 30 for indicating same. The processor 110 performs, for example, counting and calculation, on the incoming Hall Effect tics. The basic elements that can be determined by the processor 110 are shaft speed, amount of rotation, direction of rotation, and time between events. All elements, except for direction, can be determined by using only one Hall sensor, whereas the latter requires two or three. Thus, in its simplest form the processor 110 counts a number of tics as the spool turns after a fish strike, and determines the number of tics needed to enter “free spool” mode and then back to normal drag. In this regard, the processor 110 may be any general-purpose or special purpose computer, such as, for example, a processor, a digital signal processor, a microcomputer, a field programmable array, a programmable logic unit (PLU), a microprocessor or any other device capable of performing the foregoing counting and responding to and executing mode instructions pursuant to the present method. The processor 110 may run software for implementing the method and functions described above. The processor 110 also may access, store, manipulate, process, and create data in response to these applications. The software applications may include a computer program, a piece of code, an instruction, or some combination thereof, for instructing the processor 110 to operate as desired. In addition, a more rudimentary digital counter and gate array may be used (functionally equivalent to a PLU). If desired, PC-board-mounted DIP switches may be provided on circuit board 5 and connected to processor 110 to allow factory or user-selection of the number of tics (or time interval) needed for drag-to-free spool and for free-spool to drag. This way, by setting a DIP switch the angler has a choice of however many revolutions are desired to allow line to spool out in drag mode before putting the reel in free spool, and then back again. The processor 110 also counts tics or times an interval before putting the reel back into drag mode. The PC-mounted DIP switches are preferably sealed inside the master sleeve, accessible by rubberized covers or by the angler taking off the master sleeve 13 .
[0040] FIG. 6 is a diagram illustrating three exemplary control schemes using various switches S 1 , S 2 , S 3 mounted on the circuit board 30 for implementing the control scheme.
[0041] In FIG. 6A , when the ON/OFF control S 1 is turned OFF, no power is applied, the ON/OFF LED L 1 remains off, and the reel is usable as normal with a manual lever drag and manual free-spool button. When the ON/OFF control S 1 is turned ON, power is applied, the ON/OFF LED L 1 illuminates, and the AUTOMATIC or MANUAL Mode switches S 2 , S 3 offer two choices of ON/AUTOMATIC MODE or ON/MANUAL MODE override. By depressing the AUTOMATIC mode ON switch S 2 , the AUTO ON LED L 2 illuminates, the processor 110 assumes control and senses revolution of the spool when a fish strikes. It waits (in normal drag) until the reel has turned a programmable first distance, and then the reel automatically enters free spool. The reel remains in free spool a programmable number of revolutions and then returns to normal drag. This automates the entire process of switching modes from drag to free spool and back when a fish strikes. However, this AUTO ON Mode is interruptible by depressing the MANUAL ON control S 3 , which is essentially a manual override to ON/MANUAL MODE as described above. The MANUAL ON LED L 3 illuminates, and the processor 110 relinquishes control to the angler. The MANUAL ON control S 3 is preferably a momentary switch that allows the angler to pick up the rod during the programmed AUTOMATIC free spooling time period, depress the momentary MANUAL ON button S 3 , and the reel enters ON/MANUAL Mode and free spools, returning to ON/AUTOMATIC Mode when the angler releases the MANUAL ON button S 3 . The angler can manually go in and out of free spool anytime simply by depressing or releasing the MANUAL ON button S 3 . This interrupts the ON/AUTOMATIC MODE countdown to maintains free spool for a longer duration of time, or if ON/AUTOMATIC Mode has already switch to normal the momentary MANUAL ON button S 3 will immediately force the reel to free spool for as long the button is depressed, thereafter returning to ON/AUTOMATIC Mode.
[0042] Effectively, the combination of AUTO ON S 2 and MANUAL ON S 3 modes afford a predetermined interval of free-spooling time for the angler to reach the reel and manually switch to drag mode, before the processor 110 automatically switches to drag mode. This provides a safeguard in case no angler is quick enough to jump up and manually set the drag.
[0043] In FIG. 6B , the control scheme is similar to 6 A but the AUTOMATIC ON and MANUAL ON switches S 2 , S 3 are consolidated in a single rocker switch S 2 which flips back and forth between AUTO ON Mode and MANUAL ON Mode. Operation is the same, and the angler can manually go in and out of free spool anytime simply by switching the button S 2 from MANUAL ON to AUTO ON.
[0044] In FIG. 6C , the control scheme is similar to 6 B but the AUTOMATIC ON and MANUAL ON switches S 2 , S 3 are consolidated in a single toggle switch S 2 which toggles back and forth between AUTO ON Mode/OFF Mode/MANUAL ON Modes. Operation is the same, and the angler can manually go in and out of free spool anytime simply by toggling the button S 2 from MANUAL ON to AUTO ON.
[0045] FIG. 7 is a side view of the master sleeve 13 illustrating placement of a plurality of through-bores for displaying LED indicators L 1 -L 3 mounted on the circuit board 5 described above, and for accessing the PC-mounted switches S 1 -S 3 . Three LEDs L 1 -L 3 are mounted behind clear acrylic waterproofed inserts at A, B and C, and these include the Power On LED (L 1 ), the Manual Mode ON LED indicator (L 3 ), and the Auto Mode ON Indicator (L 3 ) as shown in FIG. 6A . In addition, the Manual/Auto PC-mounted switches S 2 , S 3 and ON/OFF switch S 1 are mounted at P, Q and R behind rubberized waterproof covers. Another bore-hole at E is preferably provided with a surface-mount environmentally-sealed female receptacle for connection to an external power 12 VDC power source.
[0046] FIG. 8 is a composite drawing illustrating a front view (A) and side perspective view (B) of the non-ferrous position disk 22 with a plurality of magnets 28 mounted in the non-ferrous disk 22 . The disk 22 is a flat washer-like member with a central aperture and machined with a number of boreholes 62 patterned uniformly-spaced around the periphery. Each borehole 62 seats a magnet 28 in a facing relationship with circuit board 30 . As shown, the magnets 28 may be 0.125″ annular disks press-fit or glued into the corresponding boreholes 62 . In the illustrated embodiment, four sets of three magnets 28 are employed, the magnets 28 of each set being offset and positioned at different radii to form spiracle radii. Thus, for a reel requiring eighteen “clicks” to accomplish a complete revolution, the disk 8 is partitioned into eighteen 20 degree sectors, and the magnets 28 are spaced by 20 degrees with each set separated by a dead space. This way, each click of the reel corresponds to a Hall Effect tic. Of course, different reel models employ different click-measures of rotation and it is envisioned that the specific number and spacing of magnets will be driven by the particular reel for which it is designed. However, this multiple angularly-spaced magnet design offers a flexible programming capabilities to suit most commercial reels.
[0047] One skilled in the art will readily understand that any mechanical, optical or magnetic index-counting device may be used in place of Hall Effect sensor(s) 27 and position disk 22 for rotation/angular measurement of the spool 2 .
[0048] One skilled in the art should also understand that solenoid 34 is but one mechanism for controlled shifting of spindle 17 along its axis in order to disengage the brake washer 7 . Other suitable linear positioning mechanisms exist. For example, two motorized embodiments are described below.
[0049] FIG. 9 illustrates an alternate embodiment in which the solenoid 34 of FIGS. 3-4 is replaced by a small electric motor 134 and a translation gear assembly. The motor 134 is a standard 12 VDC electric motor such as, for example, Thomson P/N 21507A. In this instance the motor 134 shaft is equipped with a gear 136 . The distal end of the spindle 17 is equipped with a gear-driven linear actuator 100 for converting rotary motion of the motor 134 into the necessary 0.060″ displacement of spindle 17 . Rotation of the gear 136 turns a larger reduction gear 140 mounted on a hub 170 . The spindle 17 is slidably and rotatably carried in hub 170 , hub 170 including an end collar 172 mounted stationary within master sleeve 13 that provides a limited degree of axial movement for spindle 17 as shown. The actual linear displacement of spindle 17 is accomplished with a set of ramped camming discs 150 . One camming disc 150 B is affixed to the reduction gear 140 , and the other camming disc 150 A is affixed by a collar 160 to spindle 17 . Camming disc 150 B bears against camming disc 150 A via opposed inclined bearing surfaces, and as camming disc 150 B rotates relative to camming disc 150 A the opposed inclined bearing surfaces force the camming discs 150 A, 150 B apart. Counter-rotation allows them back together. This linear motion is transferred directly to the spindle 17 , and is used for selectively engaging or disengaging free spool in the manner described above relative to FIGS. 2-3 . The position disc 22 is identical to that described previously, and the spool control circuit board 30 is identical to FIG. 5 except that a motor driver is used rather than a solenoid driver.
[0050] Rather than camming discs 150 A, 150 B it is also possible to use a linear worm gear as the linear actuator for converting rotary motion of the motor 134 into the necessary 0.060″ displacement of spindle 17 .
[0051] FIG. 10 illustrates an exemplary worm gear linear actuator 120 . The components are largely the same as described relative to FIG. 9 but the camming discs 150 A, 150 B are replaced by a spindle 17 shaft threaded with worm gear threads 180 and journaled through a threaded hub 170 . This way, when reduction gear 140 turns, the hub 170 engages the threads 180 of spindle 17 and moving it linearly. This linear motion is used for selectively engaging or disengaging free spool in the manner described above relative to FIGS. 2-3 . The position disc 22 is identical to that described previously, and the spool control circuit board 30 is identical to FIG. 5 except that a motor driver is used.
[0052] One skilled in the art will readily understand that a more expensive but conventional servo or step motor may be used in place of motor 134 , in which case the driver of FIG. 5 must be a digital driver. It is also common for these types of actuators to include an integral encoder for position feedback, and this may be interfaced directly to the spool control circuit board eliminating the need for position disc 22 .
[0053] For certain reels that do not include a supplied brake disc 7 as shown in FIGS. 1-4 , or whenever desired, any of the above-described embodiments may be adapted to apply a braking force directly to the rotating spindle 17 rather than by imparting a linear shift to spindle 17 to use the supplied brake disc 7 . For example, FIG. 11 illustrates yet another embodiment in which an electronic brake 200 operates directly to apply a braking force to spindle 17 . The spindle 17 is extended from spool 2 through the electronic brake mechanism 200 , which is mounted to the spool control circuit board 30 in this case on the lefthand side of the reel. In the illustrated embodiment, the electronic brake 200 includes a linear solenoid 221 coupled to a mechanical wedge assembly 222 both affixed to the reel body 23 . The spindle 17 passes through the wedge assembly 222 and is gripped thereby. The solenoid 221 operates the wedge assembly 222 in a guillotine-like manner. When in normal drag mode, the electronic brake 200 closes the wedge assembly 222 on the bushing 230 and imposes a direct drag on the spool 2 to prevent free spooling. The solenoid 221 here is a conventional linear solenoid with plunger shaft. The wedge assembly 222 comprises two opposing yokes slidably journaled together. Electrical activation and extension of the solenoid 221 bears outward upon a lever which draws open the opposed yokes, freeing the spool 2 . Conversely, contraction of the solenoid 221 closes the opposed yokes, which in turn imparts a drag against the spool 2 . When power is removed from the solenoid 221 the wedge assembly 222 returns and drag is placed back on the spool 2 . This requires a return mechanism and for this return mechanism the wedge assembly 22 may be spring loaded. One skilled in the art should recognize that any suitable electro-mechanical braking mechanism will suffice for electronic brake 200 , so long as it is capable of putting the reel in and out of free spool. Thus, the illustrated solenoid with slidable/expanding wedge design is just one possible embodiment, and one skilled in the art should understand that a variety of known mechanical expansion configurations exist and may be suitable.
[0054] It should now be apparent that the above-described drag/free spool controller 2 senses a fish strike, automatically places the reel in free spool mode, and then affords the angler a predetermined interval of free-spooling to manually switch to drag mode before automatically applying drag, thereby providing a safeguard if the anglers are not quick enough to jump up and manually set the drag. The free spool controller can easily be incorporated into the footprint of a conventional fishing reel.
[0055] Having now fully set forth the preferred embodiment and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with said underlying concept. For example, rather than a Hall-effect sensor, the drag may be released and reset by sensing torque on the reel, though this is a more complicated and expensive endeavor.
[0056] It is to be understood, therefore, that the invention may be practiced otherwise than as specifically set forth in the appended claims.
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A drag/free spool controller incorporated into a fishing reel that has a signal generator mechanically attached to the reel. When the spool spins the signal generator produces a voltage signal, and after a pre-determined number of rotations, the generated signal is compared to a pre-determined value to determine if the spooling corresponds to a fish strike. When the generated voltage signal exceeds the pre-determined value, indicating a fish strike, a solenoid attached to the reel is actuated to disengage the drag mechanism, placing the reel into a free spool position. This action allows the fish to run with the bait while the angler repositions himself to manually engage the drag to set the hook. If after a pre-determined interval the angler fails to manually engage the drag, the solenoid will do so automatically.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The application claims the benefit of the earlier filing date of co-pending European Patent Application No. 12150055.7, filed Jan. 3, 2012, and incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a method and an apparatus for in situ mobilizing of heavy oil or crude oil by steam injection.
DESCRIPTION OF THE RELATED ART
[0003] Oil sand, as well referred to as tar sand comprises sand grains coated with tar like petroleum crude oil, briefly referred to as crude oil. The crude oil in the oil sand has a high viscosity and must be heated or diluted to flow. In-situ exploitation of oil sands can be accomplished by “steam assisted gravity drainage”, abbreviated as SAGD. SAGD uses a horizontally extending steam injection well forming a steam generation chamber for mobilizing the crude oil in the oil sand. The mobilized crude oil pours downward and is recovered by a second horizontally extending well, as so called production well, as disclosed in U.S. Patent Publication No. 2001/0278001A1.
[0004] The steam can be either produced by above ground facilities or downhole by an electrical heater as suggested by U.S. Pat. No. 4,805,698. The water is supplied from above ground by a water supply line. The electrical steam generator heats the water to generate steam. The steam is injected into the sand and mobilizes the crude oil, which is collected by adjacent production wells.
SUMMARY OF THE INVENTION
[0005] The problem to be solved by the invention is to improve in-situ oil sand exploitation.
[0006] Solutions of the problem are provided by a downhole apparatus and a method for exploitation of an oil sand reservoir as described by the respective independent claims. The dependent claims relate to further improvements of the invention.
[0007] The downhole apparatus for oil sand exploitation, comprises a least a casing which houses a water conduit for receiving water via a water pipe and at least one steam generation chamber being in fluid communication with said water conduit and having at least one steam outlet. The steam generation chamber is thermally connected to an electrical heater. The downhole apparatus further comprises at least one crude oil conduit for recovering crude oil, which has been mobilized by said steam. Such downhole apparatus permits to inject steam for mobilization of the crude oil into the oil sand and to recover the crude oil by a single apparatus, and thus requires only a single bore.
[0008] The casing may preferably house the at least one crude oil conduit. The casing may for example be or include a multiple conduit tube, wherein the at least one water conduit and the at least one crude oil conduit are each at least one of the multiple conduits. This permits a stable design of the housing.
[0009] The at least one steam generation chamber is preferably supported by the peripheral surface of the casing. This position of the steam generation chamber permits a simple injection of the steam generated in said steam generation chamber into the oil sand.
[0010] Preferably there are multiple, e.g. five or nine, at least two steam generation chambers arranged around the peripheral surface of the casing defining a bundle of steam generation chambers. In one embodiment, there is one bundle of steam generation chambers. In another embodiment, there are two or more bundles arranged at different positions along a distal length of the casing. The one or more bundles of steam generation chambers permit homogeneous injection of steam and thus an efficient exploitation of the oils sand. Because the one or more bundles of steam generation chambers are arranged around the casing, the one or more bundles also act to maintain or raise a temperature of the casing which aids in removal of crude oil from a reservoir (via the crude oil conduit in the casing).
[0011] Each steam generation chamber preferably has a cladding compartment surrounding a heater tube. The heater tube may house at least one electrical heater cartridge. This permits on the one hand to efficiently heat the water and on the other hand a simple replacement of the electrical heater cartridge in case of failure. The heater tube preferably houses at least one spare electrical heater cartridge. This permits longer operating intervals between retracting the downhole apparatus.
[0012] The heater tube may be hollow and may have an interior containing a composition of inorganic compounds and possibly pure elemental species. Examples for such a composition are described in U.S. Pat. Nos. 6,132,823; 6,911,231; 6,916,430; 6,811,720 and U.S. Patent Publication No. 2005/0056807, which are incorporated by reference as if fully disclosed herein. Such composition acts as a thermally conductive material or medium to provide at least an almost perfect homogenous distribution by the heater tube of the heat provided by the heater cartridge. The heater tube may as well be evacuated as suggested in the above references.
[0013] The heater tube may extend over the steam generation chamber, e.g. extend axially. Thus, at least one section of the heater tube extends out of the steam generation chamber into the bore. The heater tube thus reheats steam or water that cooled in a reservoir after its injection and enhances the efficiency of the exploitation.
[0014] The method for exploitation of an oil sand reservoir comprises at least the steps of producing steam in a steam generation chamber of a downhole apparatus, injecting said steam via steam outlets into the oil sand reservoir for mobilizing crude oil of the oil sand reservoir. At least part of the mobilized crude oils is recovered by said downhole apparatus. This method reduces the minimum number of bores for in situ oil sand exploitation compared to SAGD, and thus the costs.
DESCRIPTION OF DRAWINGS
[0015] In the following, the invention will be described by way of example, without limitation of the general inventive concept, on examples of embodiment with reference to the drawings.
[0016] FIG. 1 shows a schematic depiction of an oil sand exploitation system,
[0017] FIG. 2 shows a perspective view of a section of downhole apparatus,
[0018] FIG. 3 shows section of steam generation chamber.
[0019] FIG. 4 shows a schematic depiction of a second embodiment of an oil sand exploitation system.
DETAILED DESCRIPTION
[0020] The oil sand exploitation system 100 in FIG. 1 has a ground station 110 for housing the above ground facilities, like for example a controlling station 115 for monitoring and controlling the oil sand exploitation. Ground station 110 also includes a power source to, for example, provide power to an extraction well. Finally, ground station 110 includes a water source, such as a reservoir, to provide water (e.g., fresh water) to an extraction well. The ground station 110 is depicted as an onshore station, but can as well be a swimming station for exploitation of water covered oil sands.
[0021] The oil sand exploitation system 100 includes an extraction well 120 with a downhole apparatus inserted into bore 105 . The downhole apparatus includes a multi conduit tube like casing 130 , e.g. for a power cable 230 (see FIG. 2 ) for supplying power to downhole equipment, for example a protector 165 , and/or a motor 153 for driving a well head and a well monitor device 140 , as schematically depicted in FIG. 1 . The extraction well 120 includes a steam generator 200 which may be mounted to the peripheral surface of the casing 130 . The steam generator 200 is explained below in more detail with respect to FIGS. 2 and 3 . The steam generator 200 is positioned in this embodiment around casing 130 at a bottom or distal portion of casing 130 a first preferably vertical section of the extraction bore 105 . The steam generator 200 injects steam generally laterally into oil sand as shown in FIG. 1 . The steam mobilizes crude oil in the oil sand.
[0022] Extraction well 120 is configured to collect oil (including mobilized oil in the oil sand). To this end casing 130 of the extraction well 120 includes one or more oil inlets 135 along its length that allow oil to infiltrate the casing. Disposed within casing 130 is oil conduit 125 . The oil conduit 125 extends from the bottom or distal portion of casing 130 to the above ground station 110 . Oil that infiltrates casing 130 enters oil conduit 125 at the conduit's distal end and is pumped to the surface and fed to a production line 109 for example by a centrifugal pump 180 being arranged in the bottom or distal portion of casing 130 . Before pumping the crude oil to the above ground station 110 , water may be separated from the crude oil by separator 176 . Also, in the bottom or distal portion of casing 130 are an Electric Cable Clip 195 , a Venting Valve 172 , Single Flow Valve 185 , a Power Cable 175 , the Rotary Separator 176 , a Protector 165 , a Cable Head 162 , a Motor 152 and Well Monitor Device 140 . In between are a couple of water spray holes 145 to eject water or steam (e.g., when connected to steam generation unit 200 described below) and oil inlets 135 .
[0023] FIG. 2 shows a section of an isometric view of casing 130 including the steam generator 200 of extraction well 120 . The casing 130 is tube like and constructed of a metal material such as steel. Casing 130 and has multiple compartments or conduits around an inner periphery which may serve as water conduit 250 (for water from ground station 110 to steam generator 200 ), oil conduit 125 (for oil infiltrating oil inlets 135 in casing 130 ) or as cable conduit (for providing power to components in the casing (e.g., centrifugal pump 180 , motor 152 ) and to heat cartridges associated with the steam generator 200 ).
[0024] The steam generator 200 comprises a bundle of heating members 300 (cf. FIG. 3 ). The heating members 300 are arranged around the peripheral surface of the casing 130 and are each connected to the casing 130 by, for example, one or more weld connections. Where it is desired to have more than one bundle associated with a well like extraction well 120 , the bundles may be stacked one above the other along the casing 130 . Referring to FIG. 3 , each heating member 300 includes a heater conduit, illustrated as heater tube 310 , and steam generation chamber 375 respectively made of and defined by a metal material such as steel.
[0025] In one embodiment, heater tube 310 has a circular cross-section and a diameter on the order of 57 millimeters and a length on the order of 3800 millimeters. The front facing (upper) side of the heater tube 310 is closed by conical cap 330 , which may be weld connected to the heater tube 310 . The rear facing side of the heater tube 310 is closed by an end cap 340 , which may preferably be a water tight but releasable connection, e.g. a threaded connection.
[0026] Heater tube 310 , conical cap 330 and end cap 340 define a volume or chamber 335 . In one embodiment, the components, heater tube 310 , conical cap 330 and end cap 340 may be pressure tested to withstand, for example, a 1.5 millipascal (mPa) pressure test. Further, an inside surface of heater tube 310 defining a volume of chamber 335 , in one embodiment, is free of burrs or other debris or oil to provide a smooth, unvaried and clean surface.
[0027] As shown in FIG. 3 , chamber 335 of heating member 300 is divided into a first portion and a second portion by cap 360 of a thermally conductive material such as a metal material (e.g., steel). In one embodiment, a heating element such as electrical heater cartridge 350 with positive and negative terminals located at a single end (a proximal end as viewed) is positioned in a first portion of chamber 335 (proximal to cap 360 ). Heater cartridge 350 may have a length on the order of 300 millimeters or less, such as a length on the order of 150 millimeters. In one embodiment, cap 360 divides chamber 335 at a distance from a first end to be sufficient to allow heater cartridge 350 to be disposed in a first portion of chamber 335 but minimizes any additional volume for the first portion. As shown in FIG. 3 , when heater cartridge 350 is disposed in a first portion of chamber 335 terminals 355 extend into a volume of end cap 340 . In one embodiment, end cap 340 includes lateral opening 365 that is, for example, a threaded opening for power connection to terminals 355 . A conductor is fed through a peripheral conduit of casing 130 into lateral opening 365 . Current is supplied to the conductor from an above ground power source in ground station 110 .
[0028] Each steam generation chamber 375 is defined by, for example, cylindrical shell 320 a front wall 380 and a rear wall 370 connected by, for example, weld connections. The front wall 380 and the rear wall 370 each have an opening through which a heater tube 310 is disposed. The heater tube 310 extends axially through the steam generation chamber 375 . The connection of the heater tube 310 and the front wall 380 and/or the rear wall 370 may be a weld connection.
[0029] In one embodiment, shell 320 has a length dimension on the order of 3,000 millimeters. Front wall 380 and rear wall 370 each have a diameter on the order of 110 millimeters. Rear wall 370 of shell 320 includes inlet 395 for a water source to be connected thereto to provide water to steam generation chamber 375 . Water is provided from a water source at, for example, ground station 110 to steam generation chamber 375 by a peripheral conduit of casing 130 that is in fluid communication with inlet 395 .
[0030] The electrical heater cartridge 350 is thermally connected to the heater tube 310 and electrically connected with a power line e.g. by power cable 230 . The power (e.g., electrical current) line is preferably controlled by the controlling station 115 and may be ducted via a lateral opening like lateral opening 365 . A gasket may be used for sealing the cable feedthrough. Inside heater tube 310 is a thermally conductive material like it is described in the U.S. Pat. Nos. 6,132,823; 6,911,231; 6,916,430; 7,220,365 and U.S. Patent Publication No. 2005/0056807.
[0031] Water inserted into the steam generation chamber 375 via a water inlet 395 may be heated by a heat generated in heater tube 310 . A current supplied to electrical heater cartridge 350 generates heat in the heater tube 310 . This heat is transferred to the steam generation chamber 375 . Steam develops inside the steam generation chamber 375 and escapes through steam outlet 390 into the oil sand. A single flow pressure valve may be provided in the steam outlet 390 . Thereby it can be avoided that foreign matter, like sand grains and the like enter the steam generation chamber 375 . Further, the steam can be pressurized. As the heater tube 310 extends over the steam generation chamber part of the heat provided by the electrical heater cartridge 350 is as well transferred directly to the oil sand. This heat reduces the condensation of the steam close to the extraction well 120 and thus permits the steam to heat a bigger area around the extraction well and thus to better mobilize the crude oil. The mobilized crude oil can be collected via oil inlets 135 (see FIGS. 1 and 2 ), separated from water by rotary separator 176 and pumped by centrifugal pump 180 into the production line 109 a schematically represented in FIG. 1 .
[0032] As described above and shown in FIGS. 2 and 3 , heater tube 310 of heating member 300 includes a heat source (heater cartridge 350 ) and a thermally conductive material or media 355 . Thermally conductive material 355 is present in the second portion of heater tube 310 an amount sufficient to transfer heat from heater cartridge 350 to the surface of heater tube 310 . Suitable representative thermally conductive material is described in U.S. Pat. Nos. 6,132,823; 6,911,231; 6,916,430; 7,220,365 and U.S. Patent Publication No. 2005/0056807, which are incorporated by reference herein. In another embodiment, thermally conductive material 355 is an inorganic material that is a combination of oxides and one or more pure elemental species, particularly titanium and silicon. One such combination is provided in Table 1.
[0000]
TABLE 1
sodium peroxide
2.705%
disodium oxide
2.505%
silicon
1.6%
diboron trioxide
0.505%
titanium
0.405%
copper oxide
0.405%
cobalt oxide
0.255%
beryllium oxide
0.255%
water, distilled, conductivity or of similar purity
89.256%
dirhodium trioxide
1.6%
trimanganese tetraoxide
0.255%
strontium carbonate
0.255%
[0033] In an embodiment using the thermally conductive material described in Table 1, the material is introduced into each heater tube 310 of bundle 200 (see FIG. 1 ) in a representative range amount minus the water component, equivalent to 1/400,000 of the volume of a heating tube. In other words, a 2400 mm heating tube with a 20 mm inside diameter would have a volume of 3,215,360 mm and the thermally conductive material would be present in an amount of 8 mm3 by volume. Other amounts may also be suitable such as an amount ranging from 1/400,000 to 1/200,000 by volume. For those thermally conductive materials described in the referenced incorporated patent documents, other amounts of thermally conductive material may also be used. For example, U.S. Pat. No. 7,220,365 describes an inorganic thermally conductive material of cobalt oxide, boron oxide, calcium dichromate, magnesium dichromate, potassium dichromate, beryllium oxide, titanium diboride and potassium peroxide in amounts of 0.001 to 0.025 by volume.
[0034] In one embodiment, the thermally conductive material is introduced into a second portion of each heater tube 310 of tube bundle 200 (the second portion of heater tube 310 is defined by cap 360 ). Each tube is heated to evaporate the water component. The presence of cap 360 allows a proximal portion of chamber 335 to be accessed (to, for example, remove or replace heater cartridge 350 ) without disrupting the seal or the contents of the second portion of chamber 335 . Without wishing to be bound by theory, it is believed that the thermally conductive material in the second portion of each heater tube 310 operates by mechanically conducting heat generated by a heating cartridge to the steam generation chamber 375 (e.g., solid particles of the thermally conductive material colliding with one another and with a wall of the heater tube). The thermally conductive material in heater tube 310 permits heat distribution through the tube and conducts the heat to steam generation chamber 375 (e.g., axially conducts heat). That heat, in turn, evaporates water added to chamber 375 and produces steam.
[0035] With 1 kW power provided by a heat source (e.g., an electrical heating rod), heater tube 310 including 1/400,000 by volume of the thermally conductive material described in Table 1 can generate on the order of 2000 kcal of heat or more on the surface (on an outer surface of outer cylinder 310 ).
[0036] Representatively, as described above with reference to FIG. 1 , one or more tube bundles 200 of extraction well 120 may be used to generate and discharge steam into a petroleum reserve to, in the case of oil sands, provide sufficient liquidity to the crude oil in oil sands to allow its extraction through casing 130 and pumping conduit 125 , and secondarily to provide thermal insulation to casing 130 . In one embodiment, maintenance of an appropriate temperature is desired. In one embodiment, ideal performance attempts to maintain an appropriate target temperature of the steam discharge temperature despite possible changing condition (e.g., heating of the reserve). In such embodiment, the temperature of the steam produced in tubes of a tube bundle may be monitored and/or controlled by controller 115 . For example, a processing protocol delivered to control computer 115 includes instructions for receiving temperature measurements from temperature sensors. Based on these measurements, instructions are provided in a machine-readable form to be executed by controller 115 . Accordingly, controller 115 executes the instructions to increase or decrease the power output to one or more heating rods 350 to achieve a target temperature in a range f (e.g., 250° C. to 280° C.). It is appreciated that controller 115 may be increasing power to some heating cartridges 350 while at the same time decreasing power to other heating cartridges 350 . Still further, controller 115 may be connected to pump 180 and other components in pumping conduit 125 and control the pump and/or other components based on program instructions to achieve a desired throughput from the well.
[0037] FIG. 4 shows an another embodiment of an oil sand exploitation system. In this embodiment, oil sand exploitation system 400 includes ground station 410 for housing the above ground facilities, like for example, a controller 415 , a power source and a water source. Similar to FIG. 1 , the above ground station 410 is depicted as onshore station, but can as well be a swimming station for exploitation of water covered oil sands. The system 400 includes a bore 405 into which an extraction well 420 with a downhole apparatus is inserted. In FIG. 1 , the extraction well was inserted vertically or approximately vertically the entire length of the well. In FIG. 4 , the extraction well 420 extends vertically through bore 405 at a ground surface of the well, but then extends laterally into the well. Otherwise, the construction and operation of extraction well 420 and system 400 is similar to the construction and operation of extraction well 120 and system 100 described with reference to FIGS. 1-3 . The downhole apparatus includes casing 430 which is, for example a multi-conduit casing configured similar to casing 130 in FIG. 1 , and one or more bundles of steam generators 500 configured similar to steam generators 200 . FIG. 4 shows a single bundle disposed about and connected to a distal portion of casing 430 . Water provided to each steam generation chamber of steam generator 500 is converted to steam by heat provided to the chamber by a heater tube containing a heater cartridge and a thermally conductive material as described above with reference to FIGS. 1-3 . The steam is dispensed from steam outlets 490 of a steam generation chamber into the oil sands reservoir to mobilize oil in the oil sand. Mobilized oil infiltrates casing 430 through oil inlets 435 and is pumped to the surface of the well.
[0038] In the description above, for the purposes of explanation, numerous specific details have been set forth in order to provide a thorough understanding of the embodiments. It will be apparent however, to one skilled in the art, that one or more other embodiments may be practiced without some of these specific details. The particular embodiments described are not provided to limit the invention but to illustrate it. The scope of the invention is not to be determined by the specific examples provided above but only by the claims below. In other instances, well-known structures, devices, and operations have been shown in block diagram form or without detail in order to avoid obscuring the understanding of the description. Where considered appropriate, reference numerals or terminal portions of reference numerals have been repeated among the figures to indicate corresponding or analogous elements, which may optionally have similar characteristics.
[0039] It should also be appreciated that reference throughout this specification to “one embodiment”, “an embodiment”, “one or more embodiments”, or “different embodiments”, for example, means that a particular feature may be included in the practice of the invention. Similarly, it should be appreciated that in the description various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects may lie in less than all features of a single disclosed embodiment. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of the invention.
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A downhole apparatus for oil sand exploitation, including at least a casing for housing a water conduit for receiving water, at least one steam generation chamber being in fluid communication with said water conduit and having at least one steam outlet, at least one electrical heater, being thermally connected to said steam generation chamber, at least one crude oil conduit for recovering crude oil. A method including injecting steam from at least one steam generation chamber coupled to an oil recovery conduit into a reserve; and removing oil from the reserve through the conduit, wherein the least one steam generation chamber is disposed on the oil recovery conduit, and the steam generation chamber includes a plurality of heating conduits each including a heating element and a thermally conductive material therein, and at least one reservoir surrounding the plurality of heating conduits from which the steam is produced.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for uniformly charging an image holding member, and more particularly to a process for performing, in an image forming apparatus comprising an image holding member to be driven at two different speeds, the electrostatic charging of said image holding member in relation to the speed thereof, thereby realizing a uniform potential thereon. Said image holding member includes a photosensitive drum, an insulating drum, a transfer sheet material, a recording sheet material etc.
2. Description of the Prior Art
An image forming apparatus comprising an image holding member to be driven at two different speeds is already known and disclosed for example in the U.S. Pat. No. 4,044,671. In such apparatus the image holding member, for example composed of a photosensitive drum, is rotated at a first speed in the step of forming a first latent image thereon, while it is driven at a second speed at a subsequent step of transferring said first latent image onto another member or of forming a second latent image corresponding to said first latent image on another member by means of ion modulation, thereby obtaining a reproduced image.
In case a corona discharger is employed for obtaining a uniform potential on an image holding member having a changeable speed as explained above, there is proposed a process of changing the intensity of corona discharge in response to the speed of said image holding member in order to prevent significant fluctuation in the charged potential resulting from the speed change. However if the discharge intensity of the corona discharger is changed simultaneously with the speed change-over as has been usually conducted, there will result an abnormally charged portion in the boundary area of said change-over (area located directly under the discharger at said change-over) even if the discharge intensity is maintained constant after said change-over. Such abnormally charged portion becomes visible on the final image or results in an unnecessary carry-over of the developer material.
The analysis on this drawback has revealed that it is generated from the difference between the start-up speed state of the image holding member and the start-up state of the change of corona discharge. More specifically the image holding member, which is mechanically accelerated or decelerated from the first speed to the second for example by the change of motor pole number or by a transmission, will receive excessive or deficient corona discharge, the intensity of corona discharge is increased or decreased before the speed of the image holding member is stabilized to the new value, until said speed is thus stabilized.
SUMMARY OF THE INVENTION
The object of the present invention is to provide an improvement over the above-explained drawback of the conventional process, said improvement more specifically being featured in reducing the change in the charged potential on the image holding member even in case of speed change-over during the latent image formation on said member thereby preventing the uneven contrast resulting from the potential change and thus assuring satisfactory image formation.
The above-mentioned object is achieved according to the present invention in an image forming apparatus in which the image holding member is to be driven at a first speed and a second speed, by performing, in response to the change-over from the first speed to the second speed of said image holding member, either (a) the start of charging operation by the charging means onto the image area of the image holding member, or (b) the end of said charging operation, or (c) the change of the charging ability of said charging means after said change-over of speed thereby realizing a uniform potential on said image holding member. The above-mentioned change-over of speed includes the change to a higher speed and that to a lower speed. The above-mentioned potential control is achieved by the change of voltage or current supplied to said corona discharger.
For example in an apparatus in which the speed of the image holding member is changed to a larger value, the above-mentioned object is achieved by increasing the intensity of corona discharge of the corona discharge means later than the speed increase of the image holding member. Also the above-mentioned object is achieved even when said intensity increase of corona discharge is made simultaneously with the speed change-over if the voltage supplied to the corona discharger is regulated in such a manner that the start-up characteristic of corona discharge coincides with that of the speed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross-sectional view of an experimental apparatus;
FIG. 2 is a chart showing the change of peripheral speed of the photosensitive drum shown in FIG. 1 and of the surface potential thereof as a function of time;
FIG. 3 is a chart showing the change of surface potential on said drum as a function of time; and
FIG. 4 is a schematic cross-sectional view of a copier embodying the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be explained in detail by the embodiments thereof.
FIG. 1 shows the working principle of the process of the present invention, and FIGS. 2 and 3 show the experimental results obtained in the apparatus shown in FIG. 1.
In FIG. 1, 1 is a photosensitive member functioning as the image holding member and composed of a Carlson-type two-layered photosensitive member comprising a conductive layer 2 and a photoconductive layer 3. In facing relationship to said drum-shaped photosensitive member 1 there are provided a corona discharger 4 for charging said photosensitive member, a charge-eliminating grounded electrode 5 and a potential measuring device S. In the following there will be given an explanation of a case in which the photosensitive member 1 in the apparatus shown in FIG. 1 is shifted from a first speed to a second speed which is three times faster than said first speed. In this embodiment, in response to said shifting from the first speed to the second speed, the voltage supplied to the corona discharger 4 is regulated so as to triple the quantity of ions directed toward the photosensitive member 1 in order to maintain a constant potential on said photosensitive member 1 both in the first speed and the second speed. FIG. 2 shows the drum peripheral speed (v) and corona current (i) in ordinate, which are obtained in the apparatus shown in FIG. 1, as a function of time (T) in abscissa. When the peripheral speed of the photosensitive member 1 is switched at the time T 0 , the photosensitive member reaches the triple speed after a certain start-up period. On the other hand, in order to achieve uniform charging under the thus tripled speed, the current from the corona discharger 4 to the photosensitive member 1 should likewise be tripled. However, if the current of said discharger 4 is tripled simultaneously with the speed change-over of said photosensitive member, the discharge becomes stabilized with a start-up time shorter than said start-up time of the photosensitive member, as represented by the chain line. Such start-up time of the photosensitive member tends to be longer than that of the high-voltage source unless the motor for driving the photosensitive member has an ample torque. In FIG. 2 there is shown a state in which the start-up time of the photosensitive member is almost ten times as long as that of the corona discharger.
FIG. 3 shows the change in the amount of charge received by the photosensitive member in the presence of the difference as explained above between the start-up times. Said amount of charge is proportional to the corona current toward said photosensitive member divided by the speed thereof, said amount being represented by the full line in FIG. 3. As shown in FIG. 3, the photosensitive member receives, at the speed change-over, a charge almost three times as large as that in the normal state. Such excessive charge on the photosensitive member cannot be smoothed for example by potential adjustment with a corona discharger in the succeeding steps and appears on the final image after image development of the photosensitive member. In order to prevent such excessive charging the start-up time of the corona discharger should be made to coincide with that of the photosensitive member. Thus, for realizing a uniform charging, it is required to extend the start-up time of the high-voltage source in synchronization with the start-up time of the photosensitive member. A forced extension of said start-up time will however require a large capacitor, and even with such method it is difficult to regulate the ending time of the corona discharger in synchronization with the deceleration of the photosensitive member.
The charging process of the present invention enables the prevention of the aforementioned excessive charging without such associated drawbacks as mentioned above, and it minimizes the unevenness in the charge through a simple charging control. More specifically, according to this process, a corona discharger with a short start-up time is put into function after the speed change-over of the photosensitive member.
It is now assumed in FIG. 2 that the peripheral speed of the photosensitive member is changed at the time T 0 , and the charging is switched at the time T 1 as shown by the chain line. In such case, as shown by the chain line in FIG. 3, the amount of charge on the photosensitive member decreases hyperbolically after the time T 0 toward a value equal to one-third of the charge amount before the speed change-over, since the corona current does not change until the time T 1 while the speed of the photosensitive member has started to increase from the time T 0 . The above-mentioned hyperbolic change is observed in case the peripheral speed of the photosensitive member increases linearly in time as shown in FIG. 2.
Upon a triple increase of the corona current at the time T 1 , the amount of charge shows a change along the full-lined curve thereafter. Thus, around the time T 1 there are created areas which are respectively charged excessively and deficiently, but the extent of such excess and deficiency is significantly smaller than the excessive charge in the foregoing case not embodying the present invention.
In the following the present invention will be further clarified by an embodiment in which the present invention is applied to a copier employing a screen-shaped photosensitive member.
FIG. 4 shows said copier in a schematic cross-sectional view, in which a latent image is formed on a screen-shaped photosensitive member 6 (hereinafter simply referred to as screen) by means of primary latent image forming means 7 and is utilized for modulating the corona ions from a corona discharger 8 to an insulating drum 9, thereby forming a secondary latent image on said drum 9. Said screen is composed of a special photosensitive member provided with a plurality of small openings, and, as detailedly disclosed in the British Pat. No. 480,841 of the present applicant, is capable of producing plural secondary latent images from a single primary latent image.
Along the periphery of said insulating drum 9 there are provided developing means 10 for performing toner development of said secondary latent image, a transfer corona discharger 11, cleaning means 12 for removing the toner remaining on said drum and a charge eliminating corona discharger 13 for eliminating the remaining charge, while sheet materials P are supplied one by one from an unrepresented sheet stack to the image transfer station. Upon completion of image transfer under the function of said corona discharger 11, said sheet materials are separated from said drum 9, guided to fixing means and ejected from the apparatus.
In the above-explained apparatus said screen 6 is driven at a first peripheral speed of 14 cm/sec during the formation of said primary latent image in correlation with the displacing speed of the optical system and also in order to secure a sufficient corona discharge onto said screen, while it is driven at a second peripheral speed of 42 cm/sec, which is three times as fast as said first speed, during the modulation step by the discharger 8 as the primary latent image forming means is not in function in this state. Thus, although the corona discharger around the screen 6 is not used after the formation of the primary latent image, the dischargers around the insulating drum 9 have to be controlled so as to achieve necessary charging at the operation with said second speed and still so as not to generate abnormal potential on the insulating drum 9 even during the operation at said first speed.
In the apparatus shown in FIG. 4, the charge eliminating corona discharger 13, because of the presence of a control grid, does not result in a significant fluctuation in the charged potential even when the peripheral speed of the insulating drum 9 is changed from said first speed to said second speed, or vice versa. Consequently attention should be paid to the potential on the drum 9 caused by the transfer corona charger 11, which will be explained in detail in the following.
The insulating drum 9 is initially charged to a uniform potential of ca. +50 V by the charger 13, and, upon subsequent receipt of negative corona ions modulated imagewise by said screen, the image area of said drum is charged to a potential of ca. -150 V. The transfer corona discharger 11 is designed to have an intensity, in the absence of the transfer sheet P which is to be charged by said discharger, of changing the potential of said drum 9 from +50 V to -300 V. Also the discharger 13 has an ability of reducing a potential unevenness of ca. 100 V present on the insulating drum to an unevenness of ca. 5 V. The transfer corona discharger 11, receiving a potential of -4.7 V or -6.0 KV respectively at the low- or high-speed operation (14 or 42 cm/sec), generates an excessively charged area of -1000 V if the voltage is switched simultaneously with the speed change-over. Said excessively charged area showed a potential of +15 V after passing the charge eliminating corona discharger which is different by 35 V from the potential of 50 V in other areas. In this case the increase of the drum peripheral speed from the first speed to the second speed requires 0.3 seconds while the switching of the high-voltage source only requires 0.03 seconds. When the switching of said high-voltage source is delayed by 0.14 seconds according to the present invention from the change-over of the drum peripheral speed, the charge in the excessively charged area is reduced from -1000 V to -450 V. After passing the discharger 13 said area shows a potential of 43 V which is different only by 7 V from 50 V in other areas. In this manner the unevenness in potential is significantly reduced from the aforementioned fluctuation of 35 V.
It is to be noted that various modifications are possible in achieving the above-mentioned uniform potential. For example it is possible to turn off the transfer corona discharger during the operation at the higher second speed. Naturally also in such case there is required means for delaying the application of voltage to the transfer corona discharger or for delaying the increase of voltage at the change-over to the higher speed.
Furthermore the present invention is applicable also to the case in which the image holding member is changed from the high speed to the low speed. In such case the observed behaviors are as if the curves in FIGS. 2 and 3 are made upside down.
As explained in the foregoing, the present invention provides for charging the image holding member to an approximately constant potential by means of a simple process, thus assuring an improvement in the image quality.
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The present invention relates to an electrostatic charging process for uniformly charging an image holding member such as a photoconductive or insulating drum. In an image forming apparatus in which such image holding member is driven both at a first speed and at a second speed different from said first speed, there results a phenomenon of uneven charging due to the difference between the start-up characteristic of charging performance of the charging means and the actual speed at the speed change-over of the image holding member. This drawback is prevented by the present invention in which the speed change-over time of the image holding member is selected different from the charging start time of the charging means in such a manner that the charging is initiated after the speed change-over.
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FIELD OF THE INVENTION
The present invention relates to the field of polymer chemistry and, in particular, to the field of foam composites having properties of both conventional hydrophobic and hydrophilic polyurethane foams.
BACKGROUND OF THE INVENTION
Conventional polyurethanes have taken a prominent position in the world as an inexpensive material for use in such diverse applications as foam insulation, adhesives, structural foams, shoe sole and others. The properties of conventional polyurethanes that make these uses possible are its physical strength, low cost, ability to make very low density foam, chemical resistance, and thermal stability.
One of the variations of the product family is the manufacture of what are called reticulated foams. These foams are constructed such that the “windows” that separate the individual cells making up the foam structure are open and the material in the windows collapse into the “struts and beams”. Thus when fully cured and viewed in a microscope, all one sees is a matrix of “tinker-toy-like” rods connected to one another at the ends. One of the advantages of this structure is that it presents very low resistance to the flow of air or water. It is often used as a filter media due to their typically low density and corresponding low cost per unit volume. These foams are hydrophobic, i.e. they do not absorb water.
Hydrophilic polyurethanes, on the other hand, while being of similar chemistry, are used in applications where being compatible with water is the primary reason for their use. These uses include controlled delivery devices, chronic wound care dressings and agricultural media.
An advantage of hydrophilic polyurethanes over conventional reticulated polyurethanes is their ability to be formulated with active ingredients. Hydrophilic polyurethanes are conventionally made by the emulsification and curing of an aqueous phase with a hydrophilic polyurethane prepolymer. The aqueous phase may contain an active ingredient in which case the ingredient is dispersed in the matrix of the resultant foam. In part, it is this ability to incorporate a wide variety of components in the aqueous phase that makes this chemistry commercially attractive.
The essential difference between these two related chemistries is that the hydrophlic polyurethane is compatible with and absorbs water while the conventional polyurethanes are hydrophobic and are incompatible with water. While this hydrophilic nature gives hydrophlic polyurethane its unique applications, it also leads to certain deficiencies. Among these are low physical strength, poor cell size control, relatively high densities causing a relatively high cost per unit volume, and the fact that foam swells considerably upon absorption.
Therefore, although the ability to incorporate certain active ingredients into the hydrophilic polyurethane foams is presently known in the art, this incorporation introduces many adverse characteristics into the foam, limiting the commercial use of hydrophilic polyurethane foams in engineering devices that utilize this technology.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide improved foam composites which have properties of both conventional hydrophobic and hydrophilic polyurethane foams.
It is another object of the present invention to provide foam composites which can be used as devices to release active ingredients into a fluid stream.
SUMMARY OF THE INVENTION
The present invention which addresses the needs of the prior art provides broadly composite polyurethanes that include both hydrophobic and hydrophilic polyurethane foam entities. By combining these two types of foams, the resulting composite overcomes the disadvantages associated with each, while maintaining their respective advantages.
The composite includes a hydrophobic scaffold foam, such as reticulated polyurethane foam, coated with an open cell hydrophilic polyurethane foam. This is accomplished by coating the inside surface of the reticulated foam with a polyurethane prepolymer emulsion and allowing the composite to cure. What results is a foam composite that uses the reticulated polyurethane foam as a scaffold or a substrate on which the hydrophilic polyurethane foam is cast.
In another aspect of the present invention, the composite foams are formed by contacting a reticulated hydrophobic polyurethane foam with a solution of a hydrophilic polyurethane prepolymer in a solvent such as acetone and the like. The solvent of the polyurethane prepolymer solution is subsequently recovered thus coating the reticulated hydrophobic polyurethane foam with the hydrophilic polyurethane prepolymer.
In another embodiment of the invention the composite foams are provided by contacting the hydrophobic polyurethane foam with a liquid phase of a hydrophilic polyurethane prepolymer at temperatures sufficient to lower the viscosity and thereby control the coating weight of the hydrophilic prepolymer.
It is yet another aspect of the invention to provide a composite that overcomes the disadvantages of both hydrophobic and hydrophilic foams while maintaining their respective advantages. Specifically, the hydrophilic coating, which may or may not contain an active ingredient, provides for the hydrophilic character, while the reticulated foam provides for physical strength and the good flow-through aspects that characterize a reticulated foam. Thus, while the hydrophilic coating will swell when it absorbs water, the reticulated foam is sufficiently strong to prevent an increase in the size of the composite.
It is a further aspect of the invention to provide a composite for use as a device for the controlled release of a component into a stream of fluid passing through it. The stream can be a gas or liquid, but in either case the action of the composite is to release into the stream a component resident in the hydrophilic polyurethane foam coating. Examples include devices for the controlled release of a pharmaceutical to blood, the controlled release of a fragrance to an air stream, the controlled release of a soap to water stream, and the humidification of a gas stream by the evaporation of water from the hydrophilic coating.
It is a further aspect of the invention to provide a composite for use as a device that will chemically or biologically act on the stream that passes through it. The stream can be a gas or liquid, but in either case the action of the composite is to act upon the stream to produce a chemical or compositional change. One example being a device for the bioremediation of a waste stream through the action of bacteria, enzymes, algae, yeasts or other biological species on the waste stream. Another example includes devices that produce an action comparable to those of living cells, such as liver cells, on physiological fluids to remove or react natural or synthetic toxins. Another example includes devices doped or grafted with ion exchange resins for removing complex inorganic ions from the stream. Further examples include devices having foams in doped or grafted with activated carbons or zeolite which have the ability to remove components from a stream by an adsorption or entrapment mechanism. Another example includes devices for the production or removal of chemicals in a process stream through the action of bacteria, enzymes, algae, yeasts or other biological species. Still another example includes devices for the removal of organic species from a process stream by adsorption on the surface of the hydrophilic coating.
Finally, other examples might be the removal of water from a process stream through absorption by the hydrophilic polyurethane foam.
It is a further aspect of the invention to provide a composite for use in devices for the moderation of inhaled air temperatures in low temperature environments. One example of such a device moderates the temperature of inhaled air by passing the air stream over an appropriate phase change material entrapped in the hydrophilic coating. The heat contained in the exhaled air is subsequently trapped by breathing out through another chamber that also contains the phase change material.
It is a still further aspect of the invention to provide a composite for use as an advanced soil-less growing media.
These aspects of the invention are not meant to be exclusive and other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the following description, appended claims and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the foam composite of the present invention.
FIG. 2 shows the pressure drop of hydrophobic polyurethane foams at 575 ft/min of air.
FIG. 3 is a graph of the surface area of hydrophobic polyurethane as a function of pore size.
FIG. 4 illustrates the juxtaposition of the CO 2 abstraction and the polymerization reactions to produce various foams.
FIG. 5 is an outline of manufacturing steps in the production of hydrophilic polyurethane.
FIG. 6 is a process flow diagram of a typical emulsification of a typical polyurethane prepolymer.
FIG. 7 illustrates a pin mixer used in the emulsification of polyurethane prepolymer.
FIG. 8 is a flow diagram of process to manufacture the foam composite by the emulsion process.
FIG. 9 is a graph illustrating the reduction of viscosity with increasing temperature.
FIG. 10 is a flow diagram of the process to manufacture the foam composite by the solvent process.
FIG. 11 is a flow diagram of the process to manufacture the foam composite by the direct cast process.
FIG. 12 is a schematic view of an embodiment in which the foam composite is utilized in a device for soil-less growing media.
FIG. 13 is a schematic view of an embodiment in which the foam composite is utilized in a controlled release device.
FIG. 14 is a schematic view of an embodiment in which the foam composite is utilized in a cell for bioremediation.
FIG. 15 is a schematic view of an embodiment in which the foam composite is utilized in a fermentation device.
FIG. 16 is a schematic view of an embodiment in which the foam composite is utilized in a device for the treatment of milk.
FIG. 17 is a schematic view of an embodiment in which the foam composite is utilized in an enzymatic reactor.
FIG. 18 is a schematic view of an embodiment in which the foam composite is utilized in a device used in a femoral shunt.
FIG. 19 is a schematic view of an embodiment in which the foam composite is utilized as a scaffold for the propagation of living cells.
FIG. 20 is a schematic view of an embodiment in which the foam composite is utilized in the drug delivery system.
FIG. 21 is a schematic view of an embodiment in which the foam composite is utilized in an adsorption cell.
FIG. 22 is a schematic view of an embodiment in which the foam composite is utilized in a device used for the removal of drugs from blood.
FIG. 23 is a schematic view of an embodiment in which the foam composite is utilized in a device used to deionize water.
FIG. 24 is a schematic view of an embodiment in which the foam composite is utilized in a humidifier for incubators.
FIG. 25 is a schematic view of an embodiment in which the foam composite is utilized in a humidifier for anesthetics.
FIG. 26 is a schematic view of an embodiment in which the foam composite is utilized in a device used for administering anesthetic.
FIG. 27 is a schematic view of an embodiment in which the foam composite is utilized in a device used for drying hydrocarbons.
FIG. 28 is a schematic view of an embodiment in which the foam composite is utilized in a respirator.
FIG. 29 is a schematic view of an embodiment in which the foam composite is utilized as a flow-through analytical column for multiple sequential analysis.
FIG. 30 is an illustration of a column packed with the foam composite of the invention used to determine the relationship of flow rate and pressure drop.
FIG. 31 is a graph illustrating the relationship between flow rate and pressure drop across hydrophobic polyurethane.
FIG. 32 is a graph illustrating the relationship between flow rate and a ratio of the weight of hydrophilic polyurethane to the weight hydrophobic polyurethane in foam composites of the invention.
FIG. 33 is a graph illustrating the relationship between the content of polyurethane prepolymer in solution and the ratio of the weight of hydrophilic polyurethane to the weight of hydrophobic polyurethane.
FIG. 34 is a graph illustrating the effect of temperature on the foam composites of examples 11-15.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
The term “reticulated hydrophobic polyurethane foam” refers to a polyurethane foam having a mesh like structure that does not readily absorb water. This term is defined further below.
The term “open cell, hydrophilic polyurethane form” refers to a highly flexible polyurethane foam that absorbs water readily. This term is more specifically defined further below.
The term “curing” refers to the conversion of a raw product to a finished and useful condition by application of water for a period of time sufficient to induce physicochemical changes. This term is more specifically defined below.
The term “surface area” refers to the total surface area of a substance measurable by the BET technique.
The term “functional group” refers to groups of atoms that give the composite or substance to which they are linked characteristic chemical and physical properties.
A “functionalized” surface refers to a surface on which chemical groups are absorbed or chemically attached.
The term “bioaffecting or active agent” refers to an additive that is a biological entity or produces an effect upon a biological entity or acts upon a biological entity so as to effect a response therefrom.
The term “non-bioactive ingredient” refers to an additive other than bioaffecting agents.
Referring first to FIG. 1, the foam composite 10 is shown. The hydrophobic polyurethane foam forms a reticulated scaffold 12 . The hydrophobic foam scaffold 12 forms a backbone for an open cell foam coating 14 , such as open cell hydrophilic polyurethane. The hydrophobic polyurethane foam scaffold 12 is typically a reticulated foam made from water insoluble polyester or polyether backbones and dilsocyanates as caps to the polyols. Other ingredients, such as surfactants and catalysts, may be added to aid production. Only small amounts of water are added as a necessary component of the chemistry. The reticulated foams useful in the present invention are typically produced by the so-called “one-shot” process wherein all of the ingredients are mixed in a single step to produce the final foam product. Using heat and pressure in specially designed vessels, a flexible skeletal foam structure without cell membranes is produced.
The open-pore structure can be produced in a range of precisely controlled pore sizes that contain void volumes of up to 98% and surface areas of up to 2000 ft 2 /ft 3 . Various pore sizes, typically from 4 to 100 pores per linear inch (ppi) enable the use of the hydrophobic polyurethane in specific applications. The high porosity of this material also helps control permeability and adds to design flexibility.
Among the benefits of reticulated hydrophobic polyurethane foams are easy fabrication and chemical resistance. Such reticulated foams also exhibit high tensile strength, elongation and tear properties that allow such fabrication techniques as cutting, shaping, stapling, tacking, stitching, cementing, laminating and grommeting. The reticulated hydrophobic polyurethane is supplied in sheets, rolls, die-cuts, and complex compound shapes. Hydrophobic polyurethane foams which have been found suitable for use in the foam composite of the present invention include without limitation those marketed under the trademarks Crest Foam and FoamEx. These products are commercially available from Crest Foam, Moonachie, N.J., USA and FoamEx, Eddystone, Pa., USA.
There are many commercial applications for reticulated hydrophobic polyurethane foams. Generally, these applications are based on properties such as the unusual physical strength of the hydrophobic foam, controlled pore size, and surface area.
Table 1 below summarizes the physical properties of hydrophobic polyurethane foams useful in the present invention. The information set forth in Table 1 below was obtained based on tests conducted according to ASTM 3574-91 on hydrophobic polyurethane foams from Crest® foam.
TABLE 1
Physical Properties of Reticulated Foams
Property
S-10
S-40
S-90
Pores/Linear Inch
10.0
40.0
90.0
Density lb/ft 3
1.9
1.9
1.9
25% Compression Load Deflection psi
0.5
0.5
0.5
Tensile Strength psi
16.0
20.0
30.0
Elongation %
180.0
160.0
240.0
Tear Strength lb/in
4.0
4.0
3.5
Compression Set @ 50% Deflection psi
15.0
15.0
15.0
Air Flow cfm
25.0
14.0
4.0
The pressure drop of hydrophobic reticulated foam of various pore sizes is shown in FIG. 2 at 575 ft/min. of dry air through 1 ft 2 of 1 inch thick foam. The surface area of a hydrophobic reticulated foam is seen as a function of pore size in FIG. 3 .
The chemistry of making open cell hydrophobic polyurethane foams is described as being an isocyanate-capped polyether polyol and is discussed in more detail further below. Prepolymers made of this chemistry which are suitable for the present invention are described in U.S. Pat. Nos. 3,903,232 and 4,137,200 both to Wood, et al. incorporated herein by reference as if set forth in full. The isocyanate-capped polyol is known in the industry as a prepolymer or a quasi-polymer.
Isocyanates'suitable for this invention are aromatic, such as, for example, toluene dilsocyanate (TDI) or methylene diphenyl isocyanate (MDI), or with a aliphatic duisosyanate, such as hydrogenated MDI or isopherone dilsocyanate. Isocyanates and polyols useful in making the open cell hydrophilic polyurethane foam for use in the foam composite of the invention are described in U.S. Pat. Nos. 5,064,653 and 5,065,752 both to Session, et al. incorporated herein by reference as if set forth in full. Polyether polyols are homopolymers of ethylene oxide, also known as polyethylene glycols, or copolymers of ethylene oxide and propylene oxides.
The value of this class of prepolymers is based on its compatibility with water. It is the ability to be emulsified with large amounts of water that forms the basis for the value of these prepolymers. Within the water compatible components can be included a wide variety of other materials. Among those are mineral fillers that are used to affect the compression characteristics of the foam. Peat moss can be added to foam to form the basis of a high value soil-less growing medium. While fillers can be added, they are not necessary. At the other end of the spectrum is the inclusion of a simple emulsifying agent. The result is a low extractable, biocompatible material useful for a wide variety of medical products. The ability to incorporate other materials in hydrophilic polyurethane foam offers the product designer a material that has functionality greater than its physical characteristics.
This flexibility comes at a price. The physical strength of hydrophobic polyurethane is low. The wet tensile strength of open cell hydrophilic polyurethane is only about 4 psi which is significantly lower than the tensile strength of hydrophobic polyurethane. The reaction to form hydrophilic polyurethane utilizes large amounts of water and results in a relatively high density and poor cell size control. The compressive strength of the polymer product is also low. In some applications, this is a positive characteristic since products made from this material are soft and have a pleasant feel. However, this is an undesirable characteristic for many industrial applications.
The physical characteristics of open-cell hydrophilic polyurethane foam are summarized in Table 2.
TABLE 2
Physical Properties of Hydrophilic Polyurethane Foams 1
Property
Pores/Linear Inch
200.0
Density, lb/ft 3
6.0
25% Compression Load Deflection, psi
0.1
Tensile Strength, psi
4.0
Elongation %
300.0
Tear Strength, lb/in
2.0
Compression Set @
2.0
50% Deflection, psi
Air Flow cfm @ 0.5 ΔP
0.2
1 Medical Grade
The above properties are for single component polymer systems, but other compositions are also possible. Trudell, et al. teach in U.S. Pat. No. 5,207,705 a collagen polyurethane foam blend that is useful as a biocompatible surface for human cell propagation. This system is within the scope of this invention. The collagen is added to an aqueous phase. It is then emulsified with a hydrophilic polyurethane prepolymer and applied to the scaffold as described within.
Once the open cell coating polyurethane is formed, it can be post treated by grafting ligands onto its surface thereby forming a functionalized surface. In one embodiment of the present invention, acrylic acid can be grafted onto the surface of an unsaturated hydrophilic polyurethane coated scaffold using a grafting process for hydrophilic polyurethane described by Mekras, C. L., et al., Immobilization of alpha - chymotrypsin on poly ( urethane graft - acrylic acid ), Int. J.Biol. Macromol, 1989 vol. 11 No. 2, pp. 113-118 incorporated herein by reference. The graft was prepared using 2,2′-azo-bis-isobutyronitrile as a radical initiator and acrylic acid as the monomer.
In another embodiment of the invention, a polyurethane polymer was treated with hydrogenated methylene diphenyl-isocyanate and then with human serum albumin to produce a grafted albumin surface. Such treated polymers is reported by Rye, G. et al. to have unique blood compatibility characteristics.
Prepolymers suitable for use in the present invention are isocyanate-capped polyether prepolymers with an NCO functionality of greater than 5% as more particularly described below. The prepolymers are based on polyether polyols capped with aromatic isocyanates such as for example toluene diisocyanate (TDI) or methylene diphenyl isocyanate (MDI) or with aliphatic isocyanates, such as, for example isopherone diisocyanate (IPDI) or hydrogenated methylene diphenyl isocyanate (HMDI). The polyether polyols are hydrophilic polyoxyalkylenes with a minimum of 40 mole % ethylene oxide. Crosslinking sites are developed, when necessary, during the prepolymer formation by using the techniques described in Saunders, J. H., et al., Polyurethanes. Chemistry and Technology. Part II ., Interscience Publishers, New York The method of analysis is described in Analytical Chemistry of he Polyurethanes , Robert E. Krieger Publishing Company, Huntington, N.Y. 1979 pp 357-359 incorporated herein by reference. These techniques are as follows:
1. The addition of water to the prepolymer polyols to form urea and subsequently biuret linkages in the prepolymer;
2. The formation of allophanate linkages by prolonged heating at elevated temperatures;
3. The branching of prepolymers by the addition of triols or tetrols, such as for example, trimethylolpropane, glycerol, or pentaerythritol;
4. The formation of branches by the use of selective catalysts.
Isocyanate-capped polyether prepolymers which have been found to be suitable for use in the practice of the present invention include without limitation prepolymers commercially available from the following companies: Lendell Manufacturing, St. Charles, Mich., U.S.A.; Rynel Ltd. Inc. Boothbay, Me, U.S.A.; Dow Chemical, Midland, Mich., U.S.A.; and Mace Adhesives and Coatings, Dudley, Mass., U.S.A. Table 3 below lists polyurethane prepolymers of these companies and the NCO functionality content of their respective prepolymers.
TABLE 3
% NCO
Rynel Prepolymer Type
B-1
7.4-8.32
A-62
10.0-11.4
Trepol
5.2-6.4
Mace Adhesives & Coatings
Bipol
5.5-6.5
Dow Chemical
Hypol 2000
6.3-7.2
Hypol 2002
6.3-7.2
Hypol 3000
9.5-10.3
Hypol 5000
9.5-11.13
Lendell Manufacturing
Prepol
8.0-8.5
The method of analysis of the NCO functionality is described in Analytical Chemistry of Polyurethanes , Robert E. Krieger Publishing Company, Huntington, N.Y. (1979).
Unlike the process used to make hydrophobic polyurethanes, hydrophilic polyurethanes are preferably made by the so-called pre-polymer or pseudo pre-polymer method. In this technique, the polyol and the isocyanate are reacted in various ratios and by various reaction schemes to produce an intermediate product called a pre-polymer or quasi pre-polymer. This is then emulsified in an aqueous phase to produce the final foam product 14 .
The isocyanate end groups on prepolymer molecules are reactive to any compound with an active hydrogen. Thus if a prepolymer is mixed with an alcohol or an amine, a reaction takes place that essentially caps the prepolymer and terminates the reaction as shown below:
If the alcohol or amine is difunctional (that is having an amine or alcohol group at two positions on the molecule) it will continue to react with other isocyanate end groups. The result of this process is a continuous building of molecular weight until the isocyanate groups or the other reactants are consumed. This is the basis of the elastomer technology, applicable not only to hydrophilic polyurethanes but also to all polyurethanes. This reaction is used to obtain coatings for fabric, leathers and many other surfaces. When practiced to produce hydrophilic polyurethanes a film with a very high water vapor transmission rate is obtained. When applied to a fabric such as a continuous film, it is said to have high breathability. It has the typical disadvantages of hydrophilic polyurethanes in that it is physically weak and swells upon the addition of moisture.
There are a variety of amines that are used for this purpose. Each adds it own physical properties to the resultant film.The molecular weight, molecular structure, and the hydrophilicity of the amine contribute to the properties of the resultant film.
The reaction with amines is typically very fast relative to the reaction with water.
If the prepolymer has little or no crosslinking, the resultant elastomer can be thermoplastic. With crosslinking, however, the film can develop significant strength.
If a chain-terminating component is added to the elastomer reaction, the molecular weight of the film can be limited to remain within the adhesive boundaries. Thus by the proper control of the reaction conditions, a high moisture vapor transmissive adhesive film can be produced.
The reaction of primary interest, however, is the reaction of a hydrophilic prepolymer with water as shown below.
O═C═N—R—N═C═O +HOH→O═C═N—R—NH 2 +CO 2
In this reaction, the production of CO 2 and an amine proceed simultaneously to develop, ultimately a stable foam. This is the core reaction of hydrophilic polyurethane foam technology.
The amine product of the reaction develops the physical strength of the foam composite by polymerization to contain the evolution of the CO 2 . As a result of the CO 2 evolution, a radical change in the rheology of the reacting mass takes place early in the process.
Once the water and the prepolymer are mixed, the rheology of the emulsion is that of a liquid. If it remained a liquid, the CO 2 would be able to escape the emulsion and the result would be a closed cell, high density foam of little commercial interest. Commercially available prepolymers have a significant degree of crosslinking and thus, soon after the reaction is initiated, the emulsion changes its rheology from a true liquid to a gel. It is part of the design requirements of a commercial prepolymer that there be sufficient crosslinking to rapidly develop enough gel strength to withstand the internal pressures developed by the evolving CO 2 .
Since the evolution of CO 2 and the polymerization are two separate reactions, each with its own activation energy, a change in temperature affects the rate of the reaction to a different degree. For instance, an increase in temperature of even a few degrees, accelerates the CO 2 reaction more than it accelerates the amine reaction. In as much it is the amine that produces the gelling of the mass, the CO 2 evolves, at first, in a liquid environment and, even if the emulsion has gelled, the CO 2 internal pressure may exceed the ability of the gel to contain it. As a result, the foam may expand initially, but the emulsion will reach a point where it will visibly collapse. This can be used to advantage if a high density hydrophilic polyurethane is required, but typically this is not desired.
Alternatively, if the temperature is lowered, the strength of the gel increases faster relative to the rate of evolution of CO 2 . However, the CO 2 reaction must take place first to produce the amine. Lowering the temperature has the effect of decreasing the difference in reaction rates. From a practical point of view, the gel strength develops so as to be able to withstand the internal pressures. This is evidenced by a slower rate of rise and the result is a higher density product. In the extreme, a closed cell foam is produced. An efficient process must juxtapose these reactions so as to produce the desired product as illustrated graphically in the FIG. 4 .
Accordingly, the control of temperature is a critical process parameter. An efficient process will focus the control efforts on the temperatures of the components, the degree to which the two phases are emulsified and other classical control methods. Once the emulsion is made and dispensed, there is little that can be done to control what happens. In this sense, the process changes to a more or less chaotic condition. From a control point of view, every thing that can be done to moderate the process must be done before or during the emulsion stage.
The flow diagram shown in FIG. 5 is common to most if not all hydrophilic polyurethane foam manufacturing processes.
The preparation refers to the treatment of the prepolymer and the aqueous phases before they are pumped into an emulsifier. This is typically tempering them with respect to temperature. This usually done in a jacketed vessel.
A prepolymer tank is closed and is usually blanketed with dry nitrogen to prevent reaction with the humidity in the air. Inasmuch as the prepolymer is a high viscosity liquid at room temperature, the prepolymer temperature can be raised to between 80° F. and 100° F. This lowers the viscosity of the prepolymer enough to be pumped without fear of cavitating the pump. As a final control of the temperature it is typically pumped through a heat exchanger designed to ensure that the temperature of the prepolymer is controlled to within 1° F. of a set point. If a temperature above room temperature is used, heated lines are recommended. Delivery of the prepolymer to the mixer is typically accomplished by using a gear pump. These are positive displacement devices, which ensure a precisely controlled volume of material is delivered to the emulsifier. Care must be taken, however, that an uninterrupted flow of prepolymer to the pump on the low pressure side is maintained. Attempting to pump liquid faster than the prepolymer can flow into it results in cavitation which changes the flow rates and can gel the prepolymer. FIG. 6 shows a typical prepolymer process flow diagram.
The preparation of the aqueous stream is similar. Due to the usually lower viscosity of the aqueous stream, a gear pump is not recommended. A progressive cavity pump, such as a Moyno-type, is preferred. A consideration in the choice of pumps is the components of the aqueous phase. If the aqueous phase contains a solid, as in a slurry or emulsion, a Moyno-type pump is highly preferred. When using latices, the shear forces created by the pump can coagulate the fluid.
Typically, the temperature of the aqueous stream is used to adjust the quality of the foam. For instance, if a foam is found to have large cells and a low density, the temperature of the aqueous stream might be lowered. Thus the aqueous temperature can be viewed as a primary means to fine-tune the process of preparing open-cell hydrophilic polyurethanes. Other control methods exist, such as adjusting the emulsifier speed, but controlling the temperature of the aqueous phase is the more convenient method.
As with the prepolymer stream, the important parameters of the aqueous stream are temperature and flow rate. Any pump system that meet these parameters will be effective. Pulsatory pumps, such as peristaltic, piston, diaphragm, and the like should be avoided, but can be made to work if a pulse-reducing chamber or coil is used. Depending on the nature of the aqueous stream, continuous agitation might be required.
With those exceptions, a process flow scheme of the aqueous stream would be similar to that for the prepolymer flow diagram shown in FIG. 6 .
In both cases, the prepolymer and the aqueous streams must be engineered in such a way as to deliver safely both streams to the emulsifier at a precise flow rate and a precise temperature. The absolute values are determined by a number of process specific requirements, but the ratio of aqueous to prepolymer should be controlled to within 1% preferably to within 0.5% and the temperatures should be controlled to within 1.0° F. and preferably 0.5° F.
The next step in producing an open cell hydrophilic polyurethane foam for use in the invention is the emulsification of the prepolymer and aqueous phases. The device that performs this operation is typically called the mix head. There is a wide variety of equipment whose purpose is to produce the emulsion. The preferred designs fall into the category of what are called pin mixers. FIG. 7 shows a typical design of a pin mixer. Although not shown in FIG. 7, the mixer can have what are called stators. These are pins attached to the walls of the mix head and, therefore, they do not spin. These stators increase the turbulence inside the mixhead.
What results, typically, is a prepolymer in water emulsion, i.e., with water as the continuous phase. Inasmuch as this is essentially the last stage in which we can control the quality of the foam, there are a number of variables to be discussed.
The temperature is of critical importance to a well-controlled process. For the most part, it is the temperature of the emulsion leaving the mix head which is of principal concern. This is essentially determined by the temperatures of the component parts, but in the context that a few degrees can be significant, the mix head itself can have an effect on the emulsion. Depending on the speed at which the mixer spins, it can add 2-3° F. to the emulsion.
It is the function of the mixhead, however, to create an emulsion. It is the quality of the emulsion that, for the most part, defines the cell structure of the resultant foam. Emulsions of very small droplet sizes will result in a small-celled foam, all other things being equal. Emulsions with a broad droplet size distribution will have a wide variety of cells in the foam.
The primary determinant of the size and distribution of the emulsion and the cell structure of the foam is the use of an appropriate emulsifier.
The rate at which the foam absorbs water is known by several names, but the most common is wicking. A fast wicking foam will begin to absorb as soon as it is placed in water. Values of less than a second are usually reported as “<1 second”. This can be an important technical factor and needs to be given attention during design of the open cell hydrophilic polyurethane useful in the present invention. The control of wicking is strictly a function of the emulsifier package that is used. The hydrophilic polyurethane foam itself has very slow wicking values (>5 minutes). If a water-soluble surfactant is used, such as Pluronic F-68, Tween 20, and the like, the wicking will be greatly increased. If a waxy surfactant such as Brij 72, for example, is used the wicking will not be increased as much.
The NCO concentration of prepolymers is a measure of the amount of CO 2 that can be generated upon the addition of water. Inasmuch as it is the CO 2 that creates the foam structure, the higher the percentage of NCO the more foaming takes place. At concentrations above 1%, enough CO 2 is generated not only to produce a foam but also to develop enough internal pressure to break the “windows” between developing cells of the resulting hydrophilic polyurethane. This is the origin of the open cell structure that is an essential aspect of this invention. At concentrations below approximately 1%, a dense, closed cell mass is made. On the other hand, at concentrations above 14% so much CO 2 is generated that the gas is able to break through the surface thus liberating so much of the CO 2 that the foam collapses. This effect is also seen if the temperature is too high, for instance above 120° F. The range of NCO values for the prepolymers useful in the present invention is from about 5% to about 15% by weight. In a preferred embodiment of this invention in order for the prepolymer to contain sufficient NCO to develop a preferred open-cell foam structure a range from about 6% to about 9% by weight is recommended.
The foam composite of the present invention is provided by applying an open cell hydrophilic polyurethane foam coating to a reticulated hydrophobic polyurethane foam according to the processes discussed below. By combining these two types of foams, the resulting composite overcomes the disadvantages of both hydrophobic and hydrophilic polyurethane while maintaining their respective advantages.
Specifically, a hydrophilic coating, which may or may not contain an active ingredient, provides for the hydrophilic character, while the reticulated foam provides for physical strength and the good flow-through aspects that characterize a reticulated foam. Thus, while the hydrophilic coating will swell when it absorbs water, the reticulated foam is sufficiently strong to prevent an increase in the size of the composite.
The resulting foam composite of the present invention has a density from about 0.03 g/cc to about 0.10 g/cc. Its pore size distribution varies from about 8 pores per linear inch (ppi) to about 100 ppi. In a preferred embodiment the pore size distribution is from about 10 ppi to about 45 ppi, where the ratio of the weight of the open cell hydrophilic polyurethane coating to the weight of the hydrophobic foam is from about 0.01 to about 15, and preferably from about 0.5 to about 10 depending upon the application for which the foam composite has been engineered. The surface area of the foam composite of the invention varies from about 100 ft 2 /ft 3 to about 2000 ft 2 /ft 3 and preferably from about 300 ft 2 /ft 3 to about 2000 ft 2 /ft 3 .
The absorbency characteristic of the foam composite of the present invention depends upon the amount of the open cell hydrophilic polyurethane coating.
Flow characteristics of the foam composites of the invention have been examined as a function of pore size and amount of open cell hydrophilic foam applied to the reticulated foam structure. It has been found that the smaller the cell size of the foam composite the higher the pressure drop at any given flow. For example, a foam composite having a cross sectional area of approximately 2 in 2 and the thickness of approximately 7 inches, a pore size of about 10 ppi and a weight ratio of hydrophilic to hydrophobic polyurethane of 1.1 exhibits a pressure drop of water passing through it from about 0.06 psi to about 1.25 psi at flow rates from approximately 1 to approximately 5 gal/min. A foam composite having the same cross sectional area and thickness and a pore size of 10 ppi, but an increased weight ratio of hydrophilic to hydrophobic polyurethane of approximately 2.6 exhibits a pressure drop from about 0.06 psi to about 1 psi at flow rates from about 1 to about 3 gal/min.
The foam composite of the present invention is also very durable. In one study, the foam composite of the invention was used to remove water from a hydrocarbon fluid. A column of foam composite having a diameter of 4 inches and a thickness of 12 inches was placed in a cartridge and a quantity of 10 gallon per minute of the hydrocarbon fluid was pumped through it for 60 minutes without damage to the foam composite.
The durability of the coating is further demonstrated in a study of the hydration/dry cycle. A sample of foam composite consisting of 10 grams of reticulated foam of Crest T-20 coated with 6 grams of an open cell hydrophilic foam made from Lendell PrePol® prepolymer by the emulsion process, as described in Example 1 herein, was immersed in water at ambient temperature for 30 minutes to hydrate it fully. It was removed and dried at 105° C. until the foam composite achived constant weight. It was rehydrated and dried by this process 10 times. No flaking of the hydrophilic foam coating was observed at any time. Table 4 below shows the data:
TABLE 4
Rehydration of Foam Composite
Times Hydrated and Dried
Total Weight Dry (grams)
1
16.1
3
16.1
5
16.3
7
16.1
10
16.1
The experiment demonstrates the durability of the foam composites of the invention as evidenced by their ability to be fully dried and yet not flake off
Without being bound by theory, it is believed that the durability of the foam composites of the present invention is due in part to the strong bonding existing between the open cell hydrophilic polyrurethane coating and the reticulated hydrophobic scaffold.
In another preferred embodiment of the present invention, the absorption capability of the foam composite of the present invention is enhanced by contacting the hydrophobic polyurethane scaffold with a mixture of a prepolymer emulsion of the open cell hydrophilic polyurethane and a hydrophilic hydrogel emulsion. Useful hydrophilic hydrogels for this embodiment of the invention include without limitation those based on polysaccharides and acrylics. Polysaccharide hydrogels useful in the invention include without limitation alginate, carrageenan, agar, agarose, curdlan, pullulan, gellan and the like. Acrylic hydrogels useful in the invention include, without limitation, polyacrylamide, poly (ethyl methacrylate), poly (glycol methacrylate), poly (hyroxy methyl acrylate), poly (sodium acrylate), mixtures thereof and the like. The hydrophilic polyurethane prepolymer and the hydrophilic hydrogel are preferably in a ratio from about 0.01 to about 10.0 and preferably from about 1.0 to about 5.0 of hydrogel to hydrophilic polyurethane foam. The mixed emulsion containing hydrophilic hydrogel and hydrophilic polyurethane prepolymer when reacted in place becomes firmly bound to the hydrophobic polyurethane scaffold.
According to one embodiment of the invention, a foam composite is provided by contacting a prepolymer emulsion of hydrophilic polyurethane with a reticulated hydrophobic polyurethane scaffold. The contacting of the prepolymer emulsion with the reticulated hydrophobic polyurethane scaffold can be accomplished in anyway available to one skilled in the art. Examples of contacting include, without limitation, dipping of the scaffold into a prepolymer bath, coating of the reticulated scaffold with the prepolymer emulsion by distributing it with a rolling pin, spraying the prepolymer emulsion over the reticulated scaffold and the like.
The contacting step is followed by curing the emulsion impregnated reticulated hydrophobic polyurethane for a period of time sufficient to form the foam composite. Prior to curing, the emulsion impregnated reticulated foam can, optionally, be subjected to a stream of air blowing through the curing composite. This minimizes the formation of windows across cells to ensure that the reticulated structure of the foam composite is uniformly retained. A flow diagram showing the emulsion process is shown in FIG. 8 .
Curing the prepolymer emulsion impregnated hydrophobic polyurethane is accomplished by allowing it to age undisturbed for a period of time sufficient for approximately 99% of the isocyanate functionality to have reacted with the water. Generally, the amount of time necessary for curing to take place varies from about 10 minutes to about 30 minutes depending upon the temperature of the water and the curing chamber which is typically from 20° C. to about 30° C. The curing step is ordinarily followed by an optional drying step during which any excess water present in the foam composite is driven off.
The amount of prepolymer in the emulsion used to prepare the hydrophilic foam composition is not particularly critical, but depends on a number of factors including the temperature and pore size of the reticulated foam to be coated. A ratio range of from about 0.8:1 to about 2.2:1 of aqueous phase to prepolymer phase is typical, with a ratio range of from about 1:1 to about 2:1 being preferred. The higher ratios, which typically result in lower viscosity, are preferred for smaller pore sizes. Lower ratios are preferred for larger pore sizes. Prepolymer emulsions of higher viscosities typical of lower ratios are used when higher coating weights are desired.
High ratios are also preferred when the temperature of the emulsion needs to be limited. This is the case when enzymes, bacteria or other components that are temperature sensitive are included in the emulsion.
The temperature of the emulsion used to prepare the hydrophilic foam composition is important for two reasons. First, as indicated above, temperature sensitive components in the emulsion may have to be protected by using low temperature components, i.e., a aqueous phase and prepolymer phase and minimizing the exotherm that is the natural result of the reaction of water and the prepolymer.
Secondly, the temperature is important in controlling the gel time of the emulsion. This point in the reaction, known in the industry as cream time is the point at which the reacting emulsion changes from a liquid to a gel. Gelation is an important step in the development of the polyurethane foam structure. It is an essential aspect of the present invention that the emulsion be cast onto the structure of the reticulated foam before gelation. Those skilled in the art of prepolymer emulsions will understand that gelation is a separate step for curing. During gelation only approximately up to 10% of the isocyanate functionalities present in the emulsion react primarily with other isocyanate functionalities.
The range of temperatures used in the practice of this invention is from about 4° to about 50° C., and preferably from about 15° to about 40° C.
A wetting agent is typically included in the emulsion to provide for more uniform wetting of the resultant foam. The wetting agent also aids in controlling the cell size of the foam. Wetting agents suitable for use include non-ionic surfactants. Examples of materials that are useful in the present invention include but are not limited to block copolymers of ethylene oxide and propylene oxide sold by BASF Wyandotte Corporation of Parsippany, N.J., USA under the trade name Pluronic®. Pluronic L-62 and F-88 available from BASF Wyandotte Corporation are preferred. Pluronic F-88 is suitable and has been used in medical devices due to its biocompatibility. Generally the amount of wetting agent should be from about 0.01 to about 1.0% based on the weight of the aqueous phase. A preferred amount of wetting agent is 0.05-0.5% by weight.
In another embodiment, the foam composite of the invention is made by a process wherein the reticulated hydrophobic polyurethane foam is prepared by contacting with a solution of a prepolymer in a nonreactive solvent. Useful nonreactive solvents for the solvent process of the invention include solvents that are found to dissolve the prepolymer without reacting with it within the time required for deposition on the reticulated foam. Such solvents include without limitation acetone, toluene, xylene, benzene, mixtures thereof or the like. As in the emulsion process, the contacting may be accomplished by coating, spraying or dipping the reticulated scaffold into the prepolymer solution. The coated or otherwise prepolymer impregnated reticulated hydrophobic polyurethane is squeezed or hung in place to remove the excess prepolymer solution
The critical step in this process is to reduce the viscosity of the prepolymer solution. A non-reactive solvent is used to dissolve the prepolymer and thus lower the viscosity of the prepolymer coating. The degree to which the viscosity is lowered will control the amount of prepolymer that is deposited on the reticulated scaffold.
The solvent may be evaporated or recovered for further use. Just as in the emulsion process, there must be a curing step of the reticulated scaffold coated with the prepolymer solution for the foam composite of the present invention to be formed. Curing can take place in a water bath or in a high humidity chamber. The temperature of the water bath can be from about 4° C. to about 50° C., and is preferably in the range of 20° C. to 40° C. The curing time is generally from about 10 minutes to about 30 minutes. As an alternative, a water vapor curing chamber can be used wherein the water vapor is kept typically at temperatures up to 95° F. and high relative humidity in excess of 95%. The residence time for curing in a water curing chamber varies from about 10 minutes to about 30 minutes. A flow diagram illustrating steps in the solvent process is shown in FIG. 10 .
In yet another embodiment, the foam composite of the present invention is prepared by a direct cast process. As is the case with the solvent process, in the direct cast process the critical objective is to reduce the viscosity of the prepolymer coating.
In this process the reticulated hydrophilic polyurethane scaffold is contacted with the prepolymer directly where the viscosity of the prepolymer is controlled by increasing its temperature. Increasing the temperature reduces the viscosity. FIG. 9 illustrates the effect of temperature on the viscosity of lendell PrePol® prepolymer. Other prepolymer useful in the present invention have similar viscosity/temperature curves.
A flow diagram showing the direct cast process is shown in FIG. 11 . It is readily apparent from FIG. 11 that the direct cast process has the same steps as the solvent process except that the prepolymer is not dissolved in any solvent and its viscosity is controlled by controlling the temperature of the prepolymer.
Curing can take place in a water bath or in a high humidity chamber as described above.
In another aspect of the invention, one or more additives may be incorporated in the hydrophilic polyurethane foam. The additives include bioaffecting or active agents and/or non-bioactive ingredients. Bioaffecting or active agents useful in the present invention include without limitation pharmaceuticals, fragrances, soaps, pesticides, herbicides, yeasts, bacteria, algi, enzymes, plants, animal cells, human cells, mixtures thereof and the like. Useful non-bioactive ingredients include without limitation hydrogels, fillers, activated charcoals, zeolites, ion exchange resins, phase change materials, mixtures thereof and the like.
In other preferred embodiments of the invention one or more additives can be incorporated in the foam composite. The incorporation of additives can be accomplished in any manner known in the art. In one preferred embodiment the additives are immobilized in the foam composite.
In another aspect of the invention bioaffecting agents such as, for example, antigens or ion exchange ligands are grafted onto the foam composite directly or they are grafted onto a hydrogel containing hydrophlic polyurethane coating. The grafting is accomplished by methods known in the art.
Inasmuch as the hydrophilic foam formulation can contain an active ingredient, the foam composite 10 can have a hydrophilic coating containing the active ingredient. In one example, the aqueous phase with which the hydrophilic prepolymer is emulsified may contain a fragrance. When combined with a reticulated foam 12 , as described in the above example, a foam composite 10 with the fragrance imbedded in its structure results. Such a device might be used as a room freshener.
As set forth with reference to the attached drawings, the invention has many embodiments. Referring first to FIG. 12, one embodiment of the foam composite 10 contains plant growth media, such as peat moss, to produce a device for growing plants on a soil-less media. This can be used in hydroponics, for growth of high value plants, plants for transplant and plants for export, to name a few applications.
Another embodiment is shown in FIG. 13 . As shown here, the foam composite 10 can be used as a controlled release device. In such an embodiment, the coated foam is formulated to include an additive, such as liquid soaps, fragrances, herbicides or pesticides. These additional components are released when a user uses the foam in a predetermine manner; i.e. mixing with water in the case of the soap, herbicides or pesticides, or evaporating into the air in the case of the fragrances.
Referring now to FIG. 14, in another embodiment of the invention, the foam composite 10 is formulated to include algae or bacteria to create a cell for bioremediation device. The hydrophilic foam 14 is prepared according to the procedures taught in Rao, K. K.; Hall, D. O. Trends Biotechnol. 1984. vol. 2, no. 5, pp. 124-129 and combined with the reticulated foam 12 . In this embodiment, waste stream water or domestic water flows through the device, and becomes purified via through treatment by the algae or bacteria.
In another embodiment of the invention, the foam composite 10 is formulated with yeast to yield a fermentation device. The hydrophilic foam 14 is prepared according to the procedures taught in Lorenz, O.; Haulena, F.; Rose, G. Biotechnol. Bioeng. 1987. vol. 29, no. 3, pp. 388-391 and combined with the reticulated foam 12 . As shown in FIG. 15, as sugar-containing water flows through the cell, the sugar is fermented, resulting in the production of alcohol.
Referring now to FIG. 16, in another embodiment of the invention, the foam composite 10 is formulated with a lactase enzyme which enzymatically converts whole milk into lactose-free milk. The hydrophilic foam 14 is prepared according to the procedures taught by Storey, K. B.; Chakrabarti, A.C. Appl. Biochem. Biotechnol. 1990. vol.23, no.2, pp. 139-154, and combined with the reticulated foam 12 .
FIG. 17 shows another embodiment of the invention in which the foam composite 10 is formulated with immobilized enzymes or grafted to yield a flow through chemical reactor using enzymes or an ion exchange. Such an enzymatic reactor can be incorporated with any enzyme chosen by the user to perform the desired chemical reaction. In this embodiment, the hydrophilic foam 14 is prepared according to the procedures taught by Hu, Z.C.*; Korus, R. A.; Stormo, K. E. Appl. Microbiol. Biotechnol. 1993 vol. 39, no. 3, pp.289-295, and combined with the reticulated foam 12 .
FIG. 18 shows another embodiment of the present invention, in which the foam composite 10 is formulated to include antibodies specific for a particular antigen and is incorporated into a blood shunt such as a femoral shunt. The antibodies are incorporated into the hydrophilic polyurethane coating or are otherwise immobilized on the surface of the foam composite of the invention. The foam composite with the immobilized antibody is then placed in a device such as a canister to which blood from a living subject is fed using, for example, a femoral shunt. After the blood passes through the foam composite bearing device, it is returned to a major vein. In operation, as the blood passes through the foam composite filter, the antibodies immobilized on the surface of the foam composite complex with the antigen for which they are specific, capture the antigens and remove them from the blood. The device can be used to treat the blood of persons with drug overdoses, to remove HIV virus from the blood or to remove other environmental contaminants from the blood. Other antigens which could be separated by using specific antibodies immobilized in the foam composites of the present invention include, without limitations, HIV protease, components of HIV virus, opiates, such as, for example, codeine, cocaine, heroin, their C 1 -C 6 analogs and the like.
Referring now to FIG. 19, another embodiment of the invention is a scaffold for the propagation of cells. This embodiment is created by seeding the foam composite 10 with hepatic or other human cells, as taught in Matsushita, T.; Ijima, H.; Koide, N.; Funatsu, K. Appi. Microbiol. Biotechnol. 1991. vol. 36, no. 3, pp. 324-326. The resulting embodiment can be used in the development of hybrid artificial organs or for other biomedical applications.
Another embodiment of the invention is shown in FIG. 20 . In this embodiment, the foam composite 10 is formulated with a pharmaceutical agent of choice which yields a flow through device for administering pharmaceuticals. The hydrophilic foam 14 in this embodiment is produced by the emulsification of a hydrophilic prepolymer with a solution or dispersion of the pharmaceutical in water. This is then combined with reticulated foam 12 . Fluid or blood is pumped into the apparatus, and the resulting fluid which comes out is fluid treated with the drug. This embodiment creates an advanced drug delivery system.
Referring now to FIG. 21, another embodiment of the invention is an adsorption cell for the removal of low concentration chemicals for bioremediation. Polyurethanes are known to adsorb organic molecules. (As described in Enkiri, F.; Hulen, C.; and Legault-Demare, J. Appl. Microbiol. Biotechnol. 1995 vol. 44, no. 3-4, pp. 539-545). This embodiment is created by producing a foam composite 10 by the method taught in the Example 1 described herein below. A process stream flowing through the cell is thus purified by the adsorption effect.
Another embodiment of the invention is shown in FIG. 22 . In this embodiment, the foam composite 10 is formulated with a graft of activated charcoal or zeolite, and creates a device for the removal of drugs from blood.
Referring now to FIG. 23, another embodiment of the invention is a water deionizer. In this embodiment, the foam composite is formulated with commercially available ion exchange resins or ligands attached to the surface of the foam composite 10 by grafting. The grafting is accomplished by procedures taught by Sreenivasan, K., Polymer Engineering and Science, v. 33 October 1993 p. 1366-9. As water flows through the device, the water is de-ionized.
Related embodiments of the invention are shown in FIGS. 24 and 25. In these embodiments, the invention is used as a humidifier. As shown in FIG. 24, this device can be used as a humidifier for incubators. FIG. 25 shows the embodiment as a humidifier for dry anesthetics. In both FIGS. 24 and 25, the foam composite 10 , prepared as described in the example 1 herein is wetted with water. The water then evaporates as a gas stream passes over it. This embodiment is not confined to just air and anesthetics, but other substances known in the art that require humidification.
As shown in FIG. 26, another embodiment of the invention is a device for administering anesthetic. In this embodiment, the foam composite 10 is formulated or post-treated with an anesthetic that evaporates in air flowing through the cell.
Another embodiment of the invention is shown in FIG. 27 . In this embodiment, a device for removing water from a hydrocarbon is shown. The foam composite 10 , due to the nature of its hydrophilic coating, will absorb water from the hydrocarbon stream passing through the cell.
Referring now to FIG. 28, another embodiment of the invention is shown in which the foam composite 10 is utilized as a respirator for use in low temperature applications. The hydrophilic foam 14 in this embodiment contains a phase change material that melts and freezes at just below the temperature of the human body (98.6° F/37° C.). The latent heat of fusion of the phase change material is used as a reservoir for storing the heat of exhaled air and subsequently releasing that heat to increase the temperature of inhaled air. Thus, in a respirator having two separate chambers and through which a person inhales through one chamber and exhales through the other, cold air enters the inhale side and is heated by the freezing phase change material. Air at body temperature is exhaled through the other chamber and melts the phase change material. This continues until the inhaled air freezes all of the phase change material. At that time, a valve is turned that reverses the inhale side to the exhale side and visa versa. The net effect is that the heat energy in the exhaled air is trapped and subsequently used to heat incoming air. The net effect is the breathed air temperature is tempered thus avoiding the body heat lost in very cold weather.
Referring now to FIG. 29, still another embodiment is shown in which the foam composite 10 is utilized as a flow-through analysis column. In such an embodiment, a column is made of one or more layers of foam 10 , each providing an opportunity for analysis. For example, the first layer might be a foam 12 used for filtration. The second layer can be foam 12 coated with hydrophilic foam 14 to which an enzyme has been grafted (as described in Hu, Z.C.*; Korus, R. A.; Stormo, K. E., Appl. Microbiol. Biotehcnol. 1993 vol. 39, no. 3, pp.289-295). The next layer might be a foam 12 coated with hydrophilic foam 14 to which an antigen that has been adsorbed or graphed. The device, thus constructed, is suitable for the analysis of one or more properties or constituents of a fluid passing through it.
The following examples have been carried out to illustrate the invention and to describe the best mode of the invention at the present time. These examples further illustrate the various features of the invention, and are not intended in any way to limit the scope of the invention which is defined in the appended claims.
EXAMPLES
Equipment
The equipment listed below has been used in the preparation of the foam composites of the invention. All materials used in these examples can be obtained from commercially available sources.
1. Meter/Mix
A series of devices whose function was to store, temper (with respect to temperature), meter (through the use of positive displacement pumps) and mix together the hydrophilic polyurethane prepolymer and aqueous phases component are employed. The system included heat exchangers by which the temperature of the phases were controlled. Meter/Mix systems are readily commercially available for use with hydrophilic prepolymers from Edge-Sweets & Co., Grand Rapids, Mich., USA.
2. Web
A system by which a continuous roll of reticulated foam is supplied to the process at a constant rate of speed. This equipment is typically custom made to meet the requirements of the manufacturing facility with respect to output.
3. Dip Tank
A tank or trough through which the reticulated foam web was drawn was employed in order to coat it with the prepolymer solution.
4. Nip Rollers/Doctor Blade
A device that distributes the emulsion across the surface of and causes the emulsion to penetrate into the structure of the reticulated foam.
5. Air Blow
A mechanism designed to blow air through the emulsion-coated reticulated foam in order to minimize the formation of windows across cells such that the reticulated structure of the foam composite is maintained. The use of this mechanism is optional.
6. Solvent Recovery
A mechanism for the evaporation and recovery of the solvent.
7. Immersion Curing, Bath
Used in connection with a solvent or direct cast process, this equipment is a tank or trough through which the web was drawn to effect the curing of the foam composite by immersing it in water was employed. The residence time was sufficient to cure fully the foam composite of the invention.
8. Water Vapor Curing Chamber
Alternatively, the web of prepolymer solution coated hydrophobic polyurethane scaffold was drawn through a vapor curing chamber wherein the water vapor was typically kept at elevated temperatures of up to 95° F. and a high relative humidity in excess of 95%. The residence time of the web sufficient to complete curing of the foam composite.
9. Dryer
A mechanism to evaporate the excess water from the foam composite of the invention was employed. Radio frequency or hot-air dryers are typically used and are commercially available.
Example 1
This example illustrates the preparation of foam composites by coating hydrophobic polyurethane scaffolds with an emulsion of polyurethane prepolymer.
Three (3) pieces of conventional hydrophobic reticulated foam having a pore size of 20 ppi such as Crest Foam, Grade S-20 were cut to 30.5 cm by 30.5 cm by 0.8 cm. Each weighed 16 grams. An emulsion was made using a mechanical mixer of a 0.1% Pluronic L62 (BASF Corp.) in water at ambient temperature and Rynel® (Grade B-1) hydrophilic polyurethane prepolymer (Rynel Ltd., Inc.). The emulsion was prepared by using 1 part prepolymer to 1.5 parts 0.1% Pluronic L62 solution. Three different amounts of the emulsion were immediately poured onto the three pieces of foam as shown in Table 5. In each case the entire emulsion was uniformly distributed onto the reticulated foam using a rolling pin. After curing, the entire amount of the prepolymer in the emulsion was found to form the coating of hydrophilic foam in the foam composite. The foam was allowed to cure in water for 30 minutes at ambient temperature and then dried at 105° C. The resulting foam composites were then dried and re-weighed and then placed in water to measure how much water they would absorb. The following table presents the results of those tests:
TABLE 5
Physical Properties of Uncoated Versus Emulsion-Coated Reticulated
Foams
Emulsion
Emulsion
Emulsion
Foam Property
Reticulated
1
2
3
Size
Length (cm)
30.5
30.5
30.5
30.5
Width (cm)
30.5
30.5
30.5
30.5
Thickness (cm)
0.8
0.8
0.8
0.8
Weight (grams)
16.00
35.0*
45.0*
63.0*
Density (grams/cc)
0.021
0.047
0.06
0.085
Coating Thickness
—
19.0
29.0
47.0
(grams)
Water Saturated
18.0
73.0
110.0
184.0
Weight (grams)
Grams Water
0.125
1.09
1.44
1.92
Absorbed per
Gram of Foam
*Total Weight of Foam Composite
In this example, the amount of water that each foam composite was able to absorb was used to evaluate the effectiveness of the process. The above results indicate that the absorption of the foam composite increased with increasing thickness of the hydrophilic polyurethane coating.
Example 2
This example illustrates the preparation of foam composites by coating reticulated hydrophobic polyurethane scaffolds with a solution of polyurethane prepolymer. A solution of the prepolymer was dissolved in a solvent such as acetone. The weight of the coating was controlled by varying the viscosity of the solution.
Three solutions of 10%, 20% and 30% of Rynel® prepolymer in acetone were prepared at ambient temperature. Samples of Crest® reticulated polyurethane foam as described in Example 1 above were dipped into the Rynel® prepolymer solutions. They were immediately removed and allowed to drain. They were then hung in a fume hood and the acetone was allowed to evaporate as evidenced by an absence of the acetone odor. The foam samples were then immersed in water at 25° C. for about 10 minutes to cure. The samples were then dried and reweighed. They were subsequently placed in water at 25° C. for 1 hour, patted dry to remove surface water and then re-weighed to determine the absorbed amount of water. Table 6 below summarizes the results of these tests.
TABLE 6
Physical Properties of Uncoated Versus Reticulated Foams Coated with
Prepolymer Solution
10%
20%
30%
Foam Property
Reticulated
Polymer
Polymer
Polymer
Size
Length (cm)
30.5
30.5
30.5
30.5
Width (cm)
30.5
30.5
30.5
30.5
Thickness (cm)
0.8
0.8
0.8
0.8
Weight (grams)
16
19*
23*
27*
Density (grms/cm3)
0.021
0.026
0.031
0.036
Coating Thickness
—
3.0
7.0
11.0
(grams)
Water Saturated Weight
—
18.0
26.0
43.0
(grams)
Grams Water Absorbed
—
0.125
0.37
0.87
Gram of Foam
*Total Weight of Foam Composite
The results summarized above illustrate that the weight of hydrophlic foam coated on the scaffold increased by increasing the thickness of the hydrophilic polyurethane component.
Example 3
This example illustrates the preparation of foam composites by coating hydrophobic reticulated polyurethane scaffolds with undiluted polyurethane prepolymers having different viscosities. Prepolymers at three different temperatures were applied directly to Crest Foam® hydrophobic scaffolds as described below. The viscosity of commercial prepolymers was about 15,000 cps. at 25° C. By heating the prepolymers their viscosity was lowered significantly. Three different foam composites having three different levels of open cell hydrophilic polyurethane coating were obtained.
Three (3) samples of the Rynel® prepolymer as described above were heated to 30°, 35° and 40° C. Three (3) samples of Crest® foam as described in Example 1 were each dipped into a prepolymer dip tank and then squeezed between rubber rollers. The samples were immediately immersed in water at 25° C. to cure for about 30 minutes. The samples were dried and re-weighed. They were soaked in water, patted dry and then weighed to determine the amount of water they could absorb. Table 7 below summarizes the results found in this example.
TABLE 7
Direct Coating of a Reticulated Foam
Polymer
Polymer
Polymer
Foam Property
Reticulated
@ 40° C.
@ 35° C.
@ 30° C.
Size
Length (cm)
30.5
30.5
30.5
30.5
Width (cm)
30.5
30.5
30.5
30.5
Thickness (cm)
0.8
0.8
0.8
0.8
Weight (grams)
16
25*
35*
42*
Density (grms/cm3)
0.021
0.034
0.047
0.056
Coating Thickness
—
9.0
19.0
26.0
(grams)
Water Saturated
18.0
43.0
75.0
99.0
Weight (grams)
Grams Water
0.13
0.72
1.14
1.36
Absorbed per
Gram of Foam
*Total Weight of Foam Composite
The above results indicate that the foam composites of the invention having a thicker coating of open cell hydrophilic polyurethane deposited as undiluted prepolymer absorbed increasing amounts of water.
Example 4
The relationship of the pore size of foam composites, the flow rate of water through columns packed with the foam composite of the invention and the ratio of hydrophobic foam cast The above results indicate that the foam composites of the invention having a thicker coating of open cell hydrophilic polyurethane deposited as undiluted prepolymer absorbed increasing amounts of water.
Example 4
The relationship of the pore size of foam composites, the flow rate of water through columns packed with the foam composite of the invention and the ratio of hydrophobic foam cast on a hydrophobic reticulated foam scaffold is examined. The effect of these independent variables on the pressure drop across three (3) packed columns of foam composites was studied. The equipment used included as follows:
(a) 0-25 oz/in 2 pressure gauge;
(b) 1.5 Schedule 40 PVC pipe, 7 inches long;
(c) Stop watch;
(d) Calibrated vessel to measure volume of the flow of water;
(e) Various fittings to build the apparatus shown in FIG. 30 .
Three (3) columns as shown in FIG. 30 were packed with foam composites of the invention having a pore distribution of 10 ppi, 20 ppi and 45 ppi, respectively. The samples were made using the water emulsion method described in Example 1 using 0.1% Pluronic L62 (BASF Corp.) in water and Rynel® prepolymer to form an emulsion as described in Example 1, and Crest® Foam, T-10, T-20 and T-45 for the reticulated foam.
Care was taken not to over or under pack the column by die cutting circles of 1.56 inches in diameter and stacking them into the column to a thickness of 7 inches. The end caps were screwed on and the water passed through it. The flow of water was measured by determining the time to fill a calibrated vessel. The pressure was recorded at each flow rate. The flow and pressure of the system were measured at 39° F. and are reported in Table 8.
TABLE 8
Flow Rate
(gal/min)
10 ppi
20 ppi
45 ppi
1.1
1
1
1
1.7
3.5
1.8
4.9
2.1
2
2
2.2
1.4
2.3
10.5
2.4
2.8
2.7
6
2.9
18
3.0
9.5
3.8
10
3.9
20
4.0
10
18
4.6
18
28
5.0
18
FIG. 31 is a plot of the data from Table 8. The experiments studied the relationship of flow and pressure drop on several reticulated foams. Crest® T-10, T-20 and T-45 having pores of 10 ppi, 20 ppi and 45 ppi, respectively were used for the hydrophobic polyurethane scaffold.
As is readily apparent from FIG. 30, the smaller the cell size the higher the pressure drop at any given flow rate.
Example 5
The experiment of Example 4 was repeated with foam composites according to the invention made with samples of Crest® T-10 foam and various amounts of hydrophilic foam. All samples were made using the water emulsion process of Example 1, except that different amounts of prepolymer emulsion as prepared in Example 1 were utilized to produce composites having different weights of open cell hydrophilic polyurethane coating. In Table 9 the amount of hydrophilic foam is expressed as H/R which is the ratio of the weight of the open cell hydrophilic polyurethane foam to the weight of the hydrophobic reticulate foam.
TABLE 9
Flow Rate
(gal/min)
0 H/R
1.1 H/R
2.63 H/R
3.71 H/R
4.2 H/R
1
1
1
1
1
1
1.4
5.2
9
1.7
1.5
1.7
9
1.8
10.5
18
2.1
2
3
4
2.2
15.5
2.4
2.8
2.7
10
3.0
8
17
3.8
10
4.0
10
13
4.6
15
5.0
17
20
The plot of the data in Table 9 is shown in FIG. 32. A s expected, as the amount of hydrophilic coating increases the pressure to pump water through the resulting foam composite increases at any given flow rate.
Example 6
A block of foam composite was made from a piece of Crest T45 reticulated hydrophobic foam having a porosity of 45 ppi by the solvent method of Example 2. A solution of 35% Rynel® prepolymer in acetone at ambient temperature was employed. The dimensions of the reticulated hydrophobic foam block was 6 inches by 6 inch by 2 inches thick. Following processing, the block was skived into 0.25 inch sheets each sheet being a square of 6 inch by 6 inch by 0.25 inches in thickness. Each sheet of foam composite was weighed and the amount of hydrophilic coating was determined by the difference. Table 10 below illustrates the data obtained in this experiment.
TABLE 10
Grams
Wt.
Wt. Foam
Wt.
Hydrophilic/grams
Reticulate
Composite
Hydrophilic*
Reticulate
Sheet No.
(grams)
(grams)
(grams)
Hydrophobic*
1
6.0
21.1
15.1
2.52
2
6.0
21.1
15.1
2.52
3
6.0
21.4
15.4
2.57
4
6.0
21.3
15.3
2.55
5
6.0
21.1
15.1
2.52
6
6.0
21.6
15.6
2.60
7
6.0
21.1
15.1
2.52
8
6.0
21.4
15.4
2.57
*types of polyurethane
The above data indicates a high level of uniformity in the penetration of the hydrophilic polyurethane coating into the hydrophobic polyurethane scaffold.
Examples 7-15
These examples illustrate the relationship between foam composites prepared by the solvent and direct cast processes, the weight of the hydrophilic polyurethane coating and viscosity. The foam composites of examples 7 to 10 were prepared by the solvent method according to the procedure described in Example 2 using the same prepolymer and other processing conditions. Samples of Crest® reticulated hydrophobic polyurethane foam having a pore size of 20 ppi were coated with different concentrations of prepolymer solution in acetone at 68° C. The weight of the reticulated polyurethane foam, open cell hydrophilic polyurethane and the ratio of one to the other is summarized in Table 11 and have been plotted in FIG. 33 .
TABLE 11
Solvent and Direct Cast Process
Wt.
Wt. Foam
Prepolymer
Wt. Acetone
% Prepolymer
Temperature
Wt. Reticulate
Wt. Coating
Composite
Hydrophilic/
Examples
(grams)
(grams)
(grams)
(° F.)
(grams)
(grams)
(grams)
Reticulate
7
100
30
77%
68
9.0
29.0
38.0
3.2
8
100
50
67%
68
9.0
25.0
34.0
2.8
9
100
70
59%
68
9.0
20.0
29.0
2.2
10
56
216
21%
68
9.0
6.0
15.0
0.7
11
100
0
100%
100
9.0
90.0
99.0
9.0
12
100
0
100%
118
9.0
60.0
69.0
6.7
13
100
0
100%
145
9.0
58.5
67.5
5.5
14
100
0
100%
178
9.0
48.6
57.6
4.4
15
100
0
100%
200
9.0
40.0
49.0
4.0
It is readily apparent from FIG. 33 that the higher the concentration of prepolymer in the acetone solvent, the higher the weight of the hydrophilic polyurethane coating deposited onto the polyurethane scaffold.
The foam composites of Examples 11-15 were prepared by the direct cast method according to the procedure described in Example 3. Samples of Crest® reticulated hydrophobic polyurethane foam having a pore size of 20 ppi were coated with 100% Rynel® prepolymer at temperatures graphed in FIG. 34 and otherwise processed as described in Example 3. The characteristics of the foam composites of examples 11-15 are also summarized in Table 11. FIG. 34 illustrates the effect of temperature on the foam composites of examples 11-15.
It is readily apparent that as the temperature of the prepolymer in liquid phase is increased, the weight of the hydrophilic polyurethane coating deposited decreases.
Thus, while there have been described what are presently believed to be preferred embodiments of the present invention, those skilled in the art will realize that other and further modifications and changes can be made without departing from the true spirit of the invention, and it is intended to include all such changes and modifications as come within the scope of the invention. Further, the embodiments of the invention in which exclusive rights are claimed are defined as follows:
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A foam composite made up of a scaffold of a substantially hydrophobic foam material having plurality of surfaces defining a plurality of pores, and a coating of a substantially hydrophilic foam material disposed upon the surfaces of the hydrophobic foam. The resulting foam composite exhibits structural characteristics of the hydrophobic foam and absorbency characteristics of the hydrophilic foam.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. patent application Ser. No. 11/880,000, filed on Jul. 19, 2007, which is incorporated herein by reference.
FIELD OF INVENTION
[0002] The present invention relates to a window covering that may be raised without the need to apply a force to either a control mechanism or the window covering itself as the window covering is opened. In particular, the present invention relates to a window covering having a control mechanism configured to exert an upward force on the light blocking element and bottom element that is of sufficient magnitude to raise the light blocking element and bottom rail without additional force being applied by the user during raising. The control mechanism selectively raises the window bottom element and portions of the window covering, and may be actuated by a downward force applied to the bottom element by the user.
BACKGROUND OF THE INVENTION
[0003] Window shades and coverings are found in many applications and used to regulate the amount of light entering a room, and to provide aesthetic appeal to a decor. Such window shades and coverings take many forms, including roller shades, Roman shades, Venetian blinds, and cellular shades. Conventional cellular or pleated shades utilize cord locks or a transmission mechanism to raise, lower and position the window covering in a desired position. With window coverings utilizing a cord lock, cords run up through the folded fabric, across the inside of a head rail and exit through a locking mechanism. Other cellular shades include a transmission mechanism and a continuous loop cord that is pulled by a user to raise and lower the window shade. Roman shades and Venetian blinds also tend to include raising cords that are secured to a lower bar or bottom rail.
[0004] There are some disadvantages to these designs. Cords present the potential hazard of a child getting caught in or strangled by the exposed control cord. Cords also tend to distract from the aesthetics of a window covering in that they extend along the face of the window covering and, when the window shade is opened, must either be wrapped on a hook or just left on the floor. With window coverings that utilize cord locks, the cords also experience substantial wear due to friction against surfaces as a result of raising and lowering of the window covering.
[0005] Other window coverings include common roller shades, which operate in the absence of a cord. These roller shades include a wound torsion-spring retraction mechanism in combination with a clutch or locking mechanism mounted with a roller onto which the shade is rolled and collected. In operation, a roller shade is pulled down by a user to a desired location, where it is locked in place by the clutch or locking mechanism. To unlock and release the shade so that it may be raised, the user typically pulls on a bottom rail of the shade, extending the shade sufficiently to disengage the internal clutch or locking mechanism within. When the clutch or locking mechanism is disengaged and the user releases the shade, the shade is retracted using the torsion-spring driven retraction mechanism. Known roller shades, however, are only operable with flat shade material which rolls up neatly into a confined location.
[0006] The mechanism utilized in such roller shades is not compatible with other window coverings, such as cellular shades, Venetian blinds, and Roman shades. As roller shades are raised, the amount of shade being lifted decreases such that a constant force torsional spring member is capable of applying the necessary winding or upward force throughout the opening range. By contrast, a similar lifting mechanism is typically unsuitable in cellular shades, Venetian blinds, and Roman shades. In these types of window coverings the light blocking material is typically gathered by raising a bottom member, such as a bottom rail, and increasing amounts of weight are gathered on the bottom member as the window covering is raised. The reason for this is that the shade material or light blocking element increasingly stacks on the bottom rail as the bottom rail rises, which increases the load on the lifting mechanism.
[0007] In order to address this increasing weight, very strong torsional springs have been used to accommodate the maximum weight of the shade. One drawback to this approach, however, is that the rate at which the window covering is retracted may be too fast and uncontrolled. One attempt to address this problem is found in U.S. Pat. No. 6,666,252, issued to Welfonder. This patent teaches the use of a fluid brake to control the rate at which the raising cords are retracted throughout the raising process. Another approach that has been used is shown in U.S. Pat. No. 6,056,036, issued to Todd, which employs a mechanical friction member to continuously slow the rate of retraction. One problem with these approaches has been that the spring utilized exerts a force that is difficult for a user to overcome when attempting to lower the shade. Excessive pulling force by the user often results in damage to the window covering.
[0008] Alternatively, variable force springs have been used. Such variable force springs are substantially more complicated in use and manufacture.
[0009] Therefore, there is a need for a window covering raising mechanism for window coverings such as Venetian blinds, cellular shades and Roman shades that is self-raising and overcomes the foregoing problems.
SUMMARY OF THE INVENTION
[0010] The present invention relates to a self-raising window covering and a control mechanism for the window covering. In particular, the window covering is a self-raising window covering that includes a head rail, a light blocking element, such as a cellular panel, blind slats, or Roman shade material, a bottom rail or bottom element, at least one raising cord operatively connected at a first end to the bottom rail or bottom element, and a control mechanism. The head rail may define an elongated channel wherein the control mechanism is disposed therein. In some embodiments, the control mechanism includes a drive shaft and a drive unit operatively connected with the drive shaft. The drive unit, which may be a constant force spring, is adapted to provide a substantially constant rotational force on the drive shaft.
[0011] At least one translation member is also provided in co-axial relation with the drive shaft. Typically, the number of translation members will be the same as the number of raising cords. However, in some instances, the translation member may be adapted to raised multiple cords. The translation member preferably includes at least one winding drum operatively connected to a second end of the raising cord and having a tapered portion. The translation member also includes a rotatable positioning member for moving the translation member laterally along the drive shaft upon rotation of the positioning member. In a preferred embodiment, the positioning member is a threaded tubular member connected to the winding drum. The translation member is adapted to translate the rotational force on the drive shaft to a raising force on the raising cord, wherein the raising force is greater than a downward force exerted by the light blocking element and bottom rail throughout the range of opening and closing. In a preferred embodiment, the translation member is rotationally secured with the drive shaft by a hub member adapted to engage the translation member and the drive shaft. The hub member may be in a sliding relationship with the tapered portion of the translation member.
[0012] A clutch or locking or actuating member is also operatively connected with the axle and adapted to releasably lock the drive shaft in a desired position. In a preferred embodiment, the clutch or locking or actuating member comprises a spring member adapted to releasably secure the position of the drive shaft when in a tightened condition and to permit rotation of the drive shaft when in a relaxed condition. A reciprocator may also be disposed annularly about the drive shaft and adapted to selectively hold the spring member in the tightened and relaxed positions. An annular collar may also be secured with the drive shaft and connected with the spring member. In some embodiments, it may also be desired to include a brake unit engageable with the translation member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view, partly in cutaway, of a preferred embodiment of a window covering according to the present invention;
[0014] FIG. 2 is a exploded perspective view of the single spring coil drive unit of FIG. 1 ;
[0015] FIG. 3 is a side elevational cross section view of the single spring coil drive unit of FIG. 1 ;
[0016] FIG. 4 is a side elevational cross section view of an alternative single spring coil drive unit;
[0017] FIG. 5 is a side elevational cross section view of a double spring drive unit;
[0018] FIG. 6 is a side elevational cross section view of an alternative double spring drive unit;
[0019] FIG. 7 is an exploded perspective view of the translation member of FIG. 1 ;
[0020] FIG. 8A is a front elevational view of the window covering of FIG. 1 in a closed position and with the head rail in cross section;
[0021] FIG. 8B is a front elevational view of the window covering of FIG. 1 in a partially open position and with the head rail in cross section;
[0022] FIG. 9A is a perspective view of a preferred clutch member when the window covering is in a fully raised position;
[0023] FIG. 9B is a cross sectional view of the clutch member of FIG. 9A ;
[0024] FIG. 10A is a perspective view of the clutch member of FIG. 9A as the user pulls down on the window covering;
[0025] FIG. 10B is a cross sectional view of the clutch member of FIG. 10A ;
[0026] FIG. 11A is a perspective view of the clutch member of FIG. 9A as the user releases the window covering;
[0027] FIG. 11B is a cross sectional view of the clutch member of FIG. 11A ;
[0028] FIG. 12A is a perspective view of the clutch member of FIG. 9A as the user pulls down on the window covering to release the clutch member;
[0029] FIG. 12B is a cross sectional view of the clutch member of FIG. 12A ;
[0030] FIG. 13A is a perspective view of the clutch member of FIG. 9A as the window covering self-raises;
[0031] FIG. 13B is a cross sectional view of the clutch member of FIG. 13A ;
[0032] FIG. 14 is a perspective view of an alterative embodiment of a window covering according to the present invention with a deceleration member;
[0033] FIG. 15A is a side elevational cross section view of the deceleration member of FIG. 14 disengaged from the translation member;
[0034] FIG. 15B is a side elevational cross section view of the deceleration member of FIG. 14 engaging the translation member; and
[0035] FIG. 15C is a side elevational cross section view of the deceleration member of FIG. 14 when the window covering is fully raised.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0036] The invention disclosed herein is susceptible to embodiment in many different forms. Shown in the drawings and described in detail hereinbelow are preferred embodiments of the present invention. The present disclosure, however, is only an exemplification of the principles and features of the invention, and does not limit the invention to the illustrated embodiments.
[0037] Referring to FIG. 1 , an embodiment of a self-raising window covering 10 according to the present invention is shown. A head rail 12 defining a channel is provided. A pair of drive units, such as spring units 14 and 16 are coaxially mounted about a drive axle 18 . Also mounted on drive axle 16 are translation members 20 and 22 . Each of translation members 20 and 22 includes a frustoconical winding drum 24 and 26 , respectively. Raising cords 28 and 30 , which are shown as wound on winding drums 24 and 26 , are secured at an end to the winding drums 24 and 26 . Each of the translation members 20 and 22 further comprise a threaded tubular member 32 , 34 . In this embodiment, a clutch or actuator 36 is also provided and co-axially mounted on the drive axle 18 . Each of these components is discussed in greater detail below. Window covering 10 further includes a light blocking element, such as cellular shade material 38 and a bottom member, such as bottom rail 40 . A relatively short length of cord 42 is also provided so that the user can pull down the window covering and, as will be discussed in further detail, release the clutch so that the window covering will retract itself.
[0038] Referring to FIG. 2 , a preferred embodiment of the spring unit 14 is shown. The spring unit 14 comprises a spring casing 42 , a spring axle 44 , a constant force coil spring 46 and a cover 48 . The coil spring 46 is secured with the spring axle 44 , and is secured within the casing 42 and cover 48 . With coil spring 46 , a first end 50 of the spring 46 is secured to the spring axle 44 , which is mounted on the drive axle 18 ( FIG. 1 ). In this preferred embodiment, the coil spring provides sufficient rotational force to the drive axle and winding drums to raise the light blocking element and bottom rail. Other alternative embodiments of suitable spring units are shown in FIGS. 3-6 .
[0039] For example, a spring unit 114 is shown in FIG. 3 as including a spring axle 144 and a spring member 146 . The spring axle 144 is offset from the drive axle 118 . A first end 150 of the spring member 146 is secured with the spring axle 144 and a second end 152 is secured with the drive axle 118 to impart a rotational force thereon. Another example of a suitable spring unit is shown in FIG. 4 as spring unit 214 . This example is similar to the embodiment shown in FIG. 3 except that no spring axle is provided. Instead, a portion of spring member 246 coils about itself and an end 252 of the spring member 246 is secured to the drive axle 218 . Still other suitable embodiments of spring units are shown in FIGS. 5 and 6 . In FIG. 5 , spring unit 314 includes a double spring coil member 346 which is secured to a drive axle 318 and to spring axles 344 and 345 . In FIG. 6 , a double spring coil member 446 is connected to drive axle 418 , but does not include spring axles. Although each of the embodiments shown utilize a spring as the driving mechanism for the drive unit, it should be understood that any suitable mechanism for imparting a rotational force on a drive axle may be utilized.
[0040] Referring again to FIG. 1 , the rotational force exerted upon a drive axle 18 causes the raising of the light blocking 38 by way of translation member 20 and 22 . Further details on a preferred embodiment of a translation member is provided with reference to FIG. 7 .
[0041] Translation member 20 is mounted co-axially with the drive shaft (not shown), and includes a winding drum 24 and a rotational positioning member, such as threaded tubular member 32 . The translation member 20 is preferably mounted to the drive axle by way of a hub member, such as adapter 60 . The winding drum 24 may be tapered and is preferably frustoconical in shape, and may include striations or grooves. An end of the raising cord (not shown) is secured towards the larger diameter end 62 of the winding drum 24 such that as the cord is wound, the raising cord is wrapped around increasingly narrower portions of the winding drum 24 . The translation member is mounted within the head rail 12 ( FIG. 1 ) by way of frame 64 , which includes rollers 66 . Rollers 66 engage threaded tubular member 32 , and are held in position by bracket 68 .
[0042] Referring to FIGS. 8A and 8B , the raising of the window covering is shown. When the window covering is fully closed, as shown in FIG. 8A , the raising cord 28 is fully extended and connected to the winding drum 24 at a wider portion thereof. As the bottom rail rises, the threaded tubular member 32 causes the translation member to move laterally within the head rail 12 such that the raising cord extends substantially straight down from the winding drum 24 , as shown in FIG. 8B .
[0043] As the spring units 14 and 16 raise the bottom rail 40 and stack the light blocking element 38 on the bottom rail 40 , the total weight being raised increases. The load of the springs is described with reference to one of the spring units. The load of the spring unit 14 can be approximated as the force F relative to the drive axle as being equal to the product of the suspended weight W, which includes the weight of the bottom rail plus the amount of panel stacked thereon, by a winding radius R of the winding drum 24 . As the bottom rail rises, W increases while R decreases. Because of the tapered winding drum 24 , the force of the spring unit 14 translated to an upward force on the raising cord 28 will vary slightly so that the constant force spring 46 ( FIG. 2 ) can fully raise the bottom rail 40 and light blocking element 38 . In order to lower the window covering, a user exerts an approximately constant pulling force regardless of the position in height of the window covering. When the window covering is raised, the total weight stacked on the bottom rail is at its maximum. As the user pulls down on the bottom rail 40 or cord 42 , the contribution to the force needed to overcome the upward force of the spring units 14 and 16 from the weight of the bottom rail 40 and light blocking element 38 decreases. However, the effective pulling force is increased due to the greater moment arm. As such, the user does not need to exert as much force as would be required with a cylindrical winding drum.
[0044] As discussed, the drive units are configured to provide a force sufficient to raise the bottom rail 40 and light blocking element 38 regardless of the current position of the window covering. Accordingly, a clutch member or actuator 36 is also provided in order to lock the window covering in a desired position. Clutch member 36 is mounted with the drive axle 18 and is configured to unlock the drive axle 18 as the user pulls down the bottom rail 40 , and to lock the drive axle 18 when the user releases the bottom rail 40 at the desired height. When the user pulls down slightly on the bottom rail again, the clutch disengages and allows the bottom rail 40 to be raised by the spring units 14 and 16 . Referring to FIGS. 9A and 9B , the clutch member 36 includes a casing 70 with protrusions 72 and 74 projecting therefrom. A collar 76 rotating with the drive axle 18 is provided, which reciprocates axially along the drive axle 18 . A reciprocator 78 is co-axially mounted over collar 76 and is movable both rotatably and axially therewith. A spring 80 having a first end 82 and a second end 84 is provided between collar 76 and reciprocator 78 .
[0045] FIGS. 9A and 9B show the clutch 76 when the window covering 10 is in a fully raised position. Spring 80 is in a relaxed condition with second end 84 in an abutting relationship with protrusion 74 . As shown in FIGS. 10A and 10B , when the user pulls on the bottom rail (not shown), a clockwise rotation (as shown) of the axle 18 and the collar 76 occurs and causes the second end 84 of the spring 80 to disengage from protrusion 74 . Spring 80 tightens on collar 76 such that rotation of the collar 76 brings reciprocator 78 into abutment with protrusion 72 through contact at second end 84 of the spring 80 . As the reciprocator 78 abuts against protrusion 72 , the spring 80 relaxes again such that drive axle 18 may continue to rotate as the user pulls on the bottom rail. Referring to FIG. 11A and 11B , as the user releases the bottom rail at a desired height, spring 80 again tightens on collar 76 . The drive axle 18 , as urged by the spring units 14 and 16 ( FIG. 1 ), rotates receiprocator 78 in a counterclockwise direction to a locking position. In this locking position, the spring 80 tightens to stop rotation of the drive axle 18 . Referring to FIGS. 12A and 12B , as the user pulls down slightly on the bottom rail, a resulting clockwise rotation of the drive axle 18 and collar 76 causes the reciprocator 78 to disengage from the locking position. When the user releases the bottom rail as shown in FIGS. 13A and 13B , the spring units 14 and 16 cause the drive axle 18 to rotate in a counterclockwise direction to bring second end 84 of the spring 80 into engagement with protrusion 74 , and thereby loosening spring 80 , which permits drive axle 18 to continue rotating and fully opening the window covering.
[0046] An alternative embodiment of the window covering according to the present invention is shown in FIG. 14 . In most respects, this embodiment is the same as the ones previously discussed. Window covering 510 includes a head rail 512 having a pair of spring units 514 and 516 mounted with a drive axle 518 mounted therein. Translation members 520 and 522 are also provided. Raising cords 528 and 530 pass through light blocking element 538 and are connected with bottom rail 540 . In addition, a deceleration member 550 is provided. Deceleration members 550 is engageable with the translation member 522 to slow down the rise of the bottom rail as it approaches the head rail.
[0047] The preferred embodiment of the deceleration member 520 is shown in FIGS. 15A-15C . In the position of FIG. 15A , the translation member is disengaged from the deceleration member 550 . As the winding cord 526 is wound on winding drum 24 , the translation member 522 moves towards the deceleration member 550 . As the translation member engages with the deceleration member 550 as shown in FIG. 15B , the rotation of the winding drum 526 causes a plate 552 of the deceleration member to rotate. The plate 552 is operative connected to an axle sleeve 554 . Axle sleeve 554 is in contact with an oil liquid contained inside a housing 556 and is configured to provide rotational movement resistance within the oil liquid. For example, protrusions or fins may be provided on the axle sleeve 554 . The rate at which the bottom rail is raised by the spring units 514 and 516 is slowed as the bottom rail reaches the head rail so that the bottom rail more smoothly stops at a fully opened position.
[0048] The foregoing descriptions are to be taken as illustrative, but not limiting. Still other variants within the spirit and scope of the present invention will readily present themselves to those skilled in the art.
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The present invention relates to a self-raising window covering and a control mechanism for the window covering. In particular, the window covering includes a drive unit, such as constant force spring, that is adapted to apply a substantially constant rotational force on the drive axle. A cord winding assembly is coaxially mounted on the drive axle, and includes at least one winding drum operatively connected to a second end of the raising cord and having a tapered portion, as well as a rotatable positioning member for moving the cord winding assembly laterally along the drive axle upon rotation of the positioning member. The cord winding assembly is adapted to translate the rotational force on the drive axle to a raising force on the raising cord, wherein the raising force is greater than a downward force exerted by the shade element and bottom rail throughout the range of opening and closing. A clutch member or locking member is also operatively connected with the axle and adapted to releasably lock the drive axle in a desired position.
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FIELD OF THE INVENTION
The present invention relates to a panel support and adjustment mechanism. In particular but not exclusively the invention relates to a panel support and adjustment mechanism for glass balustrades, partitioning, glass staircases and safety barriers.
BACKGROUND OF THE INVENTION
It is known to support panel members for use in a balustrade system in an elongated channel section that is bolted to the floor or any other suitable structure. The glass balustrade panel is inserted into the channel section and retained in position by the use of casting with a setting resin, clamping with bolts or with the use of wedges.
All of these methods have disadvantages. Casting in place with a setting resin has the disadvantage of making it difficult to move or replace the glass in the event of damage either during installation or during the subsequent lifetime of the balustrade. Additionally it takes a while for the resin to set and during this time the member must be supported by an additional means. Clamping with bolts or wedges requires the channel section to be bolted to the supporting structure with absolute alignment accuracy. This is to ensure that the glass balustrade is substantially vertical. Very small angular errors in the vertical alignment of the channel section as a result of an uneven floor surface or supporting structure can result in large displacements at the top of the balustrade.
It is an aim of embodiments of the present invention to at least partially mitigate the disadvantages of known panel member support and alignment methods.
BRIEF SUMMARY OF THE INVENTION
In a first aspect of the invention there is provided a mechanism for the adjustment of the vertical alignment of a panel member contained within an elongated channel section comprising;
one or more means of clamping the panel member with an adjustable force; and
one or more support means for supporting the panel member within the channel section;
wherein the one or more means of clamping the panel member is arranged to adjustably tilt and secure the panel member so as to be maintained substantially vertically aligned even when the elongated channel section is secured to a surface which is not substantially horizontal.
Embodiments of the invention have the advantage that they provide a means to adjust the vertical alignment of the panel member, regardless of the orientation of the channel section to the supporting structure.
Embodiments of the invention have the additional advantage that the panel member can be removed or replaced at any time with the use of a simple tool.
Embodiments of the invention have a yet further advantage that they can also accommodate panel members comprising a range of different thicknesses.
In at least one embodiment, the support means is a support member.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described with reference to the accompanying figures in which:
FIG. 1 is a cross section of the mechanism and channel section with a panel member secured in place.
FIG. 2 is cross section showing the angular displacement of the panel member possible by the adjustment of the bolts applying the clamping force.
FIG. 3 is an exploded perspective view of the various components of the system.
FIG. 4 is a perspective view of a section of channel support showing the panel member with clamping support plate in position.
FIG. 5 is a perspective view of a section of clamping support plate with a clamping force generating component in place.
FIG. 6 is a cross section of a second embodiment showing an alternative arrangement of extrusions with a panel clamped in place.
FIG. 7 is a cross section showing the angular displacement of the panel member possible by the adjustment of the second embodiment of the panel member clamping arrangement.
FIG. 8 is a perspective view of a section of channel support showing the panel member with clamping support plates of the second embodiment in position. Tightening the nuts generates the required clamping force.
FIG. 9 is an exploded perspective view of the various components of the second embodiment.
FIG. 10 is a perspective view of a section of the clamping support plate with a threaded rod in place.
DETAILED DESCRIPTION OF THE INVENTION
In a first embodiment of the present invention FIG. 1 shows a schematic drawing of a channel extrusion profile 2 with a glass panel 1 in place.
A support plate 3 is attached to each side of the glass or panel. This support plate 3 can be of varying thickness to accommodate glass or panels of a range of different thicknesses.
The assembly of the glass or panel member 1 , and support plate 3 is placed into the channel section extrusion 2 where it wedges into the substantially V shaped profile at the base of the channel section extrusion. It is to be understood that this locates the lower edge of the glass or panel assembly and also centres the glass or panel in the channel extrusion 2 .
Two threaded clamping extrusions comprising of parts 4 , with threaded fasteners 5 are placed on each side of the glass or panel member assembly and are also located in grooves running along each side of channel extrusion 2 . It is to be understood that the invention would also function without the requirement of the use of locating grooves.
As the fasteners 5 are wound out of clamping extrusion 4 they create a wedging action against the angled ramps 6 of the support plate profiles 3 . This opposing wedging action clamps the glass or panel member in position in the channel extrusion 2 . By adjusting the fasteners 5 each side of the glass or panel assembly, the glass or panel member can be set at a range of angles relative to channel section extrusion 2 .
Due to the angle of the ramps 6 on the side of support plate 3 , this side clamping force also generates a downward component 9 that forces the glass or panel assembly into the substantially V shaped profile 8 at the base of channel section extrusion 2 . This clamps the lower edge of the glass or panel member assembly at the same time.
The clamping extrusions 4 with fasteners 5 will self align with support plate 3 , depending on the angle the glass or panel member assembly has been positioned.
FIG. 2 shows a schematic drawing of the angular movement possible by adjusting the fasteners 5 on each side of the glass or panel member 1 and support plate 3 assembly.
Once the glass panel 1 is adjusted to the position required, fasteners both sides are tightened equally to generate the full clamping force required to keep the glass panel 1 in position.
This clamping force also generates the downward component that wedges the lower edge of the glass or panel member assembly into the V shaped profile 11 of the channel section extrusion 2 .
Clamping extrusion 4 with fasteners 5 will self align in the radius groove 10 of channel section extrusion 2 depending on the angle glass or panel member 1 is clamped.
FIG. 3 shows a perspective exploded view of a section of the various components of the system. Shown is clamping extrusion 4 with tapped holes positioned at intervals along the section. Threaded fasteners are inserted into these tapped holes and when wound out of the extrusion 4 , generate the adjustment and clamping force required on the glass or panel member 1 and support plate 3 assembly.
FIG. 4 shows a perspective view of the various components of the system. Glass or panel member 1 channel section extrusion 2 and support plate 3 .
FIG. 5 shows a perspective view of a section of clamping extrusion 4 showing fasteners 5 in position.
In an alternative embodiment of the invention, the clamping force is generated by the use of expanding wedges instead of threaded fasteners.
The core principal of the invention, generating a downward component from the side clamping force, by having the clamping force from each side of the panel angled down towards the panel centre, is retained. This downward component wedges the panel assembly into the substantially V shaped profile in the base of the channel section, this results in a clamping force being generated over the full depth of the panel assembly retained in the channel section.
Detailed Description of an Alternative Embodiment
FIG. 6 shows a schematic drawing of a channel extrusion profile 12 with a glass or panel member 1 in place.
A support plate extrusion 13 is attached to each side of the glass or panel member. This support plate extrusion 13 can be of varying thickness to accommodate glass or panels of a range of different thicknesses.
The assembly of glass or panel member 1 , and support extrusion extrusions 13 , is placed into the channel section extrusion 12 , where it wedges into the substantially V shaped profile at the base of the channel section extrusion. This locates and clamps the lower edge of the glass or panel member assembly and also centres the glass or panel member in the channel section extrusion 12 . Two assemblies of expanding wedges 16 are placed in angled grooves in support plate extrusions 13 on each side of the glass or panel member assembly. As the wedges expand they press against the sides of channel extrusion 12 and support plate extrusions 13 . This opposing wedging action clamps the glass or panel member in position in the channel extrusion 12 . By adjusting the wedges 16 , each side of the glass or panel member assembly, the glass or panel member can be set at a range of angles relative to channel section extrusion 12 . The angled clamping force also generates the downward component that clamps the lower edge of the glass or panel member in the substantially V shape profile of channel extrusion 12 .
FIG. 7 shows a schematic drawing of the angular movement possible by adjusting the expanding wedges 16 on each side of the glass or panel member 1 and support plate extrusion 13 assembly.
Once the glass or panel member 1 is adjusted to the position required, wedge assemblies both sides are tightened equally to generate the full clamping force required to keep the glass or panel member 1 in position. This clamping force also generates the downward component that wedges the lower edge of the glass or panel member assembly into the V profile of the channel section extrusion 12 .
FIG. 8 shows a perspective view of a section of the various components of the system. Shown is channel extrusion 12 with glass or panel member 1 and support plate extrusions 13 each side. Shown are two nuts at the end of the expanding wedge assemblies. Tightening these nuts expands the wedges and generates the side clamping force required on the glass or panel member 1 and support plate extrusion 13 assembly.
FIG. 9 shows a perspective exploded view of a section of the various components of the system. Shown are expanding wedge assemblies 17 glass or panel member 1 support plate extrusions 13 and channel section extrusion 12 .
FIG. 10 shows an expanding wedge assembly. As the nut 15 on the threaded rod 14 are tightened, the various segments of extrusions 16 are squeezed together. This results in the segments sliding in opposite directions as shown by the arrows 18 and generating a side force on channel section extrusion 12 and support plate extrusion 13 .
It is to be understood that alternative embodiments of the invention could make the clamping extrusion 4 and support plate extrusion 13 parts from a process other than extrusion such as but not limited to machined or injection moulded processes.
It is to be understood that alternative embodiments of the invention could use panel members made from other rigid body materials such as but not exclusively wood, steel, plastic, plywood, or plasterboard.
Other arrangements are also useful.
Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of the words, for example “comprising” and “comprises”, means “including but not limited to”, and is not intended to (and does not) exclude other moieties, additives, components, integers or steps.
Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith.
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A mechanism for the adjustment of the vertical alignment of a panel member contained within an elongated channel section comprising; one or more means of clamping the panel member with an adjustable force; and one or more support means for supporting the panel member within the channel section; wherein the one or more means of clamping the panel member is arranged to adjustably tilt and secure the panel member so as to be maintained substantially vertically aligned even when the elongated channel section is secured to a surface which is not substantially horizontal.
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This application is a division of application Ser. No. 825,172, 2/3/86, now U.S. Pat. No. 4,623,658, and Ser. No. 719,791, 4/4/85, and of application Ser. No. 763,584, 8/8/85, now abandoned.
DESCRIPTION OF THE INVENTION
It has been found that useful insecticidal and acaricidal properties are shown by compounds of the formula: ##STR2##
wherein A is fluorine or chlorine, X, X 1 , X 2 and X 3 each is hydrogen or fluorine, R is a moiety --C(O)OR 1 , or --NR 2 R 3 , in which R 1 and R 2 each is optionally substituted alkyl, optionally substituted cycloalkyl or optionally substituted phenyl, R 3 is optionally substituted alkyl, optionally substituted cycloalkyl or optionally substituted phenyl, or is a moiety --C(O)R 4 , --C(O)OR 4 or --SO 2 R 4 wherein R 4 is optionally substituted alkyl, optionally substituted cycloalkyl or optionally substituted phenyl, or R 2 and R 3 together is optionally substituted alkylene of four or five carbon atoms, in each case the optional substituents on alkyl, cycloalkyl and alkylene being selected from halogen, alkoxy, alkoxycarbonyl, haloalkoxycarbonyl, alkylcarbonyl, haloalkylcarbonyl, alkylsulphonyl and haloalkysulphonyl, and the optional substituents on phenyl being selected from these substitutents and also alkyl, haloalkyl, cyano and nitro, wherein each alkyl and haloalkyl group contains from one to six carbon atoms, especially from one to to four carbon atoms. A preferred alkyl group is methyl and a preferred haloalkyl group is trifluoromethyl. Each cycloalkyl group suitably contains from three to six carbon atoms. Preferably, A is fluorine. Preferably, each of R 1 , R 2 , R 3 and R 4 , when present, represents unsubstituted alkyl, preferably of up to six carbon atoms.
Preferably R represents a group of the formula --NR 2 R 3 . Preferably R 2 is alkyl and R 3 is alkyl substituted by alkoxycarbonyl of up to six carbon atoms in the alkyl moiety, or is a group of the formula --C(O)OR 4 , --SO 2 R 4 , or --C(O)R 4 wherein R 4 is alkyl.
Especially preferred groups R are are those of the formula --N(R 2 )C(O)OR 4 in which each of R 2 and R 4 is unsubstituted alkyl of up to six carbon atoms.
The invention also provides a process for the preparation of compounds of Formula I, which comprises treating a compound of the formula ##STR3## with a compound of the formula: ##STR4##
The reaction is suitably carried out in the presence of a solvent. Suitable solvents are aromatic solvents such as benzene, toluene, xylene, or chlorobenzene, hydrocarbons such as petroleum fractions, chlorinated hydrocarbons such as chloroform, methylene chloride or dichloroethane, and ethers such as diethylether, dibutylether, or dioxan. Mixtures of solvents are also suitable.
Preferably the reaction is carried out at a temperature from 0° C. to 100° C., suitably ambient temperature. Preferably the molar ratio of isocyanate to amine is from 1:1 to 2:1. Preferably the reaction is carried out under anhydrous conditions.
The compounds of Formula II are themselves novel and constitute a further aspect of the invention. They may be prepared by treating a compound of the formula ##STR5## with a compound of the formula
Hal--S--R (V)
in which Hal represents halogen, especially chlorine. The reaction is preferably carried out in the presence of an inert solvent, for example a hydrocarbon or chlorinated hydrocarbon, and the reaction temperature is preferably in the range of from -30° to +30° C., preferably -10° to +10° C. The reaction is suitably carried out in the presence of a base, for example an amine such as triethylamine.
Compounds of Formula IV can be prepared by treating a compound of the formula ##STR6## with a compound of the formula ##STR7##
The reaction between the compounds of formulae VI and VII is preferably carried out in the presence of an inert solvent, for example a polar aprotic solvent such as dimethylsulphoxide or dimethylformamide, in the presence of a base, for example an alkali metal hydroxide, alkoxide or carbonate, or an organic base such as pyridine or triethylamine. The reaction temperature is suitably in the range of from 0° C. to 150° C., preferably 30° C. to 100° C.
The compounds of Formula I exhibit pesticidal, for example insecticidal and acaricidal, activity. Accordingly the invention also provides a pesticidal composition comprising a compound of Formula I together with a carrier.
The invention further provides a method of combating pests at a locus, which comprises applying to the locus a pesticidal compound or composition according to the invention. The pests may be insects or acarids, especially mites. The locus may be a crop area susceptible to infestation by acarids.
The term "carrier" as used herein means an inert solid or liquid material, which may be inorganic or organic and of synthetic or natural origin, with which the active compound is mixed or formulated to facilitate its application to the plant, seed, soil or other object to be treated, or its storage, transport and/or handling. Any of the materials customarily employed in formulating pesticides--i.e., horticulturally acceptable adjuvants--are suitable.
Suitable solid carriers are natural and synthetic clays and silicates, for example, natural silicas such as diatomaceous earths; magnesium silicates, for example, talcs; magnesium aluminum silicates, for example, attapulgites and vermiculites; aluminum silicates, for example, kaolinites, montmorillonites and micas; calcium carbonate; calcium sulfate; synthetic hydrated silicon oxides and synthetic calcium or aluminum silicates; elements such as, for example, carbon and sulfur; natural and synthetic resins such as, for example, coumarone resins, polyvinyl chloride and styrene polymers and copolymers; bitumen; waxes such as, for example, beeswax, paraffin wax, and chlorinated mineral waxes; solid fertilizers, for example, superphosphates; and ground, naturally-occurring, fibrous materials, such as ground corncobs.
Examples of suitable liquid carriers are water, alcohols such as isopropyl alcohol and glycols; ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone and cyclohexanone; ethers such as cellosolves; aromatic hydrocarbons such as benzene, toluene and xylene; petroleum fractions such as kerosene, light mineral oils; chlorinated hydrocarbons such as carbon tetrachloride, perchloroethylene and trichloromethane. Also suitable are liquefied, normally vaporous and gaseous compounds. Mixtures of different liquids are often suitable.
The surface-active agent may be an emulsifying agent or a dispersing agent or a wetting agent; it may be nonionic or ionic. Any of the surface-active agents usually applied in formulating herbicides or insecticides may be used. Examples of suitable surface-active agents are the sodium and calcium salts of polyacrylic acids and lignin sulfonic acids; the condensation products of fatty acids or aliphatic amines or amides containing at least 12 carbon atoms in the molecule with ethylene oxide and/or propylene oxide; fatty acid esters of glycerol, sorbitan, sucrose or pentaerythritol; condensates of these with ethylene oxide and/or propylene oxide; condensation products of fatty alcohols or alkyl phenols, for example, p-octylphenol or p-octylcresol, with ethylene oxide and/or propylene oxide; sulfates or sulfonates of these condensation products, alkali or alkaline earth metal salts, preferably sodium salts, of sulfuric or sulfonic acid esters containing at least 10 carbon atoms in the molecule, for example, sodium lauryl sulfate, sodium secondary alkyl sulfates, sodium salts of sulfonated castor oil, and sodium alkylaryl sulfonates such as sodium dodecylbenzene sulfonate; and polymers of ethylene oxide and copolymers of ethylene oxide and propylene oxides.
The compositions of the invention may be prepared as wettable powders, dusts, granules, solutions, emulsifiable concentrates, emulsions, suspension concentrates and aerosols. Wettable powders are usually compounded to contain 25-75% by weight of active compound and usually contain, in addition to the solid carrier, 3-10% by weight of a dispersing agent, 2-15% of a surface-active agent and, where necessary, 0-10% by weight of stabilizer(s) and/or other additives such as penetrants or stickers. Dusts are usually formulated as a dust concentrate having a similar composition to that of a wettable powder but without a dispersant or surface-active agent, and are diluted in the field with further solid carrier to give a composition usually containing 0.5-10% by weight of the active compound. Granules are usually prepared to have a size between 10 and 100 BS mesh (1.676-0.152 mm), and may be manufactured by agglomeration or impregnation techniques. Generally, granules will contain 0.5-25% by weight of the active compound, 0-1% by weight of additives such as stabilizers, slow release modifiers and binding agents. Emulsifiable concentrates usually contain, in addition to the solvent and, when necessary, cosolvent, 10-50% weight per volume of the active compound, 2-20% weight per volume emulsifiers and 0-20% weight per volume of appropriate additives such as stabilizers, penetrants and corrosion inhibitors. Suspension concentrates are compounded so as to obtain a stable, non-sedimenting, flowable product and usually contain 10-75% weight of the active compound, 0.5-15% weight of dispersing agents, 1-5% of surface-active agent, 0.1-10% weight of suspending agents, such as defoamers, corrosion inhibitors, stabilizers, penetrants and stickers, and as carrier, water or an organic liquid in which the active compound is substantially insoluble; certain organic solids or inorganic salts may be dissolved in the carrier to assist in preventing sedimentation or as antifreeze agents for water.
Of particular interest in current practice are the water-dispersible granular formulations. These are in the form of dry, hard granules that are essentially dust-free, and are resistant to attrition on handling, thus minimizing the formation of dust. On contact with water, the granules readily disintegrate to form stable suspensions of the particles of active material. Such formulations contain 90% or more by weight of finely divided active material, 3-7% by weight of a blend of surfactants, which act as wetting, dispersing, suspending and binding agents, and 1-3% by weight of a finely divided carrier, which acts as a resuspending agent.
Aqueous dispersions and emulsions, for example, compositions obtained by diluting a wettable powder or a concentrate according to the invention with water, also lie within the scope of the present invention. The said emulsions may be of the water-in-oil or of the oil-in-water type, and may have thick, mayonnaise-like consistency.
It is evident from the foregoing that this invention contemplates compositions containing as little as about 0.0001% by weight to as much as about 95% by weight of a compound of the invention as the active ingredient.
The compositions of the invention may also contain other ingredients, for example, other compounds possessing pesticidal, especially insecticidal, acaricidal or fungicidal properties, as are appropriate to the intended purpose.
The method of applying a compound of the invention to control pests comprises applying the compound, ordinarily in a composition of one of the aforementioned types, to a locus or area to be protected from the insects, such as the foliage and/or the fruit of plants. The compound, of course, is applied in an amount sufficient to effect the desired action. This dosage is dependent upon many factors, including the carrier employed, the method and conditions of the application, whether the formulation is present at the locus in the form of an aerosol, or as a film, or as discrete particles, the thickness of film or size of particles, and the like. Proper consideration and resolution of these factors to provide the necessary dosage of the active compound at the locus to be protected are within the skill of those versed in the art. In general, however, the effective dosage of the compound of the invention at the locus to be protected--i.e., the dosage which the insect contacts--is of the order of 0.001 to 0.5% based on the total weight of the formulation, though under some circumstances the effective concentration will be as little as 0.0001% or as much as 2%, on the same basis.
The following examples illustrate the invention and are drawn to the subgenus of Formula I wherein all of X, X 1 , X 2 , and X 3 are hydrogen; Examples 1 to 3 illustrate the preparation of intermediates of Formula II, while Examples 4 to 6 illustrate the preparation of compounds of Formula I. In each case, the identity of the product was confirmed by appropriate elemental and spectral analyses.
EXAMPLE 1
Propyl N-[[[4-[2-chloro-4-(trifluoromethyl)phenoxy]phenyl]amino]thio]-N-methylcarbamate (1)
A solution of 3.7 g of N-chlorosulphenyl-N-methylcarbamate in 10 ml of dry methylene chloride was added over 20 minutes to a stirred solution of 6.3 g of 4-[2-chloro-4-(trifluoromethyl)phenoxy]aniline in 25 ml of the same solvent containing 2.5 g of triethylamine. The reaction mixture temperature was kept at 0°-5° C. by means of an ice bath until the addition was completed, and was then allowed to rise to ambient temperature over 2.0 hours. The solvent was removed under reduced pressure and the residue was suspended in 200 ml of diethyl ether and washed three times with water. The resulting ether solution was dried (MgSO 4 ) and the solvent was evaporated. The residue was purified by rapid chromatography on silica gel using methylene chloride as eluent. Crystallisation from diethyl ether/light petroleum gave 1, as pale buff-coloured crystals (m.p.: 61°-64° C.).
EXAMPLE 2
N-[[[4-[2-chloro-4-(trifluoromethyl)phenoxy]phenyl]amino]thio]-N-ethylmethanesulphonamide (2)
A solution of 2.6 g of sulphur dichloride in 15 ml of dry diethyl ether was added over 10 minutes to a stirred solution of 3.1 g of N-ethylmethanesulphonamide in 15 ml of the same solvent, keeping the temperature between 10°-15° by means of external cooling. A solution of 2.0 g of dry pyridine in 15 ml of dry diethyl ether was then added over 15 minutes at the same temperature and the reaction mixture was allowed to warm to room temperature over 1 hour. The resulting suspension was added over 5 minutes to a solution of 7.2 g of 4-[2-chloro-4-(trifluoromethyl)phenoxy]aniline (1A) in 75 ml of dry diethyl ether containing 2.0 g of pyridine, keeping the temperature of the mixture between 5°-10° C. After stirring at 10°-15° for 1 hour, the reaction mixture was washed three times with water, the ether layer was separated, dried (MgSO 4 ), and the solvent was evaporated under reduced pressure. The residue was purified by chromatography on silica gel using diethyl ether as eluent, to give 2, as a buff solid m.p.: 98°-101° C.
EXAMPLE 3
O-Methyl-S[[4-[2-chloro-4-(trifluoromethyl)phenoxy]phenyl]amino]thiocarbonate (3)
A solution of 4.2 g of methoxycarbonylsulphenyl chloride in 5 ml of dry methylene chloride was added over 20 minutes to a stirred solution of 8.6 g of 1A in 50 ml of the same solvent containing 6.0 ml of triethylamine, keeping the temperature of the mixture below 0° C. After the addition was complete the stirred reaction mixture was allowed to warm to room temperature over 1.0 hour. The solvent was then evaporated under reduced pressure, the residue was suspended in 180 ml of diethyl ether and washed with water. The extract was dried (MgSO 4 ) and the solvent was evaporated. The residue was purified by chromatography on silica gel using diethyl ether/petroleum ether as eluent. Recrystallisation from the same solvent gave 3, as colourless crystals, m.p.: 71°-72° C.
EXAMPLE 4
Propyl 4-[4-[2-chloro-4-(trifluoromethyl)phenoxy]phenyl]-7-(2,6-difluorophenyl)-2-methyl-5,7-dioxa-3-thia-2,4,6-triazaheptanoate (4)
A solution of 2.4 g of 2,6-difluorobenzoyl isocyanate in 10 ml of dry toluene was added, with stirring, to a solution of 5.2 g of 1 in 40 ml of the same solvent and the resulting solution was stirred at room temperature for 3 hours. The reaction mixture was then diluted with 50 ml of dry light petroleum (b.p.: 40°-60° C.) and stored at -5°-0° C. overnight.
The resulting mixture was filtered, and the collected solid product was washed with light petroleum. Recrystallisation from diethyl ether/light petroleum gave 4 as colourless crystals, m.p: 96°-98° C.
EXAMPLE 5
N-[[[4-[2-chloro-4-(trifluoromethyl)-phenoxy]phenyl][[(N-ethyl-N-methanesulphonyl)amino]thio]amino]carbonyl]-2,6-difluorobenzamide (5)
A solution of 2.0 g of 2,6-difluorobenzoyl isocyanate in 10 ml of dry diethyl ether was added rapidly to a stirred solution of 4.4 g of 2 in 15 ml of the same solvent at room temperature. After stirring for 4 hours, 10 ml of light petroleum (b.p.: 40°-60° C.) was added, the resulting mixture was filtered, and the collected solid was washed with diethyl ether/light petroleum. Recrystallisation from diethyl ether/light petroleum gave 5, as colourless crystals, m.p.: 149°-151° C.
EXAMPLE 6
Methyl-3-[4-[2-chloro-4-(trifluoromethyl)phenoxy]phenyl]-6-(2,6-difluorophenyl)-4,6-dioxo-2-thia-3,5-diazahexanoate (6)
A solution of 2.0 g of 2,6-difluorobenzoyl isocyanate in 10 ml of dry toluene was added to a stirred solution of 3.8 g of 3 in 30 ml of the same solvent. The mixture was stirred at room temperature for 3 hours. It was then diluted with an equal volume of petroleum ether and cooled in ice-water. After 1 hour, the mixture was cooled to -70° C. for 10 minutes, and the resulting crop of crystals was filtered off, washed with petroleum ether, and dried. Recrystallisation from petroleum ether gave 6, m.p.: 108°-109° C.
EXAMPLES 7 TO 18
By methods analogous to these described in the previous Examples, further compounds of the following formula were prepared, the identity of the moiety R and the melting point of the product being given in each case in Table I.
TABLE I______________________________________ ##STR8##Example Melting PointNo. R (°C.)______________________________________ 7 N(CH.sub.3)C(O)OCH.sub.3 96-100 8 N(CH.sub.3)C(O)O(n-C.sub.5 H.sub.11) 69-71 9 N(C.sub.2 H.sub.5)C(O)OC.sub.2 H.sub.5 82-8510 N(t-C.sub.4 H.sub.9)C(O)OCH.sub.3 82-8511 N(t-C.sub.4 H.sub.9)C(O)OC.sub.2 H.sub.5 110-11312 N(n-C.sub.4 H.sub.9)SO.sub.2 CH.sub.3 142-14413 C(O)O(n-C.sub.3 H.sub.7) 94-9514 C(O)O(n-C.sub.5 H.sub.11) 82-8315 N(n-C.sub.4 H.sub.9)C(O)OCH.sub.3 109-11216 N(t-C.sub.4 H.sub.9)C(O)O(t-C.sub.4 H.sub.9) 80-8217 N(CH.sub.3)C(O)O(i-C.sub.3 H.sub.7) 95-9818 N(CH.sub.3)C(O)O(t-C.sub.4 H.sub.9) 122-124______________________________________
EXAMPLES 19-30
By methods analogous to those described in Examples 1 to 3, further intermediates of the following formula were prepared, the identity and the melting point of each product being given in Table II. In each case, the identity of the product was confirmed by appropriate elemental and spectral analyses, and by identification of the product of Formula I prepared therefrom.
TABLE II______________________________________ ##STR9##Example Melting PointNo. R (°C.)______________________________________19 N(CH.sub.3)C(O)OCH.sub.3 106-10920 N(CH.sub.3)C(O)O(n-C.sub.5 H.sub.11) 74-7621 N(C.sub.2 H.sub.5)C(O)OC.sub.2 H.sub.5 76-7822 N(t-C.sub.4 H.sub.9)C(O)OCH.sub.3 Not isolated23 N(t-C.sub.4 H.sub.9)C(O)OC.sub.2 H.sub.5 Not isolated24 N(n-C.sub.4 H.sub.9)SO.sub.2 CH.sub.3 97-9825 C(O)O(n-C.sub.3 H.sub.7) 61-6226 C(O)O(n-C.sub.5 H.sub.11) 54-5527 N(n-C.sub.4 H.sub.9)C(O)OCH.sub.3 Brown oil28 N(t-C.sub.4 H.sub.9)C(O)O(t-C.sub.4 H.sub.9) Brown oil29 N(CH.sub.3)C(O)O(i-C.sub.3 H.sub.7) Brown oil30 N(CH.sub.3)C(O)O(t-C.sub.4 H.sub.9) Brown oil______________________________________
The following examples further illustrate the invention, being drawn to the subgenus of formula I wherein at least one of X and X 3 is fluorine; Examples 31 to 34 illustrate the preparation of intermediates of Formula II, while Examples 35 to 38 illustrate the preparation of compounds of Formula I. As in the earlier examples, in each case the identity of the product was confirmed by appropriate elemental and spectral analyses.
EXAMPLE 31
2-fluoro-4-(2-chloro-4-(trifluoromethyl)phenoxy)aniline (31)
A solution of 7.1 g of 2-fluoro-4-hydroxyaniline and 3.7 g of potassium hydroxide (85% pure) in 25 ml of dimethylsulphoxide (DMSO) was heated to 80° C. and treated with a solution of 10.9 g of 1,2-dichloro-4-(trifluoromethyl)benzene in 10 ml of DMSO. The mixture was stirred at 90°-95° C. for 20 hours, after which it was diluted with a mixture of water and dichloromethane. The organic phase was dried (Na 2 SO 4 ) and the solvent was evaporated. The residue was chromatographed over silica gel using a 4:1 v:v mixture of toluene and petroleum ether to give 31, as a yellow oil.
EXAMPLE 32
Propyl N-[[[4-[2-chloro-4-(trifluoromethyl)phenoxy]-2-fluorophenyl]amino]thio]-N-methylcarbamate (32)
A solution of 12.1 g of propyl N-chlorosulphenyl-N-methylcarbamate in 20 ml of diethyl ether was added over 20 minutes to a stirred solution of 18.3 g of 31, and 7 g of triethylamine in 70 ml of the same solvent, the temperature of the mixture being maintained at 15°-20° C. with cooling. Stirring was continued at room temperature for a further 11/2 hours. The reaction mixture was then diluted with 200 ml of diethyl ether, washed with water, dried and stripped of solvent. The residue was added to 100 ml of toluene, then the toluene was evaporated under reduced pressure to leave 32, in crude form as a pale brown oil.
EXAMPLE 33
N-[[[4-[2-chloro-4-(trifluoromethyl)phenoxy]-2-fluorophenyl]amino]thio]-N-methylbutanamide (33)
A solution of 11.3 g of sulphur dichloride in 40 ml of dichloromethane was added over 20 minutes to a solution of 10.1 g of N-methylbutanamide in 35 ml of the same solvent with stirring, the temperature of the mixture being maintained at 10° C. Stirring at this temperature was continued for a further 30 minutes, when a solution of 8.7 g of pyridine in 15 ml of dichloromethane was added. The mixture was then stirred and allowed to warm to room temperature over 2 hours, then filtered. The solvent was stripped from the filtrate and the residue was extracted with diethyl ether. After filtration, solvent removal and distillation, 12.1 g of the sulphenyl chloride precursor was obtained, as an oil, boiling point 82°-84° C. at 13 Torr. 4.4 g of this oil was dissolved in 10 ml of diethyl ether and the resulting solution was added over 20 minutes to a mixture of 7.6 g of 31 and 2.7 g of triethylamine in 30 ml of diethyl ether. After stirring for 30 minutes at room temperature, 150 ml diethyl ether was added, the resultant solution was washed three times with water, dried, stripped of solvent and purified by chromatography over silica using dichloromethane as eluent, to give 33, as a brown oil.
EXAMPLE 34
N-[[[4-[2-chloro-4-(trifluoromethyl)phenoxy]-2-fluorophenyl]amino]thio]-L-proline, methyl ester (34)
A solution of 11.3 g of sulphur dichloride in 20 ml of dichloromethane was added at room temperature over 15 minutes to a stirred solution of 16.6 g of L-proline, methyl ester hydrochloride in 50 ml of the same solvent, following which a solution of 17.4 g of pyridine in 20 ml of the same solvent was added to the reaction mixture over 30 minutes. After stirring overnight, the mixture was diluted with 150 ml of diethyl ether, filtered, and stripped of solvent to leave 17.8 g of the crude product. 4.3 g of this product was dissolved in 10 ml of diethyl ether and added over 15 minutes at room temperature to a stirred mixture of 6.1 g of 31, 2.2 g of triethylamine and 50 ml of diethyl ether. After stirring at room temperature for 30 minutes, 250 ml of diethyl ether was added, and the mixture was washed with water, dried and stripped of solvent. The residue was chromatographed over silica using a mixture of diethyl ether and petroleum ether as eluent, to give 34, as a brown oil.
EXAMPLE 35
Propyl 4-[4-[2-chloro-4-(trifluoromethyl)phenoxy]-2-fluorophenyl]-7-(2,6-difluorophenyl)-2-methyl-5,7-dioxo-3-thia-2,4,6-triazaheptanoate (35)
A solution of 2.0 g of 2,6-difluorobenzoyl isocyanate in 10 ml of dry methylene chloride was added rapidly to a stirred solution of 4.5 g of 32 in 20 ml of the same solvent at room temperature. After stirring for 4 hours the solvent was removed under reduced pressure, and the residue was purified by chromatography twice on silica, using first methylene chloride and then diethyl ether as eluent. The product thus obtained was finally purified by crystallization from diethyl ether/light petroleum to give 35, as colourless crystals, m.p.: 98°-99° C.
EXAMPLE 36
N-[[[4-[2-chloro-4-(trifluoromethyl)phenoxy]-2-fluorophenyl][[(2,6-difluorobenzoyl)amino]carbonyl]amino]thio-N-methylbutanamide (36)
A solution of 2.0 g of 2,6-difluorobenzoylisocyanate in 5 ml of a 1:1 v:v mixture of toluene and petroleum ether was added at room temperature over 30 minutes to a stirred solution of 4.4 g of 33 in 20 ml of the same solvent. After stirring at room temperature for 2 hours, the mixture was filtered, and the collected solid product was recrystallized from a mixture of diethyl ether and petroleum ether to give 36, as a white solid, m.p.: 136°-138° C.
EXAMPLE 37
N-[[[4-[2-chloro-4-(trifluoromethyl)phenoxy]-2-fluorophenyl][[(2,6-difluorobenzoyl)amino]carbonyl]amino]-thio-L-proline, methyl ester (37)
A solution of 2.8 g of 2,6-difluorobenzoylisocyanate in 10 ml of 1:1 v:v mixture of toluene and petroleum ether was added at room temperature over 30 minutes to a stirred solution of 6.5 g of 34 in 20 ml of the same solvent. After the mixture was stirred at room temperature for 3 hours, the solvent was stripped and the residue purified by chromatography over silica using dichloromethane as eluent, to give 37, as a white solid, m.p.: 65°-68° C.
EXAMPLE 38
N[[[4-[2-chloro-4-(trifluoromethyl)phenoxy]-2-fluorophenyl][[di(n-propyl)amino]thio]amino]carbonyl]-2,6-difluorobenzamide (38)
A solution of 7.1 g of 2-fluoro-4-hydroxyaniline and potassium hydroxide (3.7 g, 85% pure) in 25 ml of dimethylsulphoxide was heated to 80° C. and treated with a solution of 10.9 g of 1,2-dichloro-4-(trifluoromethyl)benzene in 10 ml of dimethylsulphoxide. The mixture was stirred at 90°-95° C. for 20 hours, after which time it was diluted wth a mixture of water and dichloromethane. The organic phase was dried over sodium sulphate and the solvent was evaporated. Chromatography of the residue over silica gel using a 4:1 v:v mixture of toluene and petroleum ether gave 1.1 g of 2-[fluoro-4-(trifluoromethyl)phenoxy]aniline (38A), as a yellow oil.
22.7 g of sulphur dichloride in 100 ml of dichloromethane was cooled to -5° C. and a solution of 17.4 g of pyridine in 50 ml of dichloromethane was added, over 30 minutes, while the temperature was maintained between -5° and 0° C. The resulting solution was stirred for 15 minutes and a solution of 20.2 g of di(n-propyl)amine dissolved in 50 ml of dichloromethane was added, over 30 minutes, while the temperature was maintained between -5° and 0° C. The resulting solution was stirred for 2 hours, while the temperature was allowed to rise to ambient. The solution was filtered and the solvent was evaporated. 150 ml of diethyl ether was added, the resulting solution was filtered, and the filtrate evaporated. Distillation of the residue gave di(n-propyl)aminosulphenyl chloride (38B), b.p.: 94°-5° C. at 15 Torr.
A solution of 3.7 g of 38B in 25 ml of diethyl ether was added, over 20 minutes at 15°-20° C., to a solution of 2.2 g of triethylamine and 6.1 g of 38A in 100 ml of diethyl ether. The resulting solution was stirred at ambient temperature for 3 hours. 100 ml of diethyl ether was added, the solution was washed with water, and dried. The solvent was removed by evaporation, and the product [4-[2-chloro-4-(trifluoromethyl)phenoxy]-2-fluorophenyl][[di-(n-propyl)amino]thio]amine (38C), was used without further purification, as follows:
2.6 g of 2,6-difluorobenzoyl isocyanate in 15 ml of diethyl ether was added over 30 seconds to 5.4 g of 38C. The solution was stirred at ambient temperature for 2.5 hours after which a slight precipitate formed. 50 ml of petroleum ether was added, and the resulting suspension was cooled in a freezer (-5° to 0° C.) for 3 hours. The precipitate which formed was filtered off and recrystallised from a 1:1 v:v mixture of diethyl ether and petroleum ether, to give 2.3 g of 38, as white crystals, m.p.: 118°-121° C.
EXAMPLE 39
N[[[4-[2-chloro-4-(trifluoromethyl)phenoxy]-2-fluorophenyl][[diisopropylamino]thio]amino]carbonyl]-2,6-difluorobenzamide (39)
39 was prepared, as a white solid, m.p.: 147°-149° C. in a similar manner to (38). The intermediate compound, di(isopropyl)aminosulphenyl chloride, boiled at 92°-4° C. at 20 Torr.
EXAMPLE 40
N-[[[4-[2-chloro-4-(trifluoromethyl]phenoxy]-2-fluorophenyl][[diethylamino]thio]amino]carbonyl]-2,6-difluorobenzamide (40)
40 was prepared, as a white solid, m.p.: 140°-142° C. in a similar manner to 38. The intermediate compound, diethylaminosulphenyl chloride boiled at 60°-62° C. at 11 Torr. the further intermediate compound, [4-[2-chloro-4-(trifluoromethyl)phenoxy)-2-fluorophenyl][[diethylamino]thio]amine was isolated, as a solid, m.p.: 58°-60° C.
EXAMPLES 41-57
By methods analogous to those of Examples 35 to 40, further compounds of the following formula were prepared from the corresponding intermediates of Formula II, the identities of the moieties R, X 1 , X 2 and X 3 and the melting point of each product being given in each case in Table III.
TABLE III______________________________________ ##STR10##Ex-am- Meltingple PointNo. R X.sup.1 X.sup.2 X.sup.3 (°C.)______________________________________41 N(t-C.sub.4 H.sub.9)C(O)OC.sub.2 H.sub.5 H H H 96-9842 N(CH.sub.3)C(O)O(i-C.sub.3 H.sub.7) H H H 82-8543 N(n-C.sub.4 H.sub.9)C(O)OCH.sub.3 H H H 116-11844 N(CH.sub.3 )C(O)O(t-C.sub.4 H.sub.9) H H H 115-11745 N(i-C.sub.3 H.sub.7)C(O)OCH.sub.3 H H H 99-10146 N(i-C.sub.3 H.sub.7)C(O)O(n-C.sub.3 H.sub.7) H H H 116-11847 N(CH.sub.3)C(O)O(n-C.sub.4 H.sub.9) H H H 72-7548 N(CH.sub.3)C(O)O(n-C.sub.10 H.sub.21) H H H Oil49 N(CH.sub.3)C(O)CH.sub.3 H H H 107-11050 N(CH.sub.3)C(O)(n-C.sub.5 H.sub.11) H H H 116-11851 N(CH.sub.3)C(O)(t-C.sub.4 H.sub.9) H H H 94-9652 N(CH.sub.3)C(O)(n-C.sub.11 H.sub.23) H H H 62-6553 N(CH.sub.3)C(O)OC.sub.2 H.sub.5 H H H 104-10654 N(i-C.sub.3 H.sub.7)C(O)(n-C.sub.3 H.sub.7) H H H 56-5955 N(t-C.sub.4 H.sub.9)C(O)(n-C.sub.3 H.sub.7) H H H 116-118561-(piperidyl)H H H 121-123571-(2-(ethoxycarbonyl)piperidyl)H H H 77-80______________________________________
EXAMPLES 58 TO 77
By methods analogous to those described in Examples 1 to 4, 31 to 34, and 38, further intermediates of formula below were prepared, the identity of moiety R and melting point of each product being given in Table IV. In each case, the identity of the product was confirmed by appropriate elemental and spectral analyses, and by identification of the product of Formula I prepared therefrom.
TABLE IV______________________________________ ##STR11##Example Melting PointNo. R (°C.)______________________________________58 N(CH.sub.3)C(O)(OC.sub.2 H.sub.5)59 N(i-C.sub.3 H.sub.7)C(O)(n-C.sub.3 H.sub.7)60 N(t-C.sub.4 H.sub.9)C(O)(n-C.sub.3 H.sub.7)611-piperidyl 94-9662 N(C.sub.2 H.sub.5).sub.2 58-6063 N(i-C.sub.3 H.sub.7).sub.264 N(n-C.sub.3 H.sub.7).sub.2651-(2-(ethoxycarbonyl)piperidyl66 N(CH.sub.3)C(O)O(iC.sub.3 H.sub.7)67 N(n-C.sub.4 H.sub.9)C(O)OCH.sub.3 Brown oil68 N(CH.sub.3)C(O)O(t-C.sub.4 H.sub.9) Brown oil69 N(n-C.sub.3 H.sub.7)C(O)OCH.sub.3 Brown oil70 N(i-C.sub.3 H.sub.7)C(O)O(n-C.sub.3 H.sub.7) Brown oil71 N(CH.sub.3)C(O)O(n-C.sub.4 H.sub.9) Brown oil72 N(CH.sub.3)C(O)O(n-C.sub.10 H.sub.21) Brown oil73 N(CH.sub.3)C(O)CH.sub.3 Brown oil74 N(CH.sub.3)C(O)(n-C.sub.5 H.sub.11) Brown oil75 N(CH.sub.3)C(O)(t-C.sub.4 H.sub.9) Brown oil76 N(CH.sub.3)C(O)(n-C.sub.11 H.sub.23) Brown oil77 N(t-C.sub.4 H.sub.9)C(O)OC.sub.2 H.sub.5) Pale brown oil______________________________________
EXAMPLE 78
Insecticidal Activity
The insecticidal activity of the compounds of the invention was determined in the following tests, employing the pests Spodoptera littoralis (S.l.) and Aedes aegypti (A.a.).
The test methods used for each species appear below. In each case the tests were conducted under normal conditions (23° C.±2° C.; fluctuating light and humidity).
In each test an LC 50 (the dosage of active material required to kill half of the test species) for the compound was calculated from the mortality figures and compared with the corresponding LC 50 for a standard insecticide, ethyl parathion, in the same tests. The results are expressed as toxicity indices thus: ##EQU1## and are set out in Table III below.
(i) Spodoptera littoralis
Solutions or suspensions of the compound were made up over a range of concentrations in 10% acetone/water containing 0.025% Triton X 100 ("Triton" is a registered trademark). These solutions were sprayed using a logarithmic spraying machine onto petri dishes containing a nutritious diet on which the Spodoptera littoralis larvae had been reared. When the spray deposit had dried each dish was infested with 10 2nd instar larvae. Mortality assessments were made 7 days after spraying.
(ii) Aedes aegypti
Several solutions of the test compound of varying concentration were prepared in acetone. 100 microliter quantities were added to 100 milliliters of tap water, the acetone being allowed to evaporate. 10 early 4th instar larvae were placed in the test solution; after 48 hours the (surviving) larvae were fed with animal feed pellets, and the final percentage mortality assessed when all the larvae had either pupated and emerged as adults or died. The results are set out in Table V.
TABLE V______________________________________Insecticidal Activity Toxicity Index (TI)Compound of Example No. S.l. A.a.______________________________________4 2900 6005 3900 8506 1100 1907 4100 9908 4000 8609 4100 68010 3700 63011 2400 65012 3900 85013 2000 31014 2100 12015 5800 74016 7300 82017 4200 93018 3400 85035 2800 79036 1500 88037 2700 130038 3300 92039 4900 49040 1800 160041 5500 62042 5200 129043 6300 81044 3000 95045 6230 137046 4360 94047 1840 57048 2860 110049 2000 47050 2100 53051 3000 61052 2000 120053 1900 84054 4400 100055 1900 68056 1500 160057 6100 650______________________________________
EXAMPLE 79
Acaricidal Activity
Leaf discs were infested with 30-60 larvae of the mite Tetranuchus urticae and sprayed with varying dosages of solutions of the test compound made up as in test (i) of Example 78 above. When dry, the discs were maintained at constant temperature for 12 days, after which mortality assessments were made, and the LC 50 values calculated. The results are set forth in Table VI.
TABLE VI______________________________________Acaricidal ActivityCompound of LC.sub.50 (% active ingredientExample No. in spray)______________________________________4 0.000275 0.000206 0.00107 0.000188 0.000179 0.0002710 0.0002211 0.0003212 0.0001513 0.003014 0.0007315 0.0001616 0.0001417 0.00009618 0.0001435 0.0002536 0.0001541 0.0003842 0.0002843 0.0002144 0.0002845 0.0001846 0.0002947 0.0001548 Not tested49 Not tested50 Not tested51 0.0001052 Not tested______________________________________
|
Benzoylurea compounds of the formula ##STR1## wherein the meaning of each of the symbols is described in the specification.
| 2
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TECHNICAL FIELD OF THE INVENTION
[0001] One or more embodiments of the present invention relate generally to intra-operative refraction or wavefront aberrometry. In particular, one embodiment is related to means to present to a surgeon the histogram and/or confidence level of intra-operative refraction or wavefront aberrometry measurement during a cataract surgery, especially the histogram, and/or confidence level of aphakic refraction and/or the associated intra-ocular lens (IOL) power recommendation.
BACKGROUND OF THE INVENTION
[0002] A need has been identified in recent years in terms of providing real time intra-operative refraction or wavefront measurement feedback to a surgeon performing a refractive cataract surgery or other vision correction procedures on the eye of a patient. The intra-operative refraction or wavefront measurement, especially one obtained from an aphakic eye when the natural lens of the eye is removed, can help to guide a surgeon better determine the optical power of an IOL (intra-ocular lens) (in terms of sphere power for a monofocal or multi-focal or extended depth of focus IOL or accommodating IOL, and cylinder in addition to sphere if the IOL is a toric IOL or even higher order aberration correction if it is a premium higher order correction IOL). Such an approach has been shown to produce better surgical outcomes. Meanwhile, an intra-operative pseudo-phakic refraction or wavefront measurement can also confirm if a targeted refraction has been achieved to within a certain acceptable tolerance and if not, further adjustment (such as a further rotation of an implanted toric IOL or limbal relaxing incision) can be made to finely tune the refraction.
[0003] However, one issue associated with the use of an intra-operative wavefront aberrometer or auto-refractor is that the real time refraction value can vary as a result of many dynamic surgical factors, including the alignment of the patient eye relative to the aberrometer or auto-refractor, patient fixation and angle alpha (angle between the center of the pupil and the visual axis), varying pupil size, the intra-ocular pressure (IOP), the hydration of the incision wound, the tear film, and the pressure exerted on the cornea from eye-lid-opening speculum. With proper control of these dynamic surgical factors and artificial intelligence including refraction confidence calculation to qualify and hence reject disqualified refraction/wavefront data, the variation in the measured refraction can be controlled to a certain range. However, there can still be some variation in the measured refraction when a patient eye is aligned relative to the intra-operative aberrometer or auto-refractor. This is more the case when an eye is aphakic, as an aphakic eye generally has a larger absolute base sphere refraction value simply because the wavefront from an aphakic eye is more divergent than that from an emmetropic eye. As a result, the recommended intra-ocular lens (IOL) power based on the real time aphakic refraction (combined with other biometric parameters) can also change in real time, for example, when the eye is re-aligned. This can cause some confusion to a surgeon in determining what exact IOL power to select for implantation during a cataract surgery.
[0004] In light of the above, there is a need in the art for a means to show a surgeon how repeatable a refraction reading is and/or how confident the refraction is. In the aphakic state, this will allow the surgeon to make a more informed decision in terms of selecting a recommended IOL power and in the pseudo-phakic state, this will allow the surgeon to finely tune the final position of an implanted IOL until with higher confidence.
[0005] One or more embodiments of the present disclosure satisfy one or more of the above-identified needs in the art. One embodiment is a means to present to a surgeon a histogram of real time refractions at each stage of a refractive cataract surgery, i.e. phakia, aphakia and pseudo-phakia. Another embodiment is to automatically and intra-operatively detect the phase of a cataract surgery (i.e. to intra-operatively determine if a patient eye is phakic, aphakic, or pseudo-phakic). Another embodiment is to display a real-time, dynamic histogram of a recommended IOL power calculated from aphakic refractions together with other biometric parameters of the eye.
[0006] One aspect of the present disclosure is to record the occurrence frequency of qualified and/or rounded real time refractions and to display the occurrence frequency distribution or histogram of the refraction data. This will present to the surgeon an information rich display of quantitative refraction instead of a most recently single qualified refraction at one point in time, which may be more variable. Another aspect of the present disclosure is to use phakic biometry measurement results of an eye obtained either pre-operatively or intra-operatively to estimate its aphakic refraction, to use an estimated aphakic refraction to automatically detect the aphakic phase of the eye. Still another aspect is to use intra-operative biometry measurement to determine the cataract surgical phase of an eye. Still another aspect is to use intra-operative Purkinje images to determine the cataract surgical phase of an eye. Still another aspect is to combine real time aphakic refraction with phakic and/or aphakic biometry to calculate an IOL power per a targeted final refraction and to present to a surgeon a dynamic histogram of the IOL power recommendations during the aphakic phase. Still another aspect is to optimize and personalize the IOL power calculation in a regression manner by collecting data over a relatively large number of patients for each surgeon to account for surgeon factors.
[0007] Another embodiment of the present disclosure is to display the confidence level of real time intra-operative refraction. One aspect is to calculate a confidence level or value based on an algorithm that takes into account all wavefront and/or aberrometry data qualifiers and to present to a surgeon the confidence level or value as a height or length varying percentage bar. Another aspect is to correlate the confidence percentage value to a color encoded confidence percentage indicator (such as the word “Rx”). In this case, the confidence value can be digitized such that for a certain real time refraction that falls within a certain digitized confidence value range, a certain color selected from a color spectrum is assigned to the real time refraction and is displayed to the surgeon.
[0008] Still another embodiment of the disclosure is to combine the calculation of the occurrence frequency or probability distribution of qualified refraction with the confidence level of the refraction to produce a combined confidence weighted histogram and to present this confidence weighted histogram to a surgeon in real time. One aspect is to use the confidence weighted histogram to pick the most steady aphakic refraction, and to use the chosen aphakic refraction to calculate the IOL power. Another aspect is to allow the surgeon the option to display only the refraction histogram and/or the refraction confidence bar and/or the combined confidence weighted refraction histogram to guide the surgery. In particular, at the aphakic phase, the surgeon can select the IOL power based on the live, dynamic IOL power histogram; and at the pseudo-phakic phase, the surgeon can use the live refraction histogram to rotate an implanted toric IOL or to perform a guided limbal relaxing incision.
BRIEF DESCRIPTION OF THE DRAWING
[0009] FIG. 1 shows a schematic diagram of an embodiment system comprising an intra-operative eye refraction measurement device, a digital processor and a display;
[0010] FIG. 2 shows the major steps involved in the presently disclosed means to provide a surgeon the histogram of live refraction;
[0011] FIG. 3 shows the major steps involved in the presently disclosed means to display the histogram of live IOL power recommendations;
[0012] FIG. 4 shows an example display of an IOL power histogram together with some other parameters as well as a live eye image;
[0013] FIG. 5A shows a generic schematic diagram similar to that of FIG. 1 but with the difference in that the intra-operative refraction measurement device can include a camera and/or a biometric parameter measuring sub-module, and the digital processor is configured to automatically detect the phase of the surgery to determine if the eye is phakic or aphakic or pseudo-phakic;
[0014] FIG. 5B shows an embodiment in which a sequential wavefront sensor is integrated with an eye camera and an optical coherence based biometric parameter measurement submodule.
[0015] FIG. 6 shows the major steps involved in one embodiment to meaningfully and automatically display either a histogram of live refraction or a histogram of IOL power recommendation or both depending on the cataract surgical phase;
[0016] FIG. 7 shows an example display similar to that of FIG. 4 but with a confidence percentage bar.
DETAILED DESCRIPTION
[0017] Intra-operative refraction of a patient eye (or alternatively, a subject eye) undergoing a refractive cataract surgery using an intra-operative refraction measurement device such as a wavefront aberrometer or auto-refractor has been shown to improve the refractive surgical outcome. Traditionally, ophthalmic refraction measurements are done in a snap-shot or single measurement manner (although such a single measurement can involve the averaging of a number of snap shots of measurements). When such a measurement is transferred to intra-operative refraction of a patient eye undergoing a refractive cataract surgery, it tends to hide the variability of the measurement result as the refraction of an eye undergoing a surgery is dependent on a number of dynamic surgical factors, including the alignment of the eye relative to the intra-operative refraction device, the condition of the cornea as well as the condition of the anterior chamber of the eye. In fact, even with the use of a snap-shot refraction measurement device, when a surgeon (or other operator) does multiple intra-operative measurements, the refraction measurement results will most likely vary and this variation can cause confusion to a cataract surgeon, especially if the surgeon relies on aphakic intra-operative refraction to determine the IOL power to be selected. Such variability in the pseudo-phakic phase can also cause confusion to a surgeon if the surgeon relies on intra-operative pseudo-phakic refraction to determine the position of an implanted IOL such as the orientation axis of a toric IOL or the amount of limbal relax incision to neutralize astigmatism. The variability of intra-operative refraction became more evident after real time intra-operative wavefront aberrometers were introduced to the refractive cataract surgery practice.
[0018] In accordance with one embodiment of the present disclosure, a real time eye refraction measurement device is coupled to a digital processor and a display. FIG. 1 shows a schematic diagram of such an embodiment, in which a real time intra-operative eye refraction measurement device such as a wavefront sensor or an auto-refractor 102 is coupled to a digital processor 104 and is linked to a display 106 . The digital processor 104 is configured to capture/record intra-operative refraction (or wavefront measurement) and to process the refraction or wavefront data in real time to qualify the data and to reject disqualified data.
[0019] The qualification of the real time data can be based on various qualification parameters or qualifiers. One important qualifier is the alignment of a patient eye relative to the refraction measurement device. From a practical point of view, for example, when an eye is aligned to within ±0.1 mm of the refraction measurement device optical axis, the alignment can be considered very good and when the eye is aligned to within ±0.5 mm of the device optical axis, the alignment can be considered still acceptable. Therefore, a threshold of ±0.5 mm can be established as the pass/fail criterion for qualifying or disqualifying the data in terms of eye alignment relative to the refraction measurement device.
[0020] Another important qualifier is the uniformity of optical power or energy among different sampled sub-wavefronts. A uniformity ratio can be defined as the relative standard deviation of optical energy or power among different sampled sub-wavefronts, i.e. as standard deviation divided by the average value. As an example, the uniformity ratio threshold can be 6%. The data qualification process will therefore reject any refraction frame data that has a uniformity ratio greater than the threshold. Alternatively, the uniformity qualification parameter can also be defined as an occlusion parameter which is the maximum minus minimum value divided by the average in terms of optical energy or power among different sampled sub-wavefronts. An associated threshold (such as three times that of the uniformity ratio) can also be defined to qualify the refraction data. Note that this qualification process will likely remove data associated with surgical factors that partially block the overall wavefront light beam or reflect the incident light probe beam that travels to a patient eye to create the returned wavefront beam. These surgical factors can include, for example, a surgical tool positioned in the probe beam path, thus reflecting the probe beam back to the refraction measurement device; a surgical tool positioned in the wavefront beam path that partially block and hence attenuate light related to some sub-wavefronts; an air bubble or cortex leftovers inside the anterior chamber or the lens capsule of a patient eye that either absorb(s) or scatter(s) light related to some sub-wavefronts; a blob or puddle of visco-elastic material or irrigation solution left on the cornea of a patient eye that directs away light related to some sub-wavefronts.
[0021] Another qualifier is the amount or degree of higher order aberrations. This qualifier can be considered as how good the overall aberrations fit as sphere and cylinder refractive errors. If the fitting is not good, we can consider the overall wavefront as more departed from being characterized as a pure combination of sphere and cylinder refractive errors. The degree of departure of the overall wavefront from a combination of sphere and cylinder refractive errors can be defined as the square root of the summation of the square of the distance of each data point from its expected position on an ellipse that represents a combination of sphere and cylinder. A threshold can be established such that if the degree of departure is above the threshold, the wavefront data will be disqualified. Factors that can increase this qualification value include a surgical tool partially blocking the wavefront, keratoconus, scars on a cornea, air bubbles or cortex leftovers inside an eye, visco-elastic gel on a cornea, and irrigation event.
[0022] Still another qualifier is the average prismatic tilt of the overall wavefront. For example, if the averaged overall wavefront tilt is pointing at an angle within 1 degree from the optical axis of the eye refraction measurement device, the prismatic tilt of the overall wavefront can be considered very highly qualified. A threshold of, for example, 11 degree can be set and if one finds that the averaged overall wavefront tilt is pointing at an angle greater than the threshold, the wavefront data can be disqualified.
[0023] Still another qualifier is the overall signal strength of the wavefront. If there is no eye under the refraction measurement device, for example, when the device is sending the probe beam directly to the floor of an OR (operating room), the wavefront signal returned from the floor will generally be much weaker than that from a real eye. A signal strength range can therefore be defined that covers the full range over all phases and all pigmentation eyes. When the returned wavefront signal strength is outside this pre-defined range, the data will be disqualified.
[0024] Still another qualifier is the steadiness of the wavefront data from one frame to the next. In a transient situation such as the movement of a patient eye, the disturbance of the wavefront by an irrigation event, or the movement of a surgical tool within the wavefront path, the wavefront data received may not be steady, i.e. measured refraction changing more than desired from frame to frame. A threshold can be established to require that the change in the sphere and cylinder value from one frame to the next need to be no more than, for example, ±0.5 diopter. If the change is more than this threshold, the data from both frames will be disqualified.
[0025] Note that there can be more qualification parameters. In addition to the qualification of the wavefront data, the digital processor 104 can also be further configured to process the qualified data to produce a real time dynamic histogram of the intra-operative refraction (or wavefront measurement) and to display such a histogram on the display. As time goes on during a particular phase of a cataract surgery (such as the aphakic phase), the histogram will also be updated in real time to reflect how steady a measured refraction with a high occurrence frequency gradually becomes.
[0026] As an option, the digital processor 104 can also be configured to digitize the qualified refraction data, for example, in quarter diopter steps, to further limit small variations of the live refraction within a quarter diopter to the same value.
[0027] By displaying such a histogram to a surgeon in real time during a cataract surgery, the surgeon can know which refraction value is produced most often by the intra-operative refraction measurement device and hence use that value as the more likely “true” refraction of the patient eye in that surgery phase.
[0028] In addition, the digital processor 104 can also be configured to automatically recognize the qualified refraction that has the highest occurrence frequency and directly present this refraction to the surgeon. It can be understood that this refraction may change as the cataract surgery initially enters a phase and will gradually stabilize once the eye is properly prepared and conditioned for refraction measurement and is aligned to the refraction measurement device 102 for a certain alignment holding time. With practice, a surgeon will figure out a reasonable holding time to enable the refraction having the highest occurrence frequency to stabilize.
[0029] As an option, the time length for the refraction that will be used to produce the histogram can also be pre-defined such that older qualified refraction data are automatically removed while more current new qualified data are added. The time length can also be personalized for a particular surgeon and be limited to a reasonable and practical value. For example, the time length can be 3 seconds to 10 seconds, during which a surgeon can normally keep the eye position of a patient aligned for a reasonably “reliable” high occurrence frequency refraction to be displayed.
[0030] FIG. 2 shows the major steps involved in one embodiment to obtain and present to a surgeon the histogram of live intra-operative refraction. The first step 202 is to capture/record intra-operative refraction or wavefront data. The second step 204 is to process the refraction or wavefront data to reject disqualified data. The third step 206 is to process the qualified historic data and to produce a real time histogram. The fourth step 208 is to display a live refraction histogram on a display.
[0031] As an option, instead of displaying the histogram that contains all the qualified refraction values, the last step can be to display digitized refraction that has the highest occurrence frequency or to display only a few digitized refraction values including the one that has the highest occurrence frequency as well as a few surrounding ones (such as one or two on each side) that have occurrence frequencies next to the highest occurrence frequency.
[0032] Alternatively and more advantageously, as another embodiment of the present disclosure, instead of being configured to display a continuously updated histogram of real time refraction, the digital processor can be configured to combine the qualified aphakic refraction data with biometric data of the eye obtained either pre-operatively or intra-operatively to calculate a recommended IOL power, to produce a live dynamic histogram of the IOL power recommendation, and to display such a histogram on a display. This will be especially beneficial to a surgeon in terms of helping the surgeon to determine which recommended IOL power to choose for implantation. In general, the recommended IOL power will change as an aphakic eye is initially prepared and aligned to the intra-operative refraction measurement device 102 and the recommended IOL power will stabilized as the aphakic eye is held aligned longer. In practice, after a surgeon has prepared and conditioned an aphakic eye, he/she can align the patient eye and hold the patient head steady for a certain time (for example 3 to 5 seconds) to get a relatively steady recommended IOL power that has the highest occurrence frequency. The surgeon can then select this recommended IOL power or compare this IOL power with that based purely on pre-operative biometry data and select a value of his/her choice such as a value in between these two values.
[0033] It should be understood that the term biometric data of an eye can include all anatomical parameters of an eye that can be measured either pre-operatively or intra-operatively. In practice, these parameters can be measured optically and ultrasonically and they include axial length, anterior chamber depth, corneal anterior (K or keratometry values) and posterior profiles, corneal steep meridian and flat meridian axis and power, corneal astigmatism, cornea thickness, aqueous depth, lens thickness, lens anterior and posterior profile, pupil size or diameter, pupil center, white to white distance, iris center, and retina thickness, etc.
[0034] The reason why these parameters can be combined with aphakic refraction to better predict an IOL is that without aphakic refraction, one can only indirectly calculate and hence predict the optical power of the cornea using for example, a keratometer or corneal topographer or an OCT or a Pentacam. With aphakic refraction, the optical power of the cornea (in both sphere and cylinder) can be directly measured with higher accuracy. Once the cornea optical power, the axial length of an eye and a targeted final refraction is determined, and the final effective lens position of the IOL is predicted, the IOL power can be calculated. In terms of predicting the effective lens position of an IOL, the prediction is generally highly dependent on a so called A-constant that reflects the property of haptics or arms of a particular IOL and the lens itself, which is manufacturer dependent. Meanwhile, the effective lens position of an IOL is also dependent on the anatomic parameters of an eye and these anatomic or biometric parameters include the white to white distance, the anterior chamber depth and the lens capsule position. Therefore, a combination of aphakic refraction with pre- or intra-operative biometric measurement can result in a better surgical outcome.
[0035] It should be noted that all other features that have been discussed with respect to real time refraction can be transferred to real time IOL power recommendation at the aphakic phase. Meanwhile, at the aphakic phase, one can also either configure the digital processor to produce and display a histogram of real time refraction or configure it to produce and display a histogram of real time IOL power recommendation or even configure it to produce and display both a histogram of real time refraction and a histogram of real time IOL power recommendation.
[0036] As in the case of refraction, the digital processor 104 can also be configured to digitize the IOL power calculated based on the qualified refraction data and the pre- or intra-op biometry data. For example, the digitization of IOL power recommendation can be in half diopter steps to further limit small variations of the recommended IOL power within half diopter to the same value. In addition, the digital processor 104 can also be configured to automatically recognize the calculated IOL power that has the highest occurrence frequency and directly present this IOL power to the surgeon.
[0037] Similarly, as another option, the time length for calculating the IOL power histogram can also be pre-defined such that older IOL power data are automatically removed while more current new IOL power data are added. Again the time length can be personalized for a particular surgeon and be limited to a reasonable and practical value. For example, the time length can be 3 seconds to 10 seconds, during which a surgeon can normally keep the position of the eye of a patient eye aligned steady for a reasonably “steady” IOL power recommendation having the highest occurrence frequency to be displayed.
[0038] FIG. 3 shows the major steps involved in the presently disclosed means to display the histogram of live IOL power recommendation at the aphakic phase. The first step 302 is to capture/record intra-operative refraction (or wavefront measurement) data. The second step 304 is to process the data in real time to qualify the data and to reject disqualified data. The third step 306 is to calculate a recommended IOL power based on the qualified aphakic refraction data and pre- or intra-op biometry data. The fourth step 308 is to process the IOL power recommendation data to produce a live dynamic histogram of the recommended IOL power. The fifth step 310 is to display such an IOL power histogram on a display.
[0039] As in the case of refraction, optionally, instead of displaying the histogram that contains all the IOL power recommendation values, the last step can be to display only a few (such as 3) digitized IOL powers including the one that has the highest occurrence frequency as well as a few surrounding ones (such as 2 with one on each side) that have their occurrence frequencies next to and on both sides of the highest occurrence frequency.
[0040] FIG. 4 shows an example of such an IOL power histogram display together with some other parameters as well as a live eye image. Note that in the right column of the display, there is an IOL power histogram 402 that shows three digitized IOL power recommendations, i.e. 25.0, 25.5 and 26.0 diopters. Associated with each recommended IOL power is a vertical bar with a height that represents the respective relative occurrence frequency or probability. In this case, the most frequently occurred IOL power recommendation is 25.5 diopter. The next most frequently occurred IOL power recommendation is 26.0 diopter.
[0041] In addition, as another embodiment, the total number of measurements/IOL calculations that are included in the histogram can be displayed in real time. Note that this value is not shown in FIG. 4 and it can be shown anywhere on the display, but is preferably shown directly on or next to the histogram.
[0042] In FIG. 4 , the live display also shows a live eye image 412 ; which eye 413 (left or right) is being operated, the orientation of the eye 414 relative to the surgeon (temporal or superior), a soft fixation light switch 415 (to turn a blinking fixation light on and off), a soft button 416 for capturing one or more snap shot(s) of the current screen print, the phase of surgery 417 (in this case, aphakia); a soft session start/stop button 418 . On the right column, in addition to the histogram 402 , there is a box 401 that shows the pre-op targeted refraction and the type of IOL intended to be used for implantation; the three boxes 404 , 405 and 406 show the latest three qualified and digitized real time refractions together with their respective corresponding IOL power recommendations and the corresponding expected final pseudo-phakic refractions; the bottom box 408 shows the current real time refraction reading together with its corresponding spherical equivalent (SE). Note that this current real time refraction reading can be qualified with a lower qualification or confidence threshold and the values can be rounded to the 0.01 digit of a diopter.
[0043] At this point, a question to ask is how the phase of surgery can be determined intra-operatively to ensure the recommended IOL power makes sense, i.e., the refraction value being used for the calculation of the IOL power needs to be that from the aphakic phase. Note that one feature in this disclosure is to automatically and intra-operatively detect the phase of a cataract surgery.
[0044] FIG. 5A shows a generic schematic diagram of such a device. Compared to the FIG. 1 , the difference is in that the eye refraction measurement device 502 may contain other eye property measurement submodules and the digital processor is configured to use pre- or intra-operative biometric and/or eye image data and real time refraction data to automatically determine the phase of the eye undergoing a cataract surgery, i.e. from phakia, to aphakia and to pseudo-phakia.
[0045] It is well known that there is a relatively big change in the average refraction (i.e. spherical equivalent) of an eye from its phakic phase to its aphakic phase, and also mostly likely from its aphakic to its pseudo-phakic phase (except for the case when the eye is extremely long). In fact, if spherical equivalent is used to gauge the difference, the difference in diopter value from a phakic phase to an aphakic phase of the same eye is of the order of about 10 diopters. In one embodiment of the present disclosure, pre- or intra-operative biometry measurement results and/or pre-operative refraction (or wavefront measurement) data are used to determine an expected refraction of the eye in its phakic phase and aphakic phase, and targeted refraction is used to determine expected pseudo-phakic refraction. Once a cataract surgery starts, qualified real time refraction measurement result is consistently compared with the expected refraction of the eye at different phases. If the qualified real time refraction (such as spherical equivalent) is within a certain tolerance range (for example, ±3.0 D or more preferably a range selectable by an end user from ±0.5 D to ±4.0 D) from the expected phakic refraction (such as the pre-op refraction or a calculated phakic refraction using pure eye biometry data or a combination of these data), the state of the eye can be considered as phakic; if the qualified real time refraction is within a certain tolerance range (for example, ±3.0 D, or more preferably a range selectable by an end user from ±0.5 D to ±4.0 D) from the expected aphakic refraction (such as a value calculated using theoretical vergence formula based on axial eye length and corneal power derived from K-measurements), the state of the eye can be considered as aphakic; and finally, if the qualified real time refraction is within a certain tolerance range (for example, ±3.0 D, or more preferably a range selectable by an end user from ±0.5 D to ±4.0 D) from the targeted refraction after the aphakic phase, the state of the eye can be considered as pseudo-phakic.
[0046] Note that the reason for choosing the example of ±3.0 D as one preferred tolerance range is that in most cases, temporary surgical factors such as the hydration of incision wound, the change in the intra-ocular pressure, and the pressure exerted on a cornea from a speculum, will not cause the average refraction of the eye to depart from its expected value by more than approximately ±2.0D.
[0047] In some cases like a dense cataract or femto laser cases, either pre-op or intra-op phakic refraction of the eye may be impossible or unreliable due to strong scattering of light by the dense cataract lens or some other strong light scattering regions in the eye such as optical bubbles created by a femto laser. Also, if the eye is extremely long, the difference in refraction between its aphakic phase and its pseudo-phakic phase can be smaller than the tolerance range which can cause an overlap between the expected refraction in the aphakic phase and that in the pseudo-phakic phase. In these cases, using just expected refractions to compare with real time refraction may not be enough to differentiate the phases of a cataract surgery.
[0048] As an embodiment, information from real time Purkinje images can be used to help determine the phase. This is because the Purkinje images are very different from one phase to another phase. In fact, the natural lens of an eye is relatively thicker when compared with an artificial intra-ocular lens (IOL) and the refractive index of a natural lens is generally lower than that of an IOL. Therefore, the third and fourth Purkinje images created by the front and back interfaces of a natural lens are less bright and more separated as compared to those of an IOL. Further, in the aphakic phase, due to the fact that there is no natural or artificial lens in the eye, there are only the first and second Purkinje images created by the front and back interfaces of the cornea. In terms of hardware, there is a need for a live eye camera to be associated or coupled to the eye refraction measurement device, and fortunately, this is generally the case as such a camera is needed to guide a surgeon in aligning an eye to the eye refraction measurement device. Note that in FIG. 5A , such a camera 508 is represented by a box linked to the eye refraction measurement device 502 via a dashed line and this camera 508 can be integrated inside the eye refraction measurement device as will be discussed shortly in FIG. 5B .
[0049] As still another embodiment, an eye biometric parameter measurement submodule 510 is coupled to or integrated inside the eye refraction measurement device 502 . In FIG. 5A this is shown with the box 510 linked by a dashed line to the box 502 . The submodule 510 can be an optical coherence tomography (OCT) module or simply an optical low coherence reflectometer (OLCR) as will be discussed shortly in more detail in FIG. 5B . The difference between an OCT and an OLCR is that an OCT can perform two dimensional scanning to obtain a three dimensional volumetric data set of optical reflection/scattering information and an OLCR does not do any transverse scanning so it can only obtain optical reflection/scattering information along a single line. However, in terms of intra-operatively obtaining information on whether there is a natural lens, or no lens or an artificial IOL in an eye, both OCT and OLCR can do the job simply because a phakic natural lens is much thicker with less strong reflection/scattering from its optical interfaces than a pseudo-phakic IOL, and meanwhile in the aphakic phase, there is no lens at all. Both OCT and OLCR can hence detect these conditions. Therefore, the digital processor in FIG. 5A can be configured to use either OCT or OLCR obtained information to determine the phase of a cataract surgery.
[0050] Note that even though either an OCT or an OLCR can provide the information on the phase of the eye under a cataract surgery, an OCT is preferred because it can also provide information on other anatomic or biometric parameters which is useful in calculating the IOL power as we discussed before.
[0051] To illustrate a more specific embodiment, FIG. 5B shows a schematic diagram in which a sequential wavefront sensor is integrated with an eye camera and an optical coherence tomographer (OCT) based biometric parameter measurement submodule. In this illustration, a sequential wavefront sensor 502 is attached to a surgical microscope 500 , and an OCT based eye biometric parameter measurement submodule 510 as well as an eye camera 508 is integrated with the wavefront sensor 502 .
[0052] The surgical microscope has its own objective lens 501 . A main beam splitter 561 is positioned below the objective lens 501 to separate and combine visible and infrared light beams. The main beam splitter 561 is transmissive to visible light meant for the microscope 500 and is reflective to near infrared light meant for the wavefront sensor and the camera as well as the biometric parameter measurement submodule. A shield window or shield lens 552 is arranged below the beam splitter 561 and a number flood illumination light sources (such as LEDs) are arranged around the shield to provide flood illumination to the patient eye for the camera to capture a live eye image.
[0053] The wavefront sensor module 502 comprises two 4-F relay stages with its light path folded to relay the wavefront from the corneal or pupil plane of a patient eye 599 to a wavefront sampling aperture 518 . The first relay stage comprises a first lens 554 and a second lens 516 and relays the wavefront (with certain optical magnification or demagnification depending on the focal length of the first and second lens) from the corneal or pupil plane to an intermediate image plane where a dynamic transmissive focus variable lens 578 is disposed. This focus variable lens can be used to partially or fully compensate the sphere component of the wavefront or to dynamically change its focus to enable a scanning of the sphere component of the wavefront.
[0054] The second relay stage comprises a third lens 540 and a fourth lens 542 and further relays the wavefront from the intermediate plane (where the dynamic transmissive focus variable lens 578 is disposed) to the final wavefront sampling aperture 518 plane. A mega-aperture 577 can be arranged at the first Fourier transform plane to prevent light outside a certain diopter range from entering the rest of the wavefront relay path. A band pass filter 576 can also be arranged in the second relay stage to reject light outside an intended wavefront sensing spectral range from entering the rest of the wavefront relay light path. A MEMS (microelectrical mechanical system) mirror 512 folds the beam path and scans the wavefront sequentially around the aperture 518 so that different sub-wavefronts are sampled. A sub-wavefront focusing lens 520 is positioned next to the sample aperture 518 to focus the sampled sub-wavefronts to a position sensing device 522 . A diffuser (not shown in FIG. 5B ) can be arranged in front of the position sensing device 522 to ensure a certain light spot size on position sensing device 522 .
[0055] The OCT based biometric parameter measurement submodule 510 can be based on an optical fiber low coherence interferometer. Light from a low coherence light source (such as a fiber pigtailed superluminescent diode or SLD) 572 is directed to a directional coupler 590 and is split into a sample arm 588 and a reference arm 592 . The reference arm can have a fiber coil that ensures an overall reference optical path length approximately matched to that of the sample arm. Light in the sample arm can be collimated and/or focused and/or scanned. Lens 586 , scanner 582 , lens 584 and scanner 580 are just some exemplary possibilities in terms of manipulating/scanning the sample beam. The sample light beam is sent to a patient eye through a polarization beam splitter (PBS) 574 . Sample light wave returned from the eye (especially by all the eye optical interfaces) that has the original polarization can be collected by the same sample arm optics to recombine with the light wave from the reference arm to create optical low coherence interference and then sent to a detector or a detection module 594 for signal extraction. Sample light from the eye having an orthogonal polarization will be reflected by the PBS 574 to be directed to the wavefront sensor module for wavefront or refraction measurement.
[0056] The eye camera module 508 comprises a camera lens 568 and an image sensor 562 . The camera lens 568 can be designed to work in combination with the first lens 554 to form an eye anterior image on the image sensor 562 . An imaging beam splitter 560 can be arranged to reflect light of the flood light spectral band meant for live eye camera imaging to the eye camera module 508 . The spectral band of the SLD can be selected to be different such that light in that spectral band will pass through the beam splitter 560 and be channeled to the rest of the wavefront sensing path.
[0057] Note that the wavefront sensor as illustrated in FIGS. 5A and 5B does not have to be a sequential wavefront sensor, it can be any refraction measurement device. The eye biometric parameter measurement device or submodule does not need to be limited to an OCT or OLCR, it can be a scheimpflug camera or even a nuclear magnetic resonance imaging module. The spectral band used for wavefront sensing does not need to be the same as the one used for biometric parameter measurement. In such a case, a WDM (wavelength division multiplexing) fiber coupler can be used to combine and split the two spectral bands of light.
[0058] Although auto-detection of the phase of an eye under a cataract surgery is desired, at this moment, it should also be noted that another embodiment of the present disclosure is to allow the surgeon to manually select or interrupt to select the phase so that it can be ensured that the refraction value used for IOL calculation is that from the aphakic phase.
[0059] Note also that as still another embodiment, the digital processor 504 can be configured to combine the information provided by either the pre-op biometry and/or refraction data or the intra-op refraction data or the intra-op Purkinje image data or the intra-op biometry data to determine the phase of a cataract surgery.
[0060] With the automatic detection of the cataract surgical phase of an eye, the digital processor can be further configured to only display refraction histogram in the phakic phase and pseudo-phakic phases, and to only display IOL power histogram in the aphakic phase or to display both refraction histogram and IOL power histogram in the aphakic phase.
[0061] FIG. 6 shows the major steps involved in one embodiment to meaningfully and automatically display either a histogram of intra-operative refraction or a histogram of IOL power recommendation or both. The first step 602 is to automatically determine the phase of an eye under cataract surgery. If the eye is phakic, the next step 604 is to display the histogram of intra-operative refraction in the phakic phase. If the eye is aphakic, the next step 606 is to display the histogram of IOL power recommendation or to display both the histogram of refraction and the histogram of IOL power recommendation. If the eye is pseudo-phakic, the next step 608 is to display the histogram of intra-operative refraction in the pseudo-phakic phase.
[0062] As another embodiment of the present disclosure, a confidence level of intra-operative refraction data is calculated and displayed in real time. As will be explained in more detail shortly, the confidence level value can be calculated based on an algorithm that takes into account different qualifiers, including alignment of the eye, wavefront signal strength, the optical energy or power distribution among all sampled sub-wavefronts, the overall average prismatic tilt of all the sampled sub-wavefronts, the amount of higher order aberrations, etc. In one embodiment, the confidence value is associated with the most recent qualified refraction.
[0063] In terms of displaying the confidence level or value in real time, one embodiment is to display it as a height or length varying percentage bar; another embodiment is to correlate the confidence percentage value to a color from a rainbow spectrum with the confidence percentage indicator (such as the word “Rx” or the numerical value that shows the refraction) being shown in different colors. In this latter case, the confidence value can be digitized such that for a certain real time refraction that falls within a certain digitized confidence level range, a certain color is assigned to the real time refraction and is displayed to the surgeon.
[0064] FIG. 7 is an example live display in which a confidence percentage bar 703 is shown in addition to those pieces of information shown in FIG. 4 . Note that the confidence percentage bar can be arranged anywhere on the live display but is preferred to be next to the current qualified refraction or current IOL power recommendation. In FIG. 7 , the confidence percentage bar 703 is below the histogram 702 and above the most recent qualified refraction. Note that in the aphakic phase, as there is a correspondence between a qualified refraction and an associated IOL power recommendation, therefore, the confidence percentage is also a confidence value for the current IOL power recommendation.
[0065] As an alternative, in another embodiment, instead of showing the confidence percentage of the current refraction, the confidence percentage shown can also be that associated with the refraction that has the highest occurrence frequency (i.e. the one having the highest value in the refraction histogram or the one having the highest value in the IOL power histogram). In addition, the confidence percentage bar can also be color coded such that one or more threshold(s) can be established to indicate to a surgeon if the confidence level is high or medium or low. For example, when the confidence value is above 90%, the confidence bar can be in green color, when the confidence value is between 75% and 90%, the confidence bar color can be yellow, when the confidence value is between 50% and 75%, the color of the confidence bar can be orange, and when the confidence value is below 50%, the color can be grey. These color codings can be configured per a surgeon's personalized preference as well. Similar color coding can also be applied to the font color of the refraction and/or IOL power and/or expected final pseudo-phakic refraction values.
[0066] In terms of calculating the overall confidence level value, we can assume that the thresholds for different qualifiers have been established and that the refraction data being processed have passed all the qualification thresholds. Then for each qualifier, a range can be defined between a practical good case and a threshold case and a confidence percentage value can be assigned to each qualifier or qualification parameter within the range. The overall confidence level can then be defined as a function of each individual qualifier confidence percentage values such as the average.
[0067] For example, consider that the degree of eye alignment relative to the refraction measurement device is a qualifier. From a practical point of view, when the eye is aligned to within ±0.1 mm of the optical axis of the eye refraction measurement device, the confidence level can be considered as 100%. Assume that the qualification threshold is established as when the eye is aligned to within ±0.5 mm of the device optical axis and the corresponding confidence level for this threshold case is 0%. Then for an arbitrary eye alignment that is between the ±0.1 mm case and the ±0.5 mm threshold case, the confidence percentage value can be assumed to be linear or non-linear. In the linear case, if the eye center is 0.2 mm away from the optical axis, the corresponding eye alignment confidence level will be 75% (0.2 mm is three quarter from 0.5 mm over the range between 0.1 mm and 0.5 mm).
[0068] Similarly, if the uniformity of optical energy or power distribution among all sampled sub-wavefronts is another qualifier. Then from a practical point of view, when the uniformity ratio (standard deviation divided by the average) is 2%, the uniformity confidence level can be considered 100%. If the uniformity ratio threshold is 6% which corresponds to a uniformity confidence level of 0%, then assuming a linear relationship, a uniformity ratio of, say, 3% will result in a uniformity confidence percentage value of 75% (3% is three quarter away from 6% over the range between 2% and 6%).
[0069] We can propagate the same argument to one more qualifier, the average prismatic tilt of the overall wavefront. From a practical point of view, when the average prismatic tilt of the overall wavefront is within 1 degree relative to the optical axis of the refraction measurement device, the confidence level can be considered as 100%. Assuming that the threshold is 11 degree which corresponds to a confidence value of 0%, then for an arbitrary average prismatic tilt of 4 degree, under the assumption of a linear relationship, the corresponding confidence level will be 70% (4 degree is 70% away from 11 degree over the range between 1 degree and 11 degree).
[0070] Similar calculations can be applied to other qualifiers, including overall wavefront signal strength, frame to frame refraction difference, and the amount of higher order aberrations, etc. An overall confidence level can be defined as the average of all the individual confidence levels. The overall confidence level can also be defined with different weighting factors depending on the importance of a particular qualifier.
[0071] Note that there are many other ways to calculate the confidence level associated with each qualifier and non-linear relationship can be established across the range between a practically good enough case and a threshold case. For example, instead of using a linear relationship across the range, a non-linear relationship such as a square root relationship can be employed. In such as case, a 75% confidence level in the linear relationship case will be equal to SQRT(75%)=86.6% in the non-linear relationship case, and a 36% confidence level in the linear relationship case will be equal to SQRT(36%)=60% in the non-linear relationship case.
[0072] Meanwhile, the overall confidence level can also be non-linear in terms of its association with different qualifier's confidence levels. For example, some qualifiers, like the alignment of the eye and the overall prismatic tilt in the aphakic phase can have a higher weighting as compared to other qualifiers such as the amount of higher order aberrations. Therefore, above shown method to calculate the confidence level is only exemplary.
[0073] In addition, there can also be a combined consideration of the confidence level and the steadiness of a qualified refraction. One embodiment of the disclosure is to combine the calculation of the occurrence frequency distribution of qualified refractions with the confidence of the corresponding refractions to produce a combined confidence weighted histogram and to display this confidence weighted histogram to a surgeon in real time. Note that in such a case, the modified histogram can show a digitized refraction that is the tallest in the histogram but the refraction may not have the highest occurrence frequency simply because it may have a high confidence level that has been weighted and factored in the histogram. Accordingly, the recommended IOL power can also be modified to factor in the calculation of the occurrence frequency distribution of IOL power and the confidence level associated with that IOL power, and to produce a combined confidence weighted histogram of IOL power recommendation.
[0074] Note that these modifications to the histogram can also be optimized over time through regression. Artificial intelligence or neural network can be built in an algorithm for a particular surgeon to automatically adjust the weighting factors of different qualifiers using clinical data collected over a large number of patients and to produce an optimized weighting function that will produce a statistically optimized real time refraction or real time IOL power recommendation, thus leading to a statistically optimized surgical outcome for that particular surgeon.
[0075] Note also that all additional features and embodiment variations as mentioned in the refraction and IOL recommendation histogram examples can be applied to the confidence weighted refraction and/or confidence weighted IOL power recommendation cases. For example, automatic detection of the phase of an eye under a cataract surgery can be implemented to determine if a confidence weighted refraction histogram should be displayed (like in phakia and pseudo-phakia) or an associated confidence weighted IOL power recommendation histogram should be displayed (like in aphakia).
[0076] In addition, in the aphakic phase, the confidence weighted refraction histogram can also be used to automatically select the most likely “true” aphakic refraction and this selected aphakic refraction can be used to calculate an IOL power using a regression formula that also takes into consideration the biometry data collected pre- or intra-operatively as well as the statistical data collected over a large number of patients. In practice, once a surgeon has conditioned an aphakic eye, and had the eye positioned steady and aligned, overtime, this recommended IOL power will be continuously updated on the display and will gradually become steady to give the surgeon higher confidence in picking the power of an IOL to be implanted.
[0077] Note also that the discussion we have had in regard to the power of an IOL can be extended to and should be considered to be extendable to the case of a toric IOL in which the power of the IOL refers to the both the sphere and the cylinder instead of just the sphere of a monofocal IOL. In addition, the extension should also be applied to the selection of more advanced IOLs including extended depth of focus IOLs, bi-focal or tri-focal or multi-focal IOLs, accommodating IOLs (AIOL) and even recommendation of LRI (limbal relaxing incision) or CRI (corneal relaxing incision) in terms of the position and/or direction of the incision and the length of the incision. In other words, the refraction or IOL power recommendation produced by the artificial intelligence of the presently disclosed means can be used to prescribe not only the sphere but also the cylinder and cylinder axis for a refraction procedure. Moreover, since the device being disclosed to measure the optical refraction property of a patient eye is not limited to an auto-refractor but should include a wavefront sensor as well as one or more optical biometry measurement devices, the disclosure should therefore be considered as including higher order aberrations and hence the prescription as exemplified in terms of IOL power recommendation etc. can also be extended to include prescription in correcting higher order aberrations such as coma, trefoil and spherical aberration.
[0078] In addition, as one embodiment of the present disclosure, the digital processor can also be configured to store stabilized prescriptions or IOL power recommendations or histogram(s) obtained while the eye is aligned and to keep some of those prescriptions still displayed for a predefined time period even after the eye is moved away from alignment.
[0079] In addition, in further embodiments of the present disclosure, the display of information can be configured such that any one of: the real time image of the subject eye; the histogram of occurrence frequency distribution of the qualified refraction values, and/or a histogram of occurrence frequency distribution of IOL powers predicted based on an IOL predictive algorithm that incorporates among other parameters the aphakic refraction of the patient eye in one or more of the phakic, aphakic, or pseudo-phakic phase of the vision correction procedure; the indication of the phase of the vision correction procedure, displaying the pre-operatively determined target refraction value; the one or more of most recent qualified intra-operative refraction values; and sampled wavefronts having overall signal strength higher than one threshold value and/or lower than another threshold value can be displayed in any one of a first portion of the display screen, a second portion of the display screen, a third portion of the display screen, a fourth portion of the display screen, a fifth portion of the display screen, and/or a sixth portion of the display screen.
[0080] Although various embodiments that incorporate the teachings of the present invention have been shown and described in detail herein, those skilled in the art can readily devise many other varied embodiments that still incorporate these teachings.
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In order to take advantage of the real time nature of intra-operative refraction or wavefront aberrometry, and visually make the history of the measurements apparent to a surgeon, a histogram of frequency vs IOL results calculated from an IOL formula is computed and IOL suggestions being accumulated are displayed in a histogram. One embodiment is a means to present to a surgeon a histogram of intra-operative refractions. Another embodiment is to automatically and intra-operatively detect the aphakic phase of a cataract surgery to display a histogram of a recommended IOL power.
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This is a divisional of application Ser. No. 08/443,250 filed on May 17, 1995, now U.S. Pat. No. 5,544,425.
The present invention relates to improved drying techniques for materials which are difficult to dry. In particular, the present invention relates to improved drying techniques which extend the use of agitated pan dryers or the like to drying of difficult to dry chemical materials.
In the production of numerous chemical products, including pharmaceuticals, it may be necessary to dry intermediates and/or the final product. This is usually accomplished by means of a drying apparatus, of which there are many different types, and which may be classified according to the drying operation. For example, Perry's Chemical Engineers Handbook (5th Edition) separates dryers into three categories; direct dryers, infrared or radiant-heat dryers, and indirect dryers.
Agitated pan dryers are generally included in the classification of indirect batch dryers wherein the heat for drying is transferred to the wet solid through a retaining wall. Liquid which is vaporized from the wet solid is removed by means separate from the heating means. In general, the rate of drying depends on the contact between the wet solid and the hot surfaces of the dryer.
Standard agitated pan dryers as shown in schematic cross-section in FIG. 1, consist of a relatively shallow flat-bottomed pan 10, covered by a dished or conical cover 20. The bottom and walls of the pan 10, are surrounded by a jacket 30, to contain the heating medium, such as steam. However, it is noted that not all agitated pan dryers include a jacket for the heating medium. A central vertical shaft 40, attached to a drive means 42, carries a slow-moving, heavy-duty agitator 45, which stirs the material in the dryer and moves the material toward and away from the heat-transfer surfaces. The agitator shaft 40, may enter either through the cover 20, or through the bottom 15, of the pan 10, and may include additional means to scrape the heat-transfer surface or to better agitate the material during drying. Heating medium may also be circulated within the agitator to add extra heating surfaces, or the only heating surfaces when no jacket is provided. The blades of the agitator may be capable of being raised and lowered to accommodate different loads within the dryer, and to adjust to the changing level of the product during drying. Agitated pan dryers may be operated either under atmospheric pressure or under vacuum. In both cases, the cover is normally provided with an outlet 50, for the release of vaporized liquids, the outlet 50, being attached to a vacuum connection if desired. A charge/discharge port 60, for charging wet material and removing dried material is normally provided through the side of the pan 10, but may also be provided through the bottom 15, of the pan 10. In the alternative, no charge/discharge port may be included and material may simply be charged and withdrawn by opening the cover 20.
Agitated pan dryers are most useful for drying batches of material which must be agitated during drying, e.g. materials which are hard to handle or for which continuous drying would be uneconomical. Agitated pan dryers are particularly useful when solvents are to be recovered upon vaporization from the wet solid; or when drying must be done under high vacuum. However, agitated pan dryers are not generally suitable for materials which suffer particle degradation during drying or which form into balls and caseharden during drying.
Many chemical products, especially pharmaceutical products, are organic in nature and may decompose if exposed to excessive temperatures. Further, such products may not be crystalline in nature, may have very small particle sizes, and may require removal of toxic, and/or flammable solvents. Volatile content following drying is often required to be very low, e.g. less than one percent. Such products may be very difficult to dry. In particular, the material often becomes sticky during drying and may form into balls which can easily caseharden. When this occurs, the required low volatile content can not be met. Therefore, long drying cycles are often necessary to obtain satisfactory results.
Direct drying wherein there is a direct contact between the wet solid and drying medium, such as hot gases, is also known. In such dryers the vaporized liquid from the wet solid is normally carried away by the drying medium. Direct dryers are often referred to as convective dryers. Most standard convective dryers can not be easily operated under vacuum and therefore may not be applicable to the drying of chemical or pharmaceutical products in which toxic solvents must be removed.
To increase drying efficiency, direct drying means have previously been added to indirect dryers. In particular, agitated pay dryers may be converted to include means for blowing drying medium over the surface of the wet solid in addition to the standard indirect heating though the walls and bottom of the pan. This technique helps to extend the range of types of materials that can be dried efficiently in agitated pan type dryers. One such combination is described below.
FIG. 2 is a cross-sectional view of a nutsche type filter/dryer, generally designated by reference numeral 100, as known in the prior art. In particular the nutsche filter/dryer 100, is a standard nutsche type filter which has been modified for use as a dryer and is essentially a variant of an agitated pan dryer. The similarities will be evident from the following description. In particular, the nutsche filter/dryer 100, includes a compression vessel 120; a gas inlet 130; and a gas outlet 140, having a dust collector 145, connected thereto. The nutsche filter/dryer 100, also includes a drive means 150, connected to a main shaft 154, having two sets of extending arms mounted at 90° to each other. A first set of arms comprise flat blades (not shown) which act to smooth product 190, introduced to the vessel 120, in batches suitable for drying. A second set of arms 156, include multiple agitator extensions 158. The filter/dryer 100, further includes an inner discharge tube 160, situated within an outer discharge shaft 170, and a filter plate 180, located at the base of the vessel 120.
The main shaft 154, may be designed to both rotate and move vertically within the vessel 120. The first set of arms are fixed to and carried by the main shaft 154, while the agitator arms 156, can be moved vertically and independently of the main shaft 154. The inner discharge tube 160, is designed to move vertically within the fixed outer discharge shaft 170.
In use, the inner discharge tube 160, and main shaft 154, are raised to their highest vertical position. This in turn raises both sets of arms to their highest position. A feed slurry of product 190, to be dried is fed into the space bounded by the filter plate 180, the walls of the vessel 120, and the discharge tube 160. Because the filter plate 180, occupies the space which would normally be occupied by the heated plate of an agitated pan dryer, heating medium is circulated through the two sets of arms (i.e. the flat blades and the agitator arms 156). In this manner heat is transferred to the product 190, to evaporate solvent therefrom. Roughly sixty percent of the heat transfer is accomplished through the agitator arms 156, and flat blades, with the remainder being accomplished by contact between the heated walls of the vessel 120, and the product 190.
In order to increase drying times land efficiency, recirculated nitrogen gas may be fed into the vessel 120, to cause some direct or convective drying to occur. Attempts to circulate the nitrogen gas either up through the filter plate 180 or down through the product 190, may be largely frustrated and ineffective when the product 190, is difficult to dry for those reasons given above; e.g. small particle size, sticky, likely to caseharden, etc. This is because such product 190 either plugs the filter plate 180, or effectively seals off the nitrogen gas flow. Therefore, the nitrogen gas may be simply fed through the inlet tube 130, to pass over the surface of the product 190, as illustrated by the arrows within the vessel 120. The drying gas exits through the gas outlet 140, and the dust collector 145, and then is recirculated for further use. As the drying gas passes over the product 190, limited convective drying occurs and volatiles within the product 190, are evaporated. This is known as cross flow drying.
Perlmutter describes a classic drying curve, as shown in FIG. 3, wherein a constant drying rate takes place during a first phase. According to Perlmutter, the constant rate period is governed by external factors such as the gas mass velocity and thermodynamic state as well as the physical state of the product. Perlmutter particularly notes that when drying products having a tendency to form balls in the constant rate drying phase, convection drying should be carried out on a static (non-agitated) bed and should so continue until the critical moisture content is reached. Perlmutter further suggests that during the falling rate period, cake properties and heat input are the controlling factors. Finally, in the diffusion period, the agitator arms break up product clumps to provide a final product which is homogenous and fine powder. (See Perlmutter; Principles Of Pressure Nutsche Filter-Dryer Technology; Drying '92; edited by A. S. Mujumdar; pp 1321-1329; Elsevier Science Publishers, B.V.; 1992).
However, as will be explained below, drying in real world applications has proven to be more complicated than suggested by the classical theory. For example, using the same gas mass flow rates, two dryers may exhibit dramatically different drying performances. Moreover, it has been, found that even doubling the flow rate of nitrogen gas provides only marginal improvement and actually significantly worsens thermal efficiency, in spite of the opposite conclusions which would be drawn from the classical theory.
Therefore, there remains a need in the art for improvements to convection drying of chemical compounds in agitated pan type dryers.
OBJECTS OF THE INVENTION
It is one object of the present invention to provide improvements to convection drying of chemical compounds in agitated pan type dryers.
It is a further object of the present invention to provide increased throughput of material through an agitated pan type dryer by increasing thermal efficiency and drying rate, thus reducing the time required for drying, without sacrificing volatile removal efficiency or yield.
SUMMARY OF THE INVENTION
The objects of above and others are accomplished according to the present invention by creating turbulence within the dryer, particularly at the surface of the product. This is accomplished by forcing pressurized drying gas into the dryer at high velocity through a nozzle. The use of a nozzle acts to convert hydrostatic energy (pressure) of the drying gas into hydrokinetic energy (flow velocity) which is necessary to create turbulence within the dryer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of an agitated pan dryer as known in the prior art.
FIG. 2 is a cross-sectional view of a nutsche type filter/dryer equipped for convection drying as known in the prior art.
FIG. 3 is a chart describing classical drying theory as known in the prior art.
FIG. 4 is a cross-sectional view of a nutsche type filter/dryer as shown in FIG. 2, further showing an improvement according to one embodiment of the present invention.
FIG. 5 is a cross-sectional view of a nutsche type filter/dryer as shown in FIG. 2, further showing an improvement according to a further embodiment of the present invention.
FIG. 6 is a cross-sectional view of a conical screw type mixer/dryer, further showing an improvement according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A nutsche type filter/dryer equipped for convection drying is described above with reference to FIG. 2. The improvements according to the present invention will be discussed below with respect to FIGS. 4 and 5, wherein like parts are identified by like reference numerals as were used in FIG. 2.
FIG. 4 is a cross-sectional view of a nutsche type filter/dryer, generally designated by reference numeral 100, and showing an improvement according to one embodiment of the present invention. The dryer 100, includes the pressure vessel 120, gas outlet 140, dust collector 145, and agitator system as describe above with reference to FIG. 2.
The improvement according to the present invention comprises a newly designed drying gas inlet including a high velocity nozzle 135A, fixed within an outer gas inlet shaft 130A. In the embodiment shown in FIG. 4, the nozzle 135A, and inlet shaft 130A, are provided within a portion of the gas outlet 140. However, the present invention also relates to the placement of a high velocity nozzle at any position within the vessel 120.
FIG. 5 is a cross-sectional view of a nutsche type filter/dryer, generally designated by reference numeral 100, and showing an improvement according to a further embodiment of the present invention. In particular, FIG. 5 shows the improvement of the present invention wherein the high velocity nozzle 135B, and inlet shaft 130B, are provided away from the gas outlet 140.
The drying process is the same as that described above, except that the drying gas is introduced under high pressure and at a high velocity through the nozzle 135A or 135B. This introduction creates turbulence within the vessel 120, as represented by the arrows within the vessel 120, in both FIGS. 4 and 5. The use of the high velocity nozzle 135A, or 135B converts the hydrostatic energy (pressure) of the drying gas in to hydrokinetic energy (flow velocity) which is necessary to create the turbulence with in the vessel 120. By creating turbulent flow within the vessel 120, the recirculating drying gas becomes saturated with the volatiles within the product 190, at a faster and higher rate and therefore shorter drying times are achieved.
A further embodiment according to the present invention relates to conical screw mixers, such as shown in FIG. 6. In particular, FIG. 6, shows a conical screw mixer, generally designated by reference numeral 200, comprising a cone-shaped vessel 210, having a cover 220, through which product may be charged. A screw with a helical blade 230, is housed within the vessel 210, and is connected to a rotating drive means 240. The rotating drive means 240, is further connected to an orbiting drive means 250. In operation, the screw 230, is driven by the rotating drive means 240, which acts to mix and carry product within the vessel 210, in an upward direction. Simultaneously, the orbiting drive means 250, drives the screw 230, around a center line of the vessel 210, for top-to-bottom circulation and mixing. Reversing the rotating drive means 240, aids in discharge of product through an outlet 260. In another embodiment the screw 230, may be moved through an epicyclic action to provide more thorough coverage and mixing of the entire volume of the vessel 210.
The result of the various movements of the screw 230, is to emulate the action of an agitated pan dryer as described above. Converting the conical screw mixer to a dryer can be easily accomplished by jacketing the vessel 210, or by including means to provide drying gas, such as through an inlet port 270, to the interior of the vessel 210. The present invention of creating turbulent flow is equally applicable to the use of a conical screw mixer/dryer. In particular, as shown in FIG. 6, a high velocity nozzle 280, is provided within the inlet/outlet port 270, through the cover 220. It will be recognized that a high velocity nozzle could also be provided through the cover 220, outside the area of the port 270, or through the wall of the vessel 210.
The present invention expands the usefulness of agitated pan type dryers (including converted nutsche filters and converted conical screw mixers) into areas which would not normally have been considered. In particular, by using the present invention, agitated pan type dryers can be efficiently used for the drying of hard to dry chemical compounds, such as pharmaceuticals. This includes organic pharmaceuticals, which are typically temperature sensitive, sticky, have small particle sizes, use solvents other than water, are not crystalline, and may form casehardened balls during the drying cycle. The present invention is makes it possible to reduce the volatile level in the wet product to the required range (e.g. less than one percent) within drying times which are considerably less than achievable when using standard agitated pan dryers.
For example, during the process of making Ioversol (an X-ray contrast agent) drying of an intermediate chemical compound is necessary. This intermediate decomposes if exposed to temperatures above 90° C. In addition, this intermediate is not crystalline, has a very small particle size, and tends to form balls which case harden making volatile removal to the necessary level very difficult. Moreover, the solvent being removed is toxic, flammable and possesses a high boiling point. All of these characteristics make drying of this intermediate extremely difficult. It should be noted that these characteristics are relatively common in pharmaceutical production.
Prior art dryers were simply not up to the task of drying such an intermediate in short time frames. Therefore, greater than twenty hour drying cycles were tolerated in the nutsche filter/dryer adapted for convective drying as described in FIG. 2 above.
However, by creating turbulence within the vessel of the dryer according to the present invention, drying cycles of less than ten hours have been achieved. This shortened drying time can add as much as 30 metric tons of annual drying capacity to the use of a nutsche filter/dryer having a 3000 lb capacity, adapted as described above with reference to FIGS. 4 and 5. This in turn can greatly reduce the costs involved with the production of chemical compounds, such as pharmaceuticals. One particular savings relates to the possible elimination of the need for multiple nutsche dryers, which can cost more than four million dollars to purchase and install.
A typical process of using the dryer according to the present invention, involves the following steps. Product is loaded within the vessel of the dryer. The flow of drying gas introduced at high velocity is then initiated. The product is continuously plowed by the agitator arms in order to expose new surface areas. Gas flow is continued until the target volatile content of the product is reached. Product is then removed from the dryer vessel.
The present invention according to the present invention has been described with reference to a high velocity nozzle for creating turbulence within the dryer. However, the present invention is equally applicable to any other means or methods of creating turbulence. Moreover, the process of drying according to the present invention has been primarily described as a single stage drying operation wherein drying gas flow velocity is constant throughout the drying cycle. However, the present invention is also applicable to multiple staged drying cycles. For example, dusty products may be dried using two stages of different flow velocities, the first stage being at a relatively high velocity during the time when the product is in a relatively wet state, and the second being at a lower velocity when the product has dried to the point that dust is becoming prevalent.
The present invention is described above as relating to apparatus and methods for drying solvent laden chemical compounds, such as pharmaceuticals. However, the present invention could also be used to dry aqueous cakes of material. Moreover, while nitrogen gas is the preferred heating gas, the present invention is equally applicable to the use of other gasses, and to the use of air instead of nitrogen gas.
The present invention is described above primarily for direct or convective drying using recirculated nitrogen gas. In practice the nitrogen gas has normally been recirculated under pressure. However, the present invention is equally applicable to procedures which do not recirculate the drying gas. In addition, the present invention provides advantages for procedures operated at atmospheric as well as subatmospheric pressure.
The present invention has been described above with reference to FIGS. 4 and 5 as including a single high velocity nozzle. However, the present invention also applies to the use of two or more high velocity nozzles to create optimum turbulence conditions within the dryer. The nozzles may be operated at the same or different flow velocities to create or change particular turbulence conditions.
The foregoing has been a description of certain preferred embodiments of the present invention, but is not intended to limit the invention in any way. Rather, many modifications, variations and changes in details may be made within the scope of the present invention.
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The present invention relates to improved drying techniques which increase the capacity and efficiency of agitated pan type dryers. In particular, the present invention relates to a nutsche type filter/dryer apparatus and method for aggressive convective drying of hard to dry chemical compounds, such as pharmaceuticals. The aggressive drying is brought about by creating turbulence within the drying vessel during the drying cycle. Significant reductions in drying cycle times have been achieved.
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REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of, and claims the benefit of, application Ser. No. 10/609,170, filed Jun. 30, 2003, entitled Blast Protective Barrier System, the entire content of which is expressly incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Area of Invention
The invention relates to protective barrier systems.
2. Prior Art
A long-standing concern with respect to terrorist attacks upon so-called soft targets has become that of the now well-known suicide bomb truck which is simply driven into such a target and then detonated. As such, a need has arisen for a barrier system having high blast and penetration resistance which may used in the protection of a wide variety of potential targets including, without limitation, oil tanks, harbors, and buildings of various types. Also, because most of such attacks originate from ground level, it is not necessary that the height of such a barrier system be equal to the height of the target to be protected.
The limited prior art which exists in the present area is reflected in U.S. Pat. No. 4,433,522 (1984) to Yerushalmi, entitled Blast And Fragment-Resistant Protected Wall Structure; U.S. Pat. No. 5,117,600 (1992) also to Yerushalmi, entitled Building Structure Having High Blast and Penetration Resistance; and U.S. Pat. No. 6,223,473 (2001) to Romig, entitled Explosion Relief System Including Explosion Relief Panel. Said reference to Yerushalmi '600 is the most directly known precursor to the instant invention. Therein, a filling material such as loose sand, gravel, pebbles or stones is interposed between opposing concrete panels to form a basic barrier structure. The instant system therefore builds upon the invention of Yerushalmi '600 in its provision of a more economic, modular and flexible system of blast barrier protection.
Other approaches to the problem of blast resistance have appeared in the form of special purpose fillers for placement within walls of structures and, as such, are reflected in U.S. Pat. No. 4,589,341 (1986) to Clark, et al entitled Method For Explosive Blast Control Using Expanded Foam; U.S. Pat. No. 4,763,457 (1988) to Caspe, entitled Shock Attenuating Barrier; and U.S. Pat. No. 5,214,894 (1993) to Glesser-Lott, entitled Wall Construction of a Non-Load Bearing External Wall. The instant invention thereby presents a system in which the void space between opposing panels may, in addition to the use of the loose filling materials taught by Yerushalmi '600, also employ foam-like materials as is taught by Clark as well as cellular units having high viscous damping as is taught by Caspe above. Further, the instant system contemplates use of blast-resistant wall panel modules separated by frangible, blast-expansible, or blast isolation elements so that destruction of one module will communicate a shock wave to adjacent modules.
The prior art does not contemplate such a solution to the need for a blast-resistant security perimeter.
SUMMARY OF THE INVENTION
Taught herein is a blast protective barrier system, sometimes termed a blast wall, which is definable in terms of an x, y, z coordinate system. Said system includes a plurality of substantially ground level (xy plane) pile caps, each itself comprising an x-axis elongate length, a y-axis width, and a z-axis depth, said x-axis length substantially defining the width of the barrier system. Each pile cap also includes an upper and lower xy plane surface, each of said upper surfaces including y-axis channels and each of said lower surfaces including a plurality of recesses. The inventive system also includes a plurality of yz plane, y-axis elongate modules comprising pairs of vertical concrete panels having an x-axis width, each panel pair having a lower y-axis edge proportioned for press-fittable securement within said y-axis channels of said upper xy surfaces of said pile caps. Positioned between opposing pairs of concrete panels is a volume of high shock-absorbent material, which material may take a wide variety of different forms including, without limitation, loose sand, gravel, pebbles, stones, inflatable and non-inflatable foams, enclosed cellular units having properties of high viscous damping, and a variety of acoustical and thermal insulative materials which also possess properties of shock and blast absorption. The system further includes a plurality of elongate piles, each having upper ends thereof proportioned for securement within said recesses of said lower xy plane surfaces of said pile caps, whereby any one of said modular units, if subjected to a blast-related failure of the expansion spacer, thereby isolating the unit from the second or adjoining module, thus preserving the integrity of the rest of the system. Opposing xz plane surfaces of said modules may be secured to each other either through the use of said z-axis vertical elements or spaces, formed of shock-dispersing material, but re-barred to opposing xz surfaces of each module.
It is accordingly an object of the invention to provide a blast protective barrier system which will protect substantially any ground level target from a ground level attack including direct impact by a vehicle loaded with explosive.
It is another object to provide a blast protective barrier system having general utility in a wide variety of security applications and in which modules thereof may suffer destruction without substantial effect on adjacent modules of the system.
The above and yet other objects and advantages of the present invention will become apparent from the hereinafter set forth Brief Description of the Drawings, Detailed Description of the Invention and Claims appended herewith.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective fragmentary end view of the inventive system.
FIG. 2 is a vertical cross-sectional view taken along Line 2 - 2 of FIG. 1 FIG. 3 is an enlarged vertical cross-sectional view of the pile cap shown in FIG. 2 .
FIG. 4 is a horizontal cross-sectional view of a concrete panel of the system taken in the direction of Line 4 - 4 of FIG. 1 .
FIG. 5 is a horizontal cross-sectional view showing one method of securement of opposing xz plane end faces of opposing panel pairs of the present system.
FIG. 6 is a top plan view of the vertical column shown in FIG. 5 .
FIG. 7 is a foundation plan of the present system taken along Line 7 - 7 of FIG. 1 and also showing a typical number of pile caps and associated structures associated with a single unit of the system.
FIG. 8 is a concrete barrier plan of the system taken along Line 8 - 8 of FIG. 1 and showing the modular character of the units of system.
FIG. 9 is a top schematic view showing opposing xz plane end faces of opposing panel pairs using columns of blast isolation material and expansion and void spaces.
FIG. 10 is a top plan view showing the manner in which the inventive system may be used to protect selected structure.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the perspective view of FIG. 1 , the present inventive blast protective barrier system for providing a security perimeter or boundary at and above a ground level definable with reference to an x, y, z coordinate system (which is shown to the lower right of FIG. 1 ). Therein, the subject system may be seen to include a plurality of substantially ground level (xy plane) pile caps 10 , each comprising a x-axis elongate length (see also FIGS. 2 and 3 ), a y-axis width and a z-axis height. The length of each pile cap 10 substantially defines the width of the inventive system within the x-axis. As may be particularly noted, each pile cap 10 includes upper and lower xy plane surfaces 12 and 14 respectively. Said upper xy plane surfaces 12 exhibit y-axis channels, or grooves 16 into which concrete panels 18 and 20 (described below) are secured at between 5 and 15% of the height thereof. Within lower xy plane 14 of pile cap 10 are provided a plurality (preferably three) of recesses 22 into which are secured a corresponding plurality of piles 24 . In a preferred embodiment, a center pile 26 is aligned with the z-axis or gravity vector, while left and right piles 28 and 30 respectively are offset from the z-axis by an angulation falling in a range of about 15 to about 30 degrees.
As may be noted in FIGS. 1 and 3 , pile cap 10 , after securement to its piles 26 , 28 and 30 is constructed as driven or augercast piles, and then back-filled so that earth 32 is then compressed about the piles and pile caps forming a stable foundation for the structure as below described.
As above noted, the inventive blast protective barrier system includes said yz plane, y-axis panels 18 and 20 , each of which defines a module. In another embodiment, a third panel placed medially between said panels 18 and 20 . As may, more particularly, be noted in FIG. 4 , each panel 18 or 20 is defined by an x-axis width and a y-axis length having a length-to-width ratio of approximately 12 to 1. A preferred x-axis width of panel 18 or 20 is about 12 inches (30 cm). Said panels 18 and 20 are also characterized by the use of vertical rebars 34 and of horizontal, xy plane rebars 36 . The function of the vertical rebars is that of reinforcement of the concrete of which panels 18 and 20 are typically formed. The primary function of horizontal rebars 36 is to permit z-axis elongate columns 38 to be poured between opposing xz plane surfaces 40 of panels 18 and 18 . 1 , and 20 and 20 . 1 . Said xz columns 38 are preferably formed of a material having a lesser density than that of panels 18 / 20 , to thus provide a path of least resistance to a blast or shock wave to which the system may be subjected. The purpose of this strategy is to preserve the integrity of wall modules of panels 18 / 20 not directed subject to attack. A column 38 may take the form of an expansion joint 48 that may comprise a foam-like shock absorbent material, partial void space or any combination that blast-isolates one module from another. Said columns may be positioned and strengthened by the use of re-bars 36 . 1 / 42 . Said columns 38 are shown in top, xy plane view in FIGS. 5 and 6 as are vertical rebars 36 . 1 / 42 within each column 38 . To provide for appropriate x-axis offset between opposing ends of panels 18 and 20 , each column 38 will typically exhibit a z-axis dimension having a ratio of about 5 to 1 relative to the x-axis dimension of each panel 18 / 20 , thereby allowing a void space in a range of about 45 to about 50 inches (about 125 cm) between each panel 18 and 20 . See FIGS. 1 , 7 and 8 .
Between concrete panels 18 and 20 is provided a volume of high shock-absorbent material such as loose sand, dirt, gravel, pebbles, special-purpose blast suppressing foam barriers, as is taught in U.S. Pat. No. 4,589,341 to Clark, and special shock attenuating cellular elements of the type taught in U.S. Pat. No. 4,763,457 to Caspe, et al.
With reference to FIG. 7 , there is shown a foundation plan of the inventive system. Therefrom, it may be appreciated that a typical unit of the present blast protective barrier system will consist of pile caps 10 , 10 . 1 , 10 . 2 , and 10 . 3 and their above-described corresponding piles 24 and vertical panels 18 and 20 (see also FIG. 8 ).
Expansion joint columns 38 are used for the joinder of opposing xz surfaces 40 (see FIG. 5 ) of panels 18 / 20 . Rather, special columns 38 include spaces 48 for expansion as shown in FIG. 9 . Said spaces assume the modularity of each panel pairs 18 / 20 . Said columns 38 may be furnished with various properties of blast isolation as set forth herewith.
It should be further appreciated that certain other salient dimensional relations exist in the above-described system. Therein, a xz plane of each pile cap 10 in cross-sections of panels 18 / 20 define a ratio of x-axis pile cap dimension to separation of an opposing panel in a range of about 2.5:1 to about 5:1, in which about 3.5:1 has been found to be preferable. Further, the x-axis length of each pile cap defines a ratio of between about 3:1 and about 1:1 relative to the x-axis width of each panel 18 / 20 . It is further noted that in an xz plane of each panel pair, inclusive of said interposed volume of shock absorbent material, total aggregate x-axis dimension of outer surfaces of said panels to said compacted material comprises an x-axis range of between about 2.5:1 and about 1.5:1. Preferably, and particularly for purposes of ease of production, each modules of panels 18 and 20 will be identical in width and other respects. It is further noted that a x-axis depth of lower ends 5 . 0 (see FIG. 2 ) which are within said pile cap channels 16 will comprise a ratio in a range of about 0.05 to about 0.15 of the entire z-axis height of the panels 18 / 20 , in which the ratio 0.07 is preferable.
The depth of piles 24 within earth 32 will typically be within a range of about 10 to about 50 feet in which the separation of the tops 52 of each pile within said recesses of the pile cap may define an aggregate length of about 10 feet. As may be noted in FIG. 6 , a ratio of column 38 y-axis length to x-axis width will define a range between about 3.5:1 and 2.2:1. As may be noted in FIGS. 5 and 6 , the x-axis width of column 38 will typically slightly exceed the x-axis width of panels 18 / 20 .
It is further noted that the height of each modules of panel 18 / 20 are typically within a range of about 8 feet (21 cm) to about 15 feet (40 cm), thereby providing sufficient height to protect a terrorist target from the vehicle of considerable height that may be filled with explosives.
It has been also determined that the ratio of z-axis height of each modules of panel 18 / 20 to the x-axis length of each pile cap 10 may be approximately equal but, more particularly, will reflect a range of about 0.7:1 to about 1.2:1. Thereby, the foundation of the instant structure, in combination with the above-described piles 24 will afford enormous lateral stability to the present structure in the event of an explosive attack or a direct armored assault by a tank, tank artillery or other state of the art ground-to-ground artillery. The structure will of course also provide a defensive perimeter in the event that security personnel are available at the time of such attack.
As above noted (see FIG. 2 ), the angulation of outer piles 28 and 30 relative to center piles 26 will generally fall within a virtual cylinder defined by the greatest x-axis dimension of pile cap 22 . However, where earth 32 is not sufficiently stable or if it is not feasible to dig deeply into the earth, the angulation of the outer piles relative to the center pile 26 may be increased substantially, as may the number of pile provided beneath each pile cap.
The above set forth ratios are deemed material and are deemed the best mode of practice of the invention.
The preferred construction method associated with the above system is:
1. Install piles 24 to the required depth to withstand gravity and lateral loads.
2. Construct pile caps 10 with grooves 16 on each side (full width or partial width) to receive pre-cast concrete wall panels 15 feet (40 cm) to 25 feet (64 cm) long.
3. Make pre-cast concrete panels 18 / 20 with extended rebars at each end and at bottom of panels with or without the extended rebar.
4. Set pre-cast panel within a groove of the pile cap and lock it in place.
5. Pour concrete connector wall between surfaces of wall panels on top of pile caps at each pile cap location. Use shape of inverted letter “I” to connect to both wall panels and foundation.
6. At every 100 feet (34 meters) to 120 feet (41 meters) provide expansion joint within the wall by construction of shape (double channel back-to-back), with an expansion joint 48 in which material or mechanical means are used to accommodate expansion and contact of individual modules withstand high pressure even if adjacent modules are destroyed.
7. Fill the space between the modules of wall panels 18 / 20 with loose sand or selected fill material to absorb impact.
8. Connect the top of the wall panels with the concrete slab with cast-in-place or pre-cast concrete panels to act as twin wall on one unit on top of the wall panels.
9. If only single panel wall is to be used, neither backfilling nor top slab is required.
While there has been shown and described the preferred embodiment of the instant invention it is to be appreciated that the invention may be embodied otherwise than is herein specifically shown and described and that, within said embodiment, certain changes may be made in the form and arrangement of the parts without departing from the underlying ideas or principles of this invention as set forth in the Claims appended herewith.
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A blast protective barrier system, termed a blast wall, providing a security perimeter or boundary at and above a ground level definable in terms of an x, y, z coordinate system, includes several substantially ground level (xy plane) pile caps, each itself having a y-axis elongate length, a x-axis width, and a z-axis depth, the x-axis substantially defining the width of the barrier system. Each pile cap also includes an upper and lower xy plane surface, each of the upper surfaces including y-axis channels and each of the lower surfaces including several recesses. The system also includes a first, second and further modules having a plurality of opposing pairs of yz plane, the y-axis elongate concrete panels including opposing integral xz end cap elements having a high shock-absorptive structure for isolating each module from the effect of a blast upon an adjacent module.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to wireless remote control devices, and more particularly, to wireless remotely controlled switch controller.
2. Description of the Related Art
Several designs for remotely activating a switch have been designed in the past. None of them, however, includes a design that wirelessly can allow the user to activate a variety of switches, keys and knobs with dexterity provided by a mechanical hand with fingers that also includes a means to quickly, easily and without marring adjacent surfaces can be applied to a wide variety of situations and uses.
Applicant believes that the closest reference corresponds to U.S. Pat. No. 6,877,347 issued to Elliason. However, it differs from the present invention because Elliason provides for a device that is limited to use with a thin metal key with a tethered physical remote linkage. These design limitations do not allow use with a variety of different keys and also requires a cumbersome attachment method while requiring the controller to be a limited distance from the active end of the device.
Other patents describing the closest subject matter provide for a number of more or less complicated features that fail to solve the problem in an efficient and economical way. None of these patents suggest the novel features of the present invention.
SUMMARY OF THE INVENTION
It is one of the main objects of the present invention to provide a wireless device to remotely control a variety of switches, knobs and keys.
It is another object of this invention to provide a mechanic or repairman the ability to remotely manipulate a device at long or short distances.
It is still another object of the present invention to provide a wireless device that does not require draping a connecting cord that could mar surfaces while at an active end does not require cumbersome connections to the switch.
It is yet another object of this invention to provide such a device that is inexpensive to manufacture and maintain while retaining its effectiveness.
Further objects of the invention will be brought out in the following part of the specification, wherein detailed description is for the purpose of fully disclosing the invention without placing limitations thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
With the above and other related objects in view, the invention consists in the details of construction and combination of parts as will be more fully understood from the following description, when read in conjunction with the accompanying drawings in which:
FIG. 1 shows an elevational view of a remote switch controller.
FIG. 2 shows a perspective view of a remote control assembly.
FIG. 3 shows a perspective view of a version of a servo assembly.
FIG. 4 shows a plan view of a remote switch controller as might be applied to a vehicle steering wheel.
FIG. 5 shows a perspective view of an alternate version of a servo assembly.
FIG. 6 shows a perspective view of an alternate version of a servo assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The subject device and method of use is sometimes referred to as the device, the invention, the remote controller, the switch controller, machine or other similar terms. These terms may be used interchangeably as context requires and from use the intent becomes apparent. The masculine can sometimes refer to the feminine and neuter and vice versa. The plural may include the singular and singular the plural as appropriate from a fair and reasonable interpretation in the situation.
Referring now to the drawings, where the present invention is generally referred to with numeral 10 , it can be observed that it basically includes a battery 12 , a switch 14 , a receiver 16 , an antenna 18 , a servo 20 , a hand 22 , fingers 24 , a key 26 , a flex rod 28 , a frame 30 , a knob 32 , an antenna 34 , a switch 36 , a case 38 and a tensioner 40 .
A preferred version of the device includes a key assembly, such as seen in FIG. 1 , and a remote assembly, demonstrated in FIG. 2 . Generally, the key assembly receives a wireless signal from the remote assembly and causes the key assembly to respond.
The key assembly is supported by the frame 30 . Onto the frame 30 is affixed a battery 12 that supplies power to the key assembly. A switch 14 is provided to turn on the device or to disconnect the battery 12 from the balance of the components to reduce battery drainage while the device is not in use.
The battery 12 powers a wireless receiver 16 . The receiver 16 listens for a signal from the remote assembly. An antenna 18 is optionally provided and attached to the receiver 16 to improve reception. The antenna 18 could be integrated into the flex rod 28 , the frame 30 or the receiver 16 depending on the application of the device.
When the receiver 16 is powered on and detects a signal from the remote assembly the receiver 16 actuates the servo 20 . In one variant of the device the servo rotates the hand 22 axially so that the fingers 24 connected to the hand 22 rotate the key 26 grasped by the fingers 24 . Alternatives to the servo motion could be rocking back and forth or in and out. However, with a key 26 the axial rotation motion is preferred.
An example of a remote assembly is shown in FIG. 2 . The case 38 may contain a battery and transmitter circuitry. When the switch 36 is manipulated the remote assembly is powered on or off. An optional antenna 34 is also depicted. An internal or low profile antenna can also be alternatively used.
The knob 32 in FIG. 2 rotates axially in similar fashion to the servo 20 in FIGS. 1 and 3 . When the knob 32 is rotated the remote assembly sends out a wireless signal that is received by the receiver 16 that in turn causes the servo 20 to rotate the key 26 . In an important version of the device the direction and degree of rotation inputted to the knob 32 directly corresponds to the direction and degree of rotation delivered by the servo 20 .
By way of example, if the user of the device rotates the knob 32 clockwise a quarter turn (ninety degrees) then the key 26 is likewise rotated a quarter turn in the clockwise direction. In this example, a quarter turn is about sufficient to turn a car ignition and start the car. Similarly the user can turn the knob 32 counter clockwise and turn the engine off or turn the ignition switch to accessory mode.
Looking at FIG. 3 , a detailed view of a version of a servo assembly is shown. The key 26 is temporarily held by the fingers 24 around the head of the key 26 . A tensioner 40 is optionally available to tension the pressure of the fingers 24 onto the key 26 . The fingers 24 are connected to the hand 22 that is in turn connected to the servo 20 actuator motor.
The fingers 24 and hand 22 are preferably adapted to grasp a variety of objects including various shaped keys. Some keys are simply made of thin metal and other keys are thicker and include other materials and electronics. The fingers 24 and hand 22 may be replaceable depending on the application of the device to be able to effectively grasp an appropriate object.
The fingers 24 may be used to grasp objects other than a key for remote manipulation. For example, a switch or lever could be grasped by the fingers 24 .
An electrician could use the device to turn a circuit breaker on or off remotely during a repair without having to walk repeatedly to a circuit breaker panel.
An auto mechanic could start a car while under the hood or while below a car on a lift during the course of maintenance. This could save time and reduce the need to raise and lower a lift. A single mechanic could perform a job at the same speed as previously was only possible with two mechanics.
A marine repairman can make adjustments in the bilge and use the device to turn on a pump or other accessory remotely at the helm or bridge. This can be done at large distances that are not possible with competing mechanically linked remote devices.
An audio technician can use the device attached to elevated lights to remotely adjust the levels or balance while the lights are difficult to reach on scaffolding.
A bedridden person could use the device to remotely control a radio or TV if unable to get up to do so. This would allow greater autonomy of the injured and a better quality of life.
FIG. 4 demonstrates one valuable use of the remote switch controller applied to a common automobile. In addition to the components described above, the vehicle includes a steering column 42 , a steering wheel 44 and an ignition switch 46 . In this view the key 26 is partially engaged into the ignition switch 46 but would typically be fully seated into the ignition switch manually by the user of the device upon initially setting it up.
When the key 26 is in the ignition switch 46 the flex rod 28 can be wrapped around an available object to secure the frame 30 and balance of the device. In this example in FIG. 4 , the flex rod 30 is woven between the steering wheel 44 and spokes on the steering wheel. In this manner the flex rod 28 can be used to secure the device to a wide variety of objects to allow effective use for many different applications.
FIG. 4 would be useful for a mechanic who is working under a car and cannot easily slide out from under the car to start the engine while working on it. Previously, this task was done with a helper in the car or required the mechanic to slide out from under the car and start the engine or turn on ignition switch 46 to the accessory mode. In fact, the mechanic could do either from under the car by turning the knob 32 counter-clockwise to move the ignition switch 46 into accessory mode or clockwise to start the engine. Equally, if the engine was already started the mechanic could turn the knob 32 on the remote control assembly counter-clockwise to stop the engine.
FIGS. 5 and 6 show examples of different features related to servo assemblies that could be used in any of the versions of the device. Some features may be present in combination or separate from other elements shown depending on the specifics of the user's needs and application of the device. The alternate elements include, but are not limited to, a servo 48 , a hand 50 , a tensioner 52 , fingers 54 , a key 56 , a servo 60 , an axle 62 , a hand 64 , fingers 66 , and a key 68 .
FIG. 5 shows wider fingers 54 that might be useful for certain knobs and switches or for thicker electronic keys. The wide grip of the fingers can prevent damage to sensitive parts to be turned. The optional tensioner 52 can be used to close or open the hand 50 that in turn opens or tightens the fingers 54 .
FIG. 6 is another example of a servo assembly that has, among other features, an alternate hand 64 and fingers 66 configuration. In this version the fingers 66 spring open and closed to grip an object such as a key 68 or other object to be manipulated. By nature of flexible materials of construction the hand 64 and fingers 66 can be forced apart to grab an object and the springy character of the flexible materials can apply force to the key 68 (or other object) to grasp it firmly.
A servo motor inside the servo assembly axially rotates the axle 62 that imparts torque onto the hand 64 then fingers 66 and ultimately the grasped object. The servo could also deliver other motions. For example, the servo could push in and out axially. This could be useful for pushing buttons. Or, the servo could flip back and forth. This could be useful for depressing a rocker switch or light switch.
In one version of the device the servo assembly is replaceable with alternate versions of servo assemblies. This allows the balance of components including the battery, receiver, frame, flex rod and other components to remain the same while increasing the adaptability of the device to work to hold different objects to be manipulated or to manipulate the object in different directions
The hands 64 and fingers 66 could be rigid if adapted to a specific object to be manipulated. For example, the fingers might be specifically designed to hold a tool or knob. Magnetic fingers are also possible for some applications.
The flex rod 28 is generally constructed of a material that is flexible and can hold a shape when bent. Metal segmented tubes sometimes used on gooseneck lamps have been successful. Wire, sheathed, coated or bare that are flexible yet hold their shape when bend around a supporting object may also be used. The flex rod may include a clip, magnet or other attachment means to provide further support of the frame and servo. There may be more than one flex rod attached to the frame to lend strength additional attachment points. An example of an effective size of the flex rod for automotive applications has been about a half inch diameter and about twelve to thirty inches long. However, these dimensions are merely a guide and greater or smaller dimensions may be appropriate based on the application, material of the flex rod, torque (or other force) applied and weight of the device. Materials other than metal may be employed if they are flexible and retain shape when bent around a supporting structure or object.
The present invention can be fairly described as a remote switch controller comprising a remote control and a switch controller. The remote control includes, among other features, a battery, a knob and a transmitter. The switch controller includes, among other features, a flex rod, battery, a receiver and a servo all attached to a frame. The flex rod is flexible and retains a shape to which it is bent so that it can attach to a support structure, for example a steering wheel. The servo imparts a motive force into a hand. The hand includes fingers that connect to an object, such as a key or switch. The transmitter communicates wirelessly to the receiver. When the knob receives a first input from a user the transmitter emits a first signal. When the receiver receives the first signal from the transmitter the receiver activates the servo to move the object in a first direction, for example turning a key clockwise. When the knob receives a second input from the user the transmitter emits a second signal. When the receiver receives the second signal from the transmitter the receiver activates the servo to move the object in a second direction, for example turning the key counter-clockwise.
The invention can also be fairly described as a method for remotely controlling a switch comprising a remote control and a switch controller. The remote control includes a battery, a knob and a transmitter. The switch controller includes a flex rod, battery, a receiver and a servo all attached to a frame. The servo is adapted to impart a force into a hand that is connected to a key, for example a rotational force to turn the key. The flex rod is flexible and retains a shape to which it is bent. The flex rod is bent around a steering wheel so that the key is held into an ignition switch. The transmitter is adapted to communicate wirelessly to the receiver. When the knob receives a first input from a user the transmitter emits a first signal. When the receiver receives the first signal from the transmitter the receiver activates the servo to rotate the key in a first direction. When the knob receives a second input from the user the transmitter emits a second signal. When the receiver receives the second signal from the transmitter the receiver activates the servo to rotate the key in a second direction.
The foregoing description conveys the best understanding of the objectives and advantages of the present invention. Different embodiments may be made of the inventive concept of this invention. It is to be understood that all matter disclosed herein is to be interpreted merely as illustrative, and not in a limiting sense.
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A wireless remote control system and method for activating a switch including a transmitter assembly and a receiver assembly. The receiver assembly attaches to and is stabilized by connecting a flex rod to an object near the switch. The receiver assembly includes a servo that connects to an object, such as a key or switch. The transmitter assembly can send differing signals to cause the servo to take alternate actions.
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BACKGROUND OF THE INVENTION
The present invention relates to improvements in vapor sampling techniques for the purpose of detecting contraband and dangerous materials carried by individuals within their clothing. The invention will find particular application in the detection of drugs and explosives carried by persons boarding aircraft or entering secured areas.
Presently, systems exist which detect an illicit substance by detecting the vapors given off by the substance. The detectors may be in the form of a hand-held device or a portal detection system Hand-held detectors can be used to scan people, but this method is slow and not acceptable to the traveling public. Portal detectors, on the other hand, have been designed to rapidly check people for explosives by establishing an air curtain through which the subject is allowed to pass. Any vapor in the clothing is purged out into the air curtain and passes into the detection system. Unfortunately, the available vapor is diluted in the large volume of air passing through the air curtain, and reduces the vapor concentration by as much as 100,000 fold. Reduction of the flow in the air curtain reduces the leeching effect of the flow, increases losses due to natural room air currents and increases the time for the test to an unacceptable level.
The extreme dilution of the vapor renders detection of many materials of interest impossible For example, an explosive such as dynamite may be easily detected because of its high vapor pressure. but many plastic explosives have very low vapor pressure and are not detected in existing air curtain portal systems. Consequently, these devices have not been widely deployed in airports to detect explosives carried on board aircraft even though a serious threat exists.
SUMMARY OF THE INVENTION
The vapor sampling system of the present system samples vapor proximal to the body of a subject to detect the presence of selected materials. The system comprises a number of moveable panels positioned in a doorway through which the subject passes. The moveable panels support a plurality of sampling tubes with intake ports through which vapor samples are drawn. The sampling tubes transport the intake gas flow from the intake ports into a vapor analyzer. The intake ports draw a gas flow from a region proximal to the body of the subject as the panels are displaced by the body of the subject passing through the doorway. The panels are preferably hinged under tension such that they swing along a vertical axis and return to their initial position. The panels are sufficient in size and number to provide the necessary examination of the individuals entire body.
A preferred embodiment utilizes two sets of panels that are placed in the doorway, with each pair of panels being hinged along a vertical axis on opposite sides of the doorframe. Each subject will be encouraged or instructed to push the uppermost panels away from their faces with their hands. The movement of the arms of each subject acts to pump vapors out of the voids in clothing thereby making the vapor available for sampling at the body surface. The body of the subject then displaces the remaining panels in opposite rotational directions as the subject passes through the doorway. The vapor samples are then drawn from the region proximal to the subject's body through the inlet ports of the sampling tubes of both panels.
The vapor sampling system may include heating means for heating the sampling tubes. The sampling tubes may also be coated on the inside with a material having low absorption properties with regard to the specific gases of interest. The vapor analyzer can be specifically designed or programmed to detect explosives or other illicit materials. By including a signalling means responsive to the vapor analyzer, a signal indicative of the presence of those gases of interest within the vapor analyzer can be generated.
The above, and other features of the invention including various novel details of construction and combination of parts, will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular portal vapor detection system embodying the invention is shown by way of illustration only and not as a limitation of the invention. The principal features of this invention may be employed in various embodiments without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a front perspective view of a preferred embodiment of the vapor sampling system The figure shows the doorway housing the moveable panels each having ports through which vapor samples are drawn.
FIG. 2 shows a more detailed rear view of a panel with the sampling tubes extending therefrom.
FIG. 3 is a detailed cross sectional view of the panel, a sampling tube positioned thereon and the ports through which the samples are taken.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a vapor sampling system which samples the available vapor from the clothing of a subject without diluting the vapor in a high flow of air. This embodiment enables the detection of a wide range of low volatility substances such as plastic explosives and narcotics, even when those substances are being carried by an individual in a concealed fashion. In particular, plastic explosives made from cyclotrimethyline trinitramine (RDX), and pentaerithritol tetranitrate (PETN) can be detected when carried by individuals in or underneath their clothing.
The front of door frame 10 is shown enclosing doorway 12. Residing in the doorway 12 and attached to doorframe 10 are individually moveable panels 14. each panel having a number of vapor sampling tubes 16 with inlet ports 18 through which an intake gas flow is drawn into the tube. Vapor in the region of the sampling tubes is drawn into the tubes and transported to vapor analyzers 20 and 22. The analyzers detect the presence of any vapors of interest, such as those emanating from explosives or narcotics.
The panels 14 are hinged to the door frame 10 and allowed to swing along a vertical axis in a rotational direction away from the center of the door frame. The doorframe 10 is sized, and the moveable panels 14 are placed such that anyone can pass through the doorway walking upright, and such that the highest moveable panels 17 are level with or above the head of the subject.
In the present embodiment, signal lights 30, 32 at the top of the doorway 12 are provided to alert the subject as to when the doorway should be entered. The signal lights 30, 32 can be controlled manually, by a timer, and can be made responsive to the vapor analyzer. The subject is encouraged to walk through the doorway pushing the upper segments with the hands, so that they move away from the face, and moving the lower panels by pushing through with the body. The action of pushing the upper panels 17 with the hands allows the hands to be rapidly sampled for any vapor by drawing the air from the surface of the hands into the inlet ports 18 of the upper panels 17. The action of lifting the arms disturbs vapor in the clothing, and as the body pushes through the doorway, the panels 14 mechanically disturb the clothing, bringing out vapor that may be contained in the fibers of the clothing and in the voids below the layers of the clothing. The sample tube transports the vapor laden air without further dilution to the vapor analyzer 20, 22.
Substances such as explosives and drugs are capable of emitting characteristic vapors. These vapors are usually termed electron absorbers. An electron capture detector which is sensitive to the presence of electron absorbers can be used in the analyzer 20,22 to detect the presence of the materials of interest. The electron capture detector normally comprises an ionisation chamber containing a source of β radiation such as tritium foil or Ni 63 . The detector output is amplified and registered on a meter or other indicating device.
The sampled air is preferably passed through a continuous trapping and desorption process such as that described in U.S. Pat. No 4,242,107 and incorporated herein by reference. This process removes many of the atmospheric components before the vapors are desorbed and passed into the detectors and operates to provide a large concentration gain for the vapors of interest.
The vapor analyzer 20,22 actually employed depends on the type of vapor that is to be detected. Any one of a number of vapor analyzer systems commonly known in the art can be used in conjunction with the present invention. The relatively small volume of gas being sampled and the resulting high sensitivity of the present invention allows different vapor analyzers to function efficiently. Working in conjunction with the vapor analyzer 20,22 is a signalling means output from the vapor analyzer 20,22. A signal, being either audible, visual, or both audible and visual in nature is provided to indicate when the vapors of interest are detected by the vapor analyzer 20, 22. Vapor analyzer 20 and vapor analyzer 22 may work in tandem, or may be designed to detect different vapors if necessary.
FIG. 3 shows in more detail a sampling tube 16 including inlet ports 18 as attached to moveable panels 14. The view is a cross section along a horizontal plane. The left side of the tube 16 faces the front of the vapor sampling system. A vacuum pump can be used to maintain a constant gas flow through each of the intake tubes. Sampling tube 16 is closed at end 24, the side of the panel near the middle of the doorway, and leads past the hinged side of the door to the vapor analyzer. Vapor is drawn in through inlet ports 18 into the tube and is transported into the vapor analyzer through sampling tube 16. In the embodiment of FIG. 3, inlet ports 18 are in front of the sampling system facing the subject entering the doorway.
A preferred embodiment utilizes heating means for heating the sampling tube. The heater is preferably provided by electric wire 26 passing through the length of the sampling tube 16. The sampling tubes, inlet ports and wire coating of this embodiment are made from the material which offers the lowest absorption surface to the vapors of interest. In the case of explosive vapors, a material such as polytetrafluoroethylene (known as TEFLON, a DuPont trade name) would provide a very low absorption surface. By having such a surface, the vapor loss is minimized.
The present invention provides a vapor sampling system with an improved level of sensitivity. Traditionally, detection systems provide responses to a fixed quantity of explosive vapor in proportion to the inverse of the sampling flow rate in which the explosive is entrained. The flows in air curtains previously deployed vary from 30 to 300 liters per second, and the air around the body is sampled in one to ten seconds. The present system employs flow rates in the range from 0.05 to 0.2 liters per second while providing a faster transport time of the vapor to the detector and reducing the time necessary for sampling
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A portal vapor detection system for sampling air proximal to the bodies of individuals in which air sampling tubes positioned within movable panels convey a gas flow into an analyzing system. Low vapor pressure materials such as plastic explosives or illicit drugs carried by individuals can be detected thereby enabling the prevention of their transport into aircraft or secured areas.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation application of U.S. application Ser. No. 13/611,572 (the “'572 Application”), filed on Sep. 12, 2012. The '572 Application is a continuation application of U.S. application Ser. No. 12/796,251 (the “'251 Application”), filed on Jun. 8, 2010, the entire contents of which is hereby incorporated by reference. The '251 Application claims priority to U.S. Provisional Patent Application Ser. No. 61/226,556, filed Jul. 17, 2009, the entire contents of which is hereby incorporated by reference. This application is also related to U.S. patent application Ser. No. 12/605,624, filed Oct. 26, 2009, U.S. Provisional Patent Application Ser. No. 61/108,552, filed Oct. 27, 2008, and U.S. Provisional Patent Application Ser. No. 61/226,533, filed Jul. 17, 2009, the entire contents of which are hereby incorporated by reference.
BACKGROUND
The present invention relates to x-ray imaging, including dental x-ray imaging. More particularly, embodiments of the invention relate to a data transfer cable for an intraoral sensor with improved mechanical strength and heat transfer properties
X-rays have been used in dentistry to image teeth and parts of the mouth for many years. In general, the process involves generating x-rays and directing the x-rays at the patient's mouth. The x-rays are attenuated differently by different parts of the mouth (e.g., bone versus tissue) and this difference in attenuation is used to create an image, such as on film or by using electronic image sensor.
SUMMARY
One challenge associated with electronic intraoral x-ray systems relates to the mechanical stress on a cable coupling the sensor capturing images and an output device, such as a computer. To capture dental x-ray images, the intraoral sensor is positioned within the oral cavity of each patient, which often includes twisting and tugging forces being exerted on the cable. The repeated and continuous positioning of the intraoral sensor for each patient results in increased mechanical stress, which wears the cable. With increased use and wear, the cable can malfunction and become unusable.
An additional challenge relates to the environment in which the intraoral sensor operates: the oral cavity of a patient. The electronics within the intraoral sensor generate heat and, if left unchecked, can result in injury to the patient. Certain governmental regulations or other standards apply to devices, such as intraoral sensors, that limit the maximum operating temperature. For instance, safety standard 60601-1 2 nd edition from the International Electrotechnical Commission (IEC) limits the outside temperature of such intraoral sensors to 41 degrees Celsius.
In one embodiment, the invention provides, among other things, an intraoral x-ray sensor including a sensor housing and a universal serial bus (USB) data cable. The sensor housing has an opening. The USB data cable includes an outer sheath and a first data line, a second data line, a ground line, a power line, and at least two independent fillers positioned within the outer sheath. At least two lines of the first data line, the second data line, the ground line, and the power line are twisted together to form a single bundle. The opening is configured to receive the data cable.
Additionally, some embodiments of the invention provide, among other things, an intraoral sensor including a sensor housing having a top portion and a bottom portion. The sensor further includes a twisted-quad universal serial bus (USB) cable coupled to the top portion. The twisted-quad USB cable includes an outer sheath and, within the outer sheath, a first data line, a second data line, a ground line, a power line, and four fillers that are twisted together to form a single bundle. The sensor also includes circuitry within the sensor housing. The circuitry converts x-rays received through the bottom portion into x-ray data and outputs the x-ray data along the twisted-quad USB cable.
In some embodiments, the first data line, the second data line, the ground line, the power line, and the four fillers are symmetrically organized about a centerline of the twisted-quad USB cable. Additionally, in some embodiments, the four fillers includes a first filler, a second filler, a third filler, and a fourth filler. The first filler abuts the ground line and the first data line; the second filler abuts the ground line and the second data line; the third filler abuts the power line and the first data line; and the fourth filler abuts the power line and the second data line. In some embodiments, the four fillers are made of a plastic, electrically insulating material.
In some embodiments, the outer sheath includes a braided shield and is coupled via a heat-conducting wire to a metallic layer substantially covering an inner surface of the top portion. In some embodiments, the outer sheath further comprises a jacket layer outside of the braided shield and a tape layer inside of the braided shield. Additionally, in some embodiments, the sensor includes an isolation layer within the sensor housing. The isolation layer is between the circuitry and the top portion and wherein the isolation layer is electrically insulating and heat conducting. In some embodiments, the isolation layer is coupled to one of the metallic layer and the braided shield via one of a second heat-conducting wire and direct contact to provide heat transfer from within the sensor housing to the twisted-quad USB cable.
Additionally, embodiments of the invention provide an intraoral x-ray sensor including a housing and circuitry within the housing. The housing includes a top portion and a bottom portion. The top portion has a first inner surface and a first thermal resistance. The first inner surface is substantially covered by a metallic layer with a second thermal resistance that is lower than the first thermal resistance. The circuitry converts x-rays received through the bottom portion into x-ray data and outputs the x-ray data along a data cable. The data cable includes wires within a metallic shield. The metallic shield is coupled to the metallic layer by a thermally conductive path that has a thermal resistance that is less than the thermal resistance of air.
In some embodiments, the bottom portion includes a second inner surface substantially covered by a second metallic layer that is coupled to the metallic layer either directly or via another thermally conductive path. The circuitry is contained on a printed circuit board (PCB) that is isolated from the metallic layer by an isolation layer. The isolation layer is thermally conductive and electrically insulating, and includes (in some implementations) an opening through which the circuitry and the wires are connected. Additionally, in some embodiments, the circuitry includes an array of pixels on a first side of the PCB and, on a second side of the PCB, a processor and an input/output module. The sensor includes x-ray attenuation components between the second side and a surface of the bottom portion through which x-rays are received. The x-ray attenuation components may include: a lead layer, a fiber optic covered by a scintillating layer, and copper planes. The top portion includes a dome (with the shape of a partial, elliptical paraboloid) having a face with a circular opening. The circular opening receives the data cable.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a dental x-ray system including an x-ray source, an intraoral sensor located in a patient's mouth, and a computer connected to the intraoral sensor.
FIG. 1 a is a schematic illustration of the intraoral sensor shown in FIG. 1 showing internal components of the sensor.
FIG. 2 depicts an exploded view of the intraoral sensor shown in FIG. 1 .
FIG. 3 depicts a cross section along line A of FIG. 4 .
FIG. 4 depicts a top view of the intraoral sensor shown in FIG. 1 and a cable connector.
FIG. 5 a depicts a cross section of a prior-art universal serial bus (USB) cable.
FIG. 5 b depicts a wiring diagram of a prior-art universal serial bus (USB) cable.
FIG. 6 a depicts a cross section of a cable according to embodiments of the invention.
FIG. 6 b depicts a wiring diagram of a cable according to embodiments of the invention.
FIG. 7 depicts the underside of the top cover of the intraoral sensor of FIG. 1 .
DETAILED DESCRIPTION
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
FIG. 1 illustrates a dental x-ray system 10 . The system includes an x-ray source 12 . In the embodiment shown, the source is located on an end 13 of a mechanical arm 15 . When activated, the x-ray source 12 generates an x-ray stream 16 that has a generally circular cross-section. (Of course, x-rays are generally invisible, but a representation of a stream is illustrated to facilitate understanding of the invention.) In many applications, a collimator is used to reduce the size of the stream and generate a smaller x-ray stream having a rectangular cross-section. A collimator may be used with a mechanical positioning device to help align the x-ray stream with an x-ray sensor. As shown in FIG. 1 , x-ray source 12 is positioned (e.g., by an operator) so that the x-ray stream 16 is directed to an intraoral sensor 20 . The intraoral sensor 20 is shown located in the mouth of a patient 21 . In some embodiments, the intraoral sensor 20 includes a scintillator that coverts x-ray radiation to visible light. In other embodiments, the sensor 20 is configured to convert x-rays into electric charge without a scintillator. Unless otherwise specified, the term pixel refers both to a pixel in the array of pixels that converts x-rays to electrons without a scintillator and a pixel in the array of pixels and its associated scintillator or portion of a scintillator.
As best seen by reference to FIG. 1 a , the sensor 20 also includes an array of pixels 22 . The components of FIG. 1 a , including the array of pixels 22 , are not drawn to scale relative to the outline of the sensor 20 . Each pixel produces an electric signal in response to light (from the scintillator) or x-ray radiation impinged upon it. In one embodiment, the sensor 20 includes one or more “on-board” analog-to-digital converters to covert analog signals generated by the pixels to digital signals. These signals are provided to a processor 23 (such as a programmable, electronic microprocessor, field programmable gate array, erasable programmable logic device(s), or similar device(s)). In the embodiment shown, the processor 23 is connected to memory 24 (ROM and RAM) and an input-output interface 25 . The sensor 20 also includes one or more electronic circuits for power supply, driving the array of pixels, and driving the output (e.g., circuits located in the I/O interface 25 ). In some embodiments, the I/O interface 25 is a universal serial bus (“USB”) interface.
In some embodiments, the processor 23 controls image capture or triggering of the sensor 20 . In other embodiments, the x-ray source 12 is coupled to the sensor 20 , e.g., via computer 30 , such that when the x-ray source 12 is activated, a command is sent (simultaneously or nearly simultaneously) to the sensor 20 to perform an image capture. Thus, it is possible to generate a burst of x-ray radiation and be assured that an image will be captured by the sensor 20 during the relatively short period of x-ray exposure either through automatic triggering or via a specific capture command sent to the intraoral sensor 20 .
Referring back to FIG. 1 , a wire, cable, or similar connector 27 of the sensor 20 connects the sensor 20 to a computer 30 . The computer 30 includes various components, including a processor or similar electronic device 32 , an input/output interface 34 , and memory 36 (e.g., RAM and ROM). In some embodiments, the input/output interface 34 is a USB connection and the cable 27 is a USB cable. FIG. 1 illustrates that image data captured by the sensor 20 and processed by the computer 30 is sent to a display 38 and viewed as image 40 . (Image 40 is drawn more distinctly than an x-ray image would typically appear.)
The location of the intraoral sensor 20 in the patient's mouth determines what part of the patient's anatomy can be imaged (e.g., the upper jaw versus the lower jaw or the incisors versus the molars.) An x-ray operator places (or assists the patient in placing) the intraoral sensor 20 at a desired location with the patient's mouth. Various sensor holders (including those that are used with or that include a collimator) may be used to keep the sensor 20 in the desired location until an image is created or captured. For example, some holders are designed so that the patient bites the holder with his or her teeth and maintain the position of the sensor 20 by maintaining a bite on the holder. After the sensor 20 is positioned behind the desired anatomical structure, and the x-ray field to be generated by the x-ray source 12 is aligned with the sensor 20 , it is possible that the source 12 and sensor 20 will, nevertheless, become misaligned. Misalignment can be caused by the patient moving his or her head, moving the intraoral sensor 20 (by re-biting the holder, moving his or her tongue, etc.), and other causes.
FIG. 2 depicts an exploded view of the intraoral sensor 20 . The sensor 20 includes a housing 45 . The housing 45 has a top portion 50 and a bottom portion 55 . Within the housing 45 is an insulator 60 , a printed circuit board (“PCB”) 65 , a silicon detecting layer 67 , an x-ray converter 70 , and a cushioning layer 71 , which protects against mechanical shocks. Some embodiments of the sensor 20 do not include the cushioning layer 71 .
The top portion 50 includes a dome 75 that receives cable 27 . The dome 75 has a shape that approximates an elliptical paraboloid divided in half by the surface 76 of the top portion 50 (a partial, elliptical paraboloid shape). Other dome shapes are contemplated for use in embodiments of the invention. The dome 75 includes a face with an approximately circular opening through which the cable 27 passes. The cable 27 includes connectors (e.g., wires), a portion of which pass through an opening 79 of the insulator 60 to connect to the PCB 65 . In some embodiments, a ribbon or other connector passes through the opening 79 to couple the wires of cable 27 to the PCB 65 . The insulator 60 provide electrical isolation between the PCB 65 and the housing 45 of the sensor 20 . In some embodiments, the insulator 60 also secures the PCB 65 and x-ray converter 70 in position and protects each against mechanical shocks. Although the insulator 60 resists conducting electricity it is a conductor of heat, which assists in transferring heat away from the PCB 65 .
The PCB 65 , silicon detecting layer 67 , and converter 70 include the components of the sensor 20 illustrated in FIG. 1 a , namely the array of pixels 22 , the processor 23 , the memory 24 , and I/O interface 25 . In the embodiment depicted in FIG. 2 , the array of pixels 22 includes a plurality of pixels, each pixel including a converting portion (i.e., a portion of converter 70 ) and a detecting portion (i.e., a portion of silicon detecting layer 67 ). The PCB 65 supports the silicon detecting layer 67 (e.g., a CMOS die) and converter 70 , with the silicon detecting layer 67 being secured, e.g., using a glue or epoxy, to the PCB 65 . The converter 70 converts x-rays received through the bottom portion 55 into light. The light travels to the silicon detecting layer 67 , which converts the received light into charge. The charge is integrated at each pixel and the quantity of charge integrated represents the amount of x-rays received (although some of the integrated charge is attributable to noise and dark current). During a read-out of the array of pixels 22 , the processor 23 determines the quantity of charge integrated at each pixel in the array of pixels 22 . In some embodiments, the converter 70 and silicon detecting layer 67 include a fiber optic with scintillator. In some embodiments, the array of pixels 22 converts x-rays directly to charge without an intermediate step of converting x-ray to light. In such embodiments, among other possible alterations, an additional insulator (similar to insulator 60 ) is positioned in place of converter 70 , and is used to provide electrical isolation between the housing 45 and the PCB 65 and help transfer heat away from the PCB 65 .
FIG. 3 depicts a cross section of the sensor 20 along line A as shown in FIG. 4 . The top portion 50 is secured to the bottom portion 55 for instance, using ultrasonic welding and machining. The welding bonds the top portion 50 to the bottom portion 55 , and machining smoothes the surface. Additionally, the top portion 50 and bottom portion 55 include interlocking portions 56 . The converter 70 , PCB 65 , silicon detecting layer 67 , and insulator 60 are shown within the housing 45 . Also depicted is the cable 27 including stress relief portion 77 . The stress relief portion 77 is secured to the cable 27 , for instance, using an adhesive. Additionally, the stress relief portion 77 includes a circumferential notch 80 that matches up with ridge 85 on the dome 75 . The stress relief portion 77 is secured to the dome 75 using the interlocking notch 80 and ridge 85 . An adhesive may also be used to secure stress relief portion 77 to the dome 75 . The stress relief portion 77 alleviates mechanical stress on the cable-to-housing coupling 81 created from twisting, pulling, and other forces on cable 27 and housing 45 . Thus, the stress relief portion 77 extends the life of the cable-to-housing coupling 81 , preventing or delaying malfunction of the sensor 20 caused by breaking the connection between the cable 27 and the housing 45 . FIG. 4 depicts a top view of the sensor 20 and a USB connector 82 at the end of cable 27 .
FIG. 5 a depicts a cross section of a standard universal serial bus (USB) cable 100 capable of high speed USB version 2.0 communication. The standard USB cable 100 includes four main wires: data line 105 (D+), data line 110 (D−), power line 115 , and ground line 120 . Additionally, surrounding the four main wires is an isolating jacket 125 , an outer shield 130 made of 65% interwoven tinned copper braid, and an inner shield 135 made of aluminum metallized polyester. The isolating jacket 125 is made of polyvinyl chloride (PVC) in some embodiments. Running lengthwise along with wire between the inner shield 135 and the outer shield 130 is a copper drain wire 140 . The standard USB cable 100 is not symmetrical. Rather, the standard USB cable 100 has an internal, non-circular, oval structure, although fillers and plastic (not shown) may be used to create an external, circular shape of the cable. The external, circular shape can be approximately 4 mm in diameter.
FIG. 5 b depicts a wiring diagram of the standard USB cable 100 . As illustrated, the standard USB cable 100 has one twisted signaling pair including the data line 105 (D+) and data line 110 (D−). In some implementations, the power line 115 and ground line 120 are twisted (possibly to a lesser extent) or, as shown in FIG. 5 b , not twisted at all.
FIG. 6 a depicts a cross section of a cable 150 according to embodiments of the invention. The cable 150 includes four main wires 210 and four fillers 175 a - d . The four main wires 210 include data line 155 (D+), data line 160 (D−), power line 165 , and ground line 170 , which provide data transmission, power transmission, and grounding, respectively. The data line 155 (D+), data line 160 (D−), power line 165 , and ground line 170 each include a metal conductor encapsulated by a co-axial insulator. The four fillers 175 a - d are made of plastic and are twisted along with the four main wires 210 to form a twisted quad cable. The four mains wires 210 and four fillers 175 a - d are surrounded by three layers that run the length of the cable 150 . The three layers include polytetrafluoroethylene (“PTFE”) tape 180 , a braided shield 185 , and a polyurethane jacket 190 . In some embodiments, other materials are used for the jacket 190 and the tape 180 (e.g., another material similar to PTFE with a low surface roughness). The braided shield 185 is made up of, for instance, tinned copper wires with 0.08 mm diameter (40 AWG). As will be discussed further below, in some embodiments, the braided shield 185 is a heat conductor. In some embodiments, the polyurethane jacket 190 is approximately 0.432 mm thick. The total diameter of the cable 150 is less than 3.0 mm. In some embodiments, additional or fewer layers surround the four main wires 210 and fillers 175 a - d used within cable 27 .
The wiring diagram of FIG. 6 b illustrates the main wires 210 and fillers 175 a - d twisted together to form a single bundle 195 . Although not shown in FIG. 6 b , the (“PTFE”) tape 180 , a braided shield 185 , and a polyurethane jacket 190 encapsulate the single bundle 195 as shown in FIG. 6 a . The twisted quad cable is symmetrical about center line 197 , as shown in FIG. 6 a . The symmetrical characteristic of the cable 150 provides increased strength and resistance to mechanical stress with a lower outside diameter, relative to the standard USB cable. That is, the cable 150 is less susceptible to damage from twisting, pulling, and other forces on the cable 150 , despite the reduced diameter of the cable 150 . In particular, the cable 150 is less susceptible to damage due to rotational mechanical stress, which is often present during use of an intraoral sensor cable.
FIG. 7 depicts the inside 200 of the top portion 50 . The inside 200 includes a metallization layer 205 . The cable 27 is shown inserted into the dome 75 . The four main wires 210 (i.e., the data line 155 (D+), data line 160 (D−), power line 165 , and ground line 170 ) are attached to a PCB connector 215 , which is connected to the PCB 65 . In some embodiments, the four main wires 210 are coupled or soldered directly to the PCB 65 . The braided shield 185 is coupled to the metallization layer 205 via a heat conducting wire 220 . The heat conducting wire 220 is coupled to the braided shield 185 and metallization layer 205 by, for instance, soldering.
As the PCB 65 generates heat while in operation, a substantial portion of the generated heat is transferred through the insulator 60 to the metallization layer 205 . The portion of generated heat is then transferred to the braided shield 185 via the heat conducting wire 220 . The level of thermal resistance may vary by application. For instance, the more heat the PCB 65 generates in a particular embodiment, the lower the thermal resistances are of the materials chosen for the metallization layer 205 , heat conducting wire 220 , and insulator 60 . In general, however, the insulator 60 and heat conducting wire 220 have a thermal resistance that is lower than the thermal resistance of air (which is approximately 1/0.025 W/(mK) at 20 degrees Celsius). Additionally, the metallization layer 205 has a thermal resistance that is less than the thermal resistance of the top portion 50 of the housing 45 and less than the thermal resistance of air. Thus, the sensor 20 provides improved heat transfer away from the sensor 20 along the cable 27 .
Although not shown, in some embodiments the inside of the bottom portion 55 also includes a metallization layer, which is similar to the metallization layer 205 in form and function. The bottom metallization layer is coupled to the braided shield 185 as well. In some embodiments, the coupling is provided by an additional heat conductor connection between the bottom metallization layer and either the braided shield 185 or the metallization layer 205 . In other embodiments, the coupling is provided by direct contact between the bottom metallization layer and the metallization layer 205 .
Thus, the invention provides, among other things, an intraoral sensor with a cable providing greater resistance to mechanical stress. Additionally, the invention provides an intraoral sensor with improved heat transfer. Various features and advantages of the invention are set forth in the following claims.
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An intraoral x-ray sensor including a sensor housing and a universal serial bus (USB) data cable. The sensor housing has an opening. The USB data cable includes an outer sheath and a first data line, a second data line, a ground line, a power line, and at least two independent fillers positioned within the outer sheath. In one embodiment, at least two lines selected from the group including the first data line, the second data line, the ground line, and the power line are twisted together to form a single bundle. The opening receives the data cable.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a backhoe having a ground working implement connected to the front of a swivel deck.
2. Description of the Related Art
In this type of conventional technique, a support frame bifurcated in plan view has a right and left longitudinal ribs and a front swing bearing member on the swivel slide. The swing bearing member of the support frame supports the ground working implement through a swing shaft. A hydraulic oil tank and a fuel tank are arranged at the right-hand side on the swivel slide, and a swing cylinder for swinging the ground working implement is disposed below these tanks. An engine and a counter weight are arranged on a rear portion of the swivel deck (see Japanese Unexamined Patent Publication No. 2005-232795, for example).
In the above conventional technique, the forward ends of the right and left longitudinal ribs are welded to right and left rear positions of the swing bearing member. The welds are short, and stress tends to concentrate on the welds. The right and left longitudinal ribs are not connected to each other, and it is therefore difficult to improve their mounting strength.
SUMMARY OF THE INVENTION
This invention intends to provide a backhoe that overcomes the disadvantages of the prior art noted above.
An object of this invention, therefore, is to provide a backhoe with improved mutual assembly strength between a swing bearing member and right and left longitudinal ribs, and with a reduced stress concentration occurring at welds.
The above object is fulfilled, according to this invention, by a backhoe comprising:
a swivel deck;
a first longitudinal rib disposed on the swivel deck, the first longitudinal rib extending in a fore and aft direction, and having a front portion extending in a transverse direction;
a second longitudinal rib disposed on the swivel deck, the second longitudinal rib extending in the fore and aft direction, and having a front end thereof connected to the front portion of the first longitudinal rib; and
a swing bearing member attached to a front surface of the front portion of the first longitudinal rib for supporting a ground working implement through a swing shaft.
This construction realizes an improvement in mutual assembly strength between the front portion of the first longitudinal rib, the front portion of the second longitudinal rib and the swing bearing member. Welds between these parts are subjected to a reduced stress concentration.
The first longitudinal rib may include an inclined portion extending rearward and outward from the front portion, and a rear portion extending from a rear end of the inclined portion transversely away from the second longitudinal rib.
Then, the first longitudinal rib forms an approximately S-shape in plan view. This shape can distribute stress applied thereto, and can improve strength in the transverse direction of the swivel deck.
The second longitudinal rib may extend from front to rear of the swivel deck, and support an engine.
Then, the second longitudinal rib can be used not only for supporting a swing cylinder on the swivel deck, but also for mounting structures such as the engine.
Preferably, the backhoe further comprises a rear longitudinal rib extending rearward from the backward portion, and a connecting member for connecting a rear end of the second longitudinal rib and a rear end of the rear longitudinal rib.
This construction allows the two longitudinal ribs to reinforce each other, and distribute stress between each other.
According to this invention, an improvement is realized in mutual assembly strength between the front portion of the first longitudinal rib, the front portion of the second longitudinal rib and the swing bearing member, and welds between these parts are subjected to a reduced stress concentration.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of a backhoe according to this invention;
FIG. 2 is a perspective view of the backhoe seen from a right forward direction;
FIG. 3 is a perspective view of the backhoe seen from a left rearward direction;
FIG. 4 is a side view of an upper structure;
FIG. 5 is a front view of the upper structure;
FIG. 6 is a plan view of an interior of the upper structure;
FIG. 7 is a perspective view of the interior of the upper structure;
FIG. 8 is a plan view of a swivel deck;
FIG. 9 is a perspective view of the swivel deck;
FIG. 10 is a side view of the swivel deck;
FIG. 11 is a schematic plan view of the upper structure.
FIG. 12 is a plan view of a platform;
FIG. 13 is a front view, partly in section, of the upper structure; and
FIG. 14 is an enlarged sectional view of a portion between an engine room and a cab apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of this invention will be described hereinafter with reference to the drawings.
In FIGS. 1-14 , a backhoe 1 of the rear small revolution type (swivel type working vehicle), includes a traveling device 2 disposed below, an upper structure 3 disposed above, a dozer apparatus 4 attached to the front of the traveling device 2 , and a ground working implement 5 attached to the upper structure 3 .
The traveling device 2 has crawler traveling means 7 arranged at right and left side of a track frame 6 to be driven by hydraulic motors. The track frame 6 supports thereon a swivel deck 10 which is a base of the upper structure 3 , to be swivelable through a swivel bearing 11 about a swivel center (vertical axis) X. The swivel deck 10 is driven by a swivel motor 8 mounted thereon. The dozer apparatus 4 has a blade vertically movable in front of the track frame 6 .
The track frame 6 has a swivel joint 12 disposed centrally of the swivel bearing 11 . The swivel joint 12 projects into the swivel deck 10 .
The track frame 6 has the swivel bearing 11 disposed on an upper surface of a top plate thereof for swivelably supporting the swivel deck 10 , and a swivel gear disposed in an inner peripheral position of the swivel bearing 11 . A mounting member is attached to a lower surface of the top plate. An attachment part of the swivel joint 12 is fixed to a lower surface of the mounting member. The swivel joint 12 is disposed centrally of a center opening of the top plate.
Referring to FIGS. 2-7 , the upper structure 3 includes, arranged on the swivel deck 10 and with reference to the swivel center X where the swivel joint 12 is located, an engine 15 at one side (right-hand side), a platform 16 at the other side (left-hand side), and a hydraulic oil tank 17 and a fuel tank 18 at the rear. A driver's seat 26 on the platform 16 is disposed adjacent the center of the swivel deck 10 and above the hydraulic oil tank 17 and fuel tank 18 .
The platform 16 may have, mounted thereon, a rollover protection structure of the four strut type or two strut type, or a cab body 27 A forming a cab apparatus 27 .
On the swivel deck 10 a support frame 21 bifurcated in plan view is provided, which includes right and left longitudinal ribs 19 R and 19 L and a swing bearing member 20 at the front. The ground working implement 5 is supported by the swing bearing member 20 of the support frame 21 through a swing shaft 22 . A swing cylinder 23 is disposed at the left-hand side on the swivel deck 10 for swinging the ground working implement 5 .
The swing shaft 22 is displaced to one side (right-hand side) from the swivel center X. The center of the driver's seat 26 is displaced to the other side (left-hand side) for enabling the driver to observe operating states of the ground working implement 5 .
The engine 15 is disposed on the swivel deck 10 further rightward than the longitudinal rib 19 R at the right-hand side, with a crankshaft 15 A extending in the fore and aft direction. A radiator 57 and an oil cooler 58 are arranged forwardly of the engine 15 , and a hydraulic pump 59 rearwardly of the engine 15 .
As shown in detail in FIGS. 6-10 , the support frame 21 has the right longitudinal rib 19 R (corresponding to the second longitudinal rib of this invention) extending substantially in the fore and aft direction and substantially parallel to the engine 15 . The left longitudinal rib 19 L (corresponding to the first longitudinal rib of this invention) has a front portion 19 La extending in a right and left direction and connected to the front of the right longitudinal rib 19 R. The swing bearing member 20 is attached to the front portion 19 La.
The front portion 19 La has a front surface of substantially the same vertical dimension as a rear surface of the swing bearing member 20 , and slightly longer in the right and left direction than the rear surface. Parts thereof protruding right and left serve as welds to the swing bearing member 20 . The lower surface of the front portion 19 La is welded to the swivel deck 10 . The upper surface of the front portion 19 La defines a mounting surface in combination with an upper rear part of the swing bearing member 20 for supporting the platform 16 through a cushion material 76 .
The left longitudinal rib 19 L includes the front portion 19 La, an inclined portion 19 Lb extending rearward and outward from the front portion 19 La, a rear portion 19 Lc extending leftward from the rear end of the inclined portion 19 Lb and supporting the swing cylinder 23 , and a tail portion 19 Ld bent rearward from rear portion 19 Lc. The rear portion 19 Lc also extends in the right and left direction and substantially parallel to the front portion 19 La.
A connecting part between the forward portion l 9 La and right longitudinal rib 19 R is reinforced with a coupling member 86 . A coupling member similar to the coupling member 86 may be provided for a bend between the front portion 19 La and inclined portion 19 Lb.
A pair of upper and lower brackets 23 are formed on a front surface of the rear portion 19 Lc for pivotally supporting a proximal portion of the swing cylinder 23 through a pin. The upper bracket 23 a is welded also to the inclined portion 19 Lb to reinforce the bend between the inclined portion 19 Lb and rear portion 19 Lc.
A rear longitudinal rib 24 extends from the rear portion 19 Lc of left longitudinal rib 19 L to the rear of the swivel deck 10 . The rear longitudinal rib 24 is connected to the rear end of the right longitudinal rib 19 R by a connecting member 25 . The support frame 21 , including the rear longitudinal rib 24 and connecting member 25 , has a closed frame configuration approximately in the shape of a trapezoid. This support frame 21 is strong particularly against loads acting in the fore and aft direction.
The left longitudinal rib 19 L curved to form an approximately S-shape in plan view has high strength for attaching to the swivel deck 10 , serves to increase strength in the right and left direction of the swivel deck 10 , and also increases mounting strength of the rear longitudinal rib 24 and connecting member 25 .
The right longitudinal rib 19 R adjacent the engine 15 extends from front to rear of the swivel deck 10 to serve as a lower partition of an engine room 14 and define a space for arranging the engine room 14 , hydraulic oil tank 17 and fuel tank 18 . A longitudinal frame 61 of the engine room 14 extends upward from the right longitudinal rib 19 R.
Mounting members l 9 Ra and l 9 Rb are provided in forward and rearward positions of the right longitudinal rib 19 R. The engine 15 is mounted on the mounting members l 9 Ra and l 9 Rb and forward and rearward mounting bases 63 arranged at the right end of the swivel deck 10 . An accessory frame 65 extends between the mounting members l 9 Ra and l 9 Rb and mounting bases 63 , straddling the engine 15 , for supporting engine accessories such as an air cleaner. The engine 15 is mounted using the right longitudinal rib 19 R, and is connected to the right longitudinal rib 19 R, thereby reinforcing the right longitudinal rib 19 R. The accessory frame 65 also reinforces the right longitudinal rib 19 R.
Referring to FIGS. 2 , 7 , 13 and 14 , the longitudinal frame 61 has a square frame 61 A, a front partition plate 61 B, a rear partition plate (not shown) and a cover frame 66 arranged between the engine room 14 and platform 16 (or cab apparatus 27 ), and is fixed to the accessory frame 65 and right longitudinal rib 19 R.
The square frame 61 A is formed of an angle pipe looped into a square to serve as a reinforcing member. The front partition plate 61 B is disposed at the front of the square frame 61 A to cover the left-hand plane of the engine room 14 . The rear partition plate is disposed at the rear of the square frame 61 A to form a tank arranging space, and serve as a member for supporting an oil filter 88 . The front partition plate 61 B and rear partition plate are fixed to the right longitudinal rib 19 R.
The cover frame 66 covers upper edges of the square frame 61 A and front partition plate 61 B, and has a cover portion 66 A covering an upper surface and a right-hand side surface of the radiator 57 .
The front partition plate 61 B may extend to the rear partition plate to cover the entire surface of the square frame 61 A, i.e. to cover the entire left-hand side plane of the engine room 14 .
The accessory frame 65 has a band plate between the square frame 61 A and the right end of the swivel deck 10 , and a band plate between the square frame 61 A and right longitudinal rib 19 R, and is located an intermediate position in the fore and aft direction of the engine room 14 .
The longitudinal frame 61 and/or accessory frame 65 pivotally support a hood 35 covering the engine room 14 , to be openable about an axis extending in the fore and aft direction. When the cab apparatus 27 is mounted, an upper part of the side wall adjacent the engine of the cab apparatus 27 is disposed to overlap the top of the longitudinal frame 61 .
Referring to FIGS. 4 , 6 and 7 , a mounting frame 30 is provided to extend between the rear longitudinal rib 24 and a rear portion of the right longitudinal rib 19 R (or the rear partition plate), straddling the hydraulic oil tank 17 and fuel tank 18 . The mounting frame 30 reinforces the rear portion of the support frame 21 , and supports a control valve 13 .
The hydraulic oil tank 17 and fuel tank 18 are elongated vertically and in the fore and aft direction to have necessary and sufficient capacities. These tanks 17 and 18 are arranged in the right and left direction together with an air-conditioner 31 also elongated vertically and in the fore and aft direction.
The hydraulic oil tank 17 is formed of sheet metal, and fixed to the upper surface of the swivel deck 10 . The fuel tank 18 is formed of a synthetic resin, and attached to the hydraulic oil tank 17 with a fork clip 18 A. It is also possible to form the hydraulic oil tank 17 with a synthetic resin, and the fuel tank 18 with sheet metal. The fuel tank 18 may be fixed to the swivel deck 10 independently of the hydraulic oil tank 17 .
The fuel tank 18 is disposed in the a middle position little influenced by a sideways tilt, so that the fuel may be fetched even when the fuel decreases in quantity and the swivel deck 10 inclines right and left.
A counter weight 73 is mounted at rear of swivel deck 10 and connecting member 25 . A battery 74 is mounted at the left side of the swivel deck 10 . The counter weight 73 has an opening 73 A in an upper middle position for exposing a filling hole 18 B of the fuel tank 18 . A door 39 is provided to open and close this opening 73 A.
The platform 16 extends from above the swing cylinder 23 and battery 74 on the swivel deck 10 to above the hydraulic oil tank 17 , fuel tank 18 and counter weight 73 . The platform 16 has a front portion thereof detachably attached through cushion material 76 to supporting legs 75 and swing bearing member 20 at the front of the swivel deck 10 , and a rear portion to the counter weight 73 (or mounting frame 30 ).
Referring to FIGS. 4 , 5 , 12 and 13 , the platform 16 is formed of sheet metal or synthetic resin as a unit. The platform 16 has a step portion 16 A defining a step surface above the swing cylinder 23 and battery 74 , a vertical portion 16 B extending upward from the rear end of the step portion 16 A and located forwardly of the hydraulic oil tank 17 and fuel tank 18 , a mounting portion extending from the upper end of the vertical portion 16 B above the hydraulic oil tank 17 and fuel tank 18 and defining a driver's seat mounting surface, a rear connecting portion 16 D from the rear end of the mounting portion 16 C rearward and upward above the counter weight 73 , and a side wall 16 E extending upward from side edges adjacent the engine of these step portion 16 A, vertical portion 16 B, mounting portion 16 C and rear connecting portion 16 D.
A driver's seat mounting base 42 is supported through a suspension 41 on the mounting portion 16 C of the platform 16 . The driver's seat 26 and a control device 29 are arranged on the driver's seat mounting base 42 . When the driver's seat 26 is rocked a great deal up and down, the control device 29 is rocked with the driver's seat 26 . The mounting portion 16 C is disposed below the top of the engine 15 , and at least an upper part of the engine room 14 . The mounting portion 16 C disposed at a low level allows use of the suspension 41 even if the driver's seat 26 is at the same height as in the prior art.
Thus, the driver's seat 26 is disposed at a proper height and in a proper fore and aft position without being obstructed by the engine which is the bulkiest object on the swivel deck 10 , and by the hydraulic oil tank 17 and fuel tank 18 . The hydraulic oil tank 17 , fuel tank 18 and air-conditioner 31 below the driver's seat 26 are similar in shape as noted hereinbefore, which is used to arrange these components compactly on the swivel deck 10 .
The platform 16 has also travel controls 28 arranged thereon, and can serve as a bottom plate of the cab apparatus 27 . The cab apparatus 27 has a cab main body 27 A mounted on the platform 16 and enclosing the driver's seat 26 , controls 28 and control device 29 .
Referring to FIGS. 1-3 and 11 - 14 , the cab main body 27 A is formed of a front portion 27 a having a windshield, a rear portion 27 b having a glass window, an upper side wall 27 c having a side window adjacent the engine, and a left side portion having a ceiling 27 d and a door 67 . A lower right side of the cab main body 27 A is formed of the side wall 16 E of the platform 16 . The side wall 16 E can also serve as a side wall of engine room 14 .
The upper side wall 27 c overhangs the longitudinal frame 61 and an elastic seal element 69 is disposed therebetween. Thus, rain water does not enter the cab apparatus 27 even when the cab apparatus 27 vibrates vertically relative to the swivel deck 10 .
The controls 28 on the platform 16 include propelling control means 43 of the pedal-lever interlock type disposed forwardly of the driver's seat 26 , swing cylinder control means 44 operable by the right foot, a foot-operated change switch 45 operable one of the right and left feet to switch between two, high and low speeds of the traveling device 2 , and a hand-operated change switch 46 arranged at the same side as the foot-operated change switch 45 and operable by hand.
The foot-operated change switch 45 for switching between two, high and low speeds of the traveling device 2 , and hand-operated change switch 46 , are arranged in positions operable by the right foot and right hand of the driver seated on the driver's seat 26 .
A foot pedal 77 is disposed in a left forward position on the platform 16 to be operable by the left foot for supplying hydraulic fluid to hydraulic equipment associated with the ground working implement 5 .
The control device 29 has two grip type work control means 43 R and 43 L arranged at the right and left sides of the driver's seat 26 , with two grips 32 sharing a plurality of operations of the ground working implement 5 . The driver can swing the left grip type work control means 43 L upwards in time of boarding or alighting.
Each of the grips 32 R and 32 L of the two grip type work control means 43 R and 43 L has a pilot valve assigned thereto for pilot operation of the hydraulic equipment constituting the ground working implement 5 , such as the motor 8 , a boom cylinder 52 , an arm cylinder 54 and a working tool cylinder 56 . Each grip has also, assigned thereto, a switch for supplying hydraulic fluid to other hydraulic equipment, if any, constituting the ground working implement 5 , and/or hydraulic equipment such as a breaker, if any, associated with the ground working implements 5 .
The right (i.e. one) grip 32 R, for example, has a volume switch 80 and a horn switch 83 for supplying hydraulic fluid to the hydraulic equipment associated with the ground working implement 5 . The left (i.e. the other) grip 32 L has a control switch 81 and a change switch 82 for selectively operating the two types of hydraulic equipment.
When the ground working implement 5 includes a boom 51 having two members for flexion, the control switch 81 may be a two-piece switch for supplying hydraulic fluid to a flexion cylinder for flexing the second boom relative to the first boom. When the hydraulic equipment associated with the ground working implement 5 has two hydraulic drivers, the control switch 81 may be a second implement switch for supplying hydraulic fluid to the second hydraulic driver. When the two types of hydraulic equipment are used, only one control switch 81 may be provided, and the change switch 82 may be operated for selectively using the two types of hydraulic equipment. The change switch 82 may be adapted to turn the control switch 81 on and off.
Numeral 85 denotes a monitor disposed in an upper right position of the platform 16 for displays running and working states. The monitor 85 is attached to the side wall 16 E (or on a strut erected on the step 16 A).
Referring to FIGS. 2 , 3 , 5 and 11 , the upper structure 3 has, provided to be openable and closable, the hood 35 for covering the upper plane and outer plane of the engine room 14 , a front cover 36 for covering the front plane of the engine room 14 at the front of the cover portion 66 A, and a lower side cover 37 for covering the space where the swing cylinder 23 and battery 74 are arranged, in a position between the swivel deck 10 and the front of the platform 16 . The swivel deck 10 has outer edges protruding laterally outward to minimize the chance of the hood 35 ; front cover 36 and lower side cover 37 contacting obstacles.
A pivotal support pivotally supporting the upper end of the hood 35 It has an axis extending in the fore and aft direction. A pivotal support pivotally supporting the lower end of the front cover 36 has an axis extending horizontally (or vertically). A pivotal support pivotally supporting the front end of the lower side cover 37 has an axis extending vertically.
The control valve 13 is disposed between the swivel deck 10 and the rear of the platform 16 and laterally outwardly of the hydraulic oil tank 17 . The control valve 13 is covered by an openable rear side cover 38 . A pivotal support pivotally supporting the rear end of the rear side cover 38 has an axis extending vertically. The rear side cover 38 may have a pivotal support in a lower front position thereof to be openable about a transverse axis.
The control valve 13 is mounted in a rear side position of the swivel deck 10 adjacent the oil tank 17 through the mounting frame 30 . A relay junction 70 is mounted in a position of the platform 16 adjacent the control valve 13 .
The relay junction 70 has a hose connected thereto and communicating with the controls 28 and control device 29 on the platform 16 . These are attached to the swivel deck 10 after being assembled, and the relay junction 70 and control valve 13 are connected to each other through the hose. Thus, piping of the swivel deck 10 and piping of the platform 16 made into assemblies, respectively, to be connected easily.
Referring to FIG. 1 , the ground working implement 5 includes a swing bracket 50 pivotally supported by swing bearing member 20 of the support frame 21 to be swingable through a swing shaft 22 , the boom 51 connected to the swing bracket 50 to be vertically movable by the boom cylinder 52 , an arm 53 connected to the boom 51 to be pivotable about a transverse axis by the arm cylinder 54 , and a working tool (bucket) 55 connected to the arm 53 and driven by the working tool cylinder 56 to perform scoop operations. The boom 51 may be a two-piece boom having two flexible members. The arm 53 or working tool 55 may have, associated therewith, one or two hydraulic devices having one or two hydraulic drivers.
According to this invention, the shape of each member in the described embodiment and the positional relationship in the fore and aft, right and left, and vertical directions are optimal when arranged as shown in FIGS. 1-14 . However, their arrangement is not limited to the above embodiment. The members and constructions may be modified in various ways, or the combinations may be changed.
For example, the radiator 57 may be disposed rearwardly of the engine 15 , and the hydraulic pump 59 forwardly of the engine 15 . It is possible to reverse the right and left arrangement of the engine 15 , platform 16 and cab apparatus 27 on the swivel deck 10 , and the right and left configuration of the support frame 21 .
Instead of the cab main body 27 A, a driver's seat protection frame of the two strut type may be erected on the rear of the platform 16 rearwardly of the driver's seat 26 . A driver's seat protection frame of the four strut type may be erected, which has rear struts at the rear of the platform 16 , front struts at the front of the swivel deck 10 , and a shading roof.
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An improvement is realized in mutual assembly strength between a swing bearing member and right and left longitudinal ribs, and welds are subjected to a reduced stress concentration. A backhoe comprises a swivel deck ( 10 ); a first longitudinal rib ( 19 L) disposed on the swivel deck, the first longitudinal rib extending in a fore and aft direction, and having a front portion ( 19 La) extending in a transverse direction; a second longitudinal rib ( 19 R) disposed on said swivel deck, the second longitudinal rib extending in the fore and aft direction, and having a front end thereof connected to the front portion of the first longitudinal rib; and a swing bearing member ( 20 ) attached to a front surface of the front portion of the first longitudinal rib for supporting a ground working implement through a swing shaft.
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FIELD OF THE INVENTION
The present invention relates to polymers from polar vinyl monomers (or activated olefins) and non-polar olefin monomers (or non-activated olefins) with the polymers having high olefin content and high weight average molecular weights and methods of preparing them. This invention also discloses polymers from polar vinyl monomers and non-polar olefin monomers with the polymers having high olefin content and high weight average molecular weights and methods of preparing them, wherein said polymers contain additional crosslinkable functionalities. The inventive polymers possess interesting properties that make them particularly attractive in several industrial applications.
BACKGROUND OF THE INVENTION
Copolymers of polar vinyl monomers and non-polar alkene monomers, especially non-polar 1-alkene monomers, have been the subject of research for a long time because the properties of the copolymer can be controlled by combining the very different properties of the starting monomers making them attractive materials for a number of applications. A number of methods have been reported for the copolymerization of acrylates with non-activated olefins. See, for example, S. Meckling et al, J. Am. Chem. Soc. 1998, 120, 888; E. Drent et al, Chem. Comm. 2002, 744; G. Tian et al, Macromolecules 2001, 34, 7656; K. Tanaka et al, Macromol. Symp. 2008, 261, 1; Y. Chen et al, Macromolecules, 2009, 42, 3951; S. L. Bartley, et al, U.S. 2010/0280198; U.S. Pat. No. 3,461,108; R. Venkatesh et al, Macromolecules, 2004, 37, 1226; H. Mei et al, Macromolecules, 2011, 44, 2552; and C. Wang et al, Organometallics, 1998, 17, 3149, for some discussions. Also of interest are U.S. Pat. Nos. 6,677,422; 7,884,161; and 4,048,422; EP 1964862; and publications U.S. 2010/0280198 and US2009/0018298.
One approach involves coordination polymerization catalyzed by transition and late transition metals, which appear to be effective for ethylene and α-olefins but polar acrylic monomers generally deteriorate the metal catalysis resulting in the copolymerization being inhibited. This method gives copolymers high in acrylate and low in the olefin content. Another reported approach involves radical copolymerization in the presence of Lewis acids. See the above-shown Y. Chen et al and K. Venkatesh et al. Use of strong Lewis acids was found to be necessary for enhancing the efficiency of copolymerization. However, obtaining copolymers and terpolymers which contain both high molecular weight with high olefin content has been generally difficult. Any success has been successful only with lower olefins such as ethylene and propylene, which too required high pressure conditions.
It would be an advantage to have a convenient process to prepare polymers (such as copolymers, terpolymers and the like) in high molecular weights and with high olefin content.
It would be an additional advantage if the process is economical and possible to be carried out with conventional equipment.
It would be a further advantage if the process is applicable to be used not only with lower olefins such as ethylene and propylene but also with higher olefins such as 1-hexene, 1-octene and the like.
It would be a still additional advantage if the polymers contain crosslinkable functionalities that can be used to further react said polymers with other desired reactants. If would be a further advantage if the process is flexible enough to introduce such crosslinkable functionalities during the polymerization reaction or even after the polymerization reaction by further reacting the polymers.
SUMMARY OF THE INVENTION
In one embodiment, the present invention provides polymers of high molecular weight and high olefin content from one or more activated olefins and one or more non-activated olefins and a process to prepare them. The term “high molecular weight” herein generally refers to weight average molecular weights (M w ) of at least about 50,000, specifically from about 100,000 to about 3.0 million, and more specifically from about 200,000 to about 2.0 million and still more specifically from about 500,000 to about 1.5 million. The term “high olefin content” herein generally refers to the olefin content (from non-activated olefin) of at least about 30%, specifically at least about 40%, more specifically about 50% and still more specifically at least about 50%.
In another embodiment, the present invention discloses a process to prepare a polymer with weight average molecular weight in the range 50,000-3.0 million, wherein said polymer comprises, in its repeat unit, (i) one or more activated olefins independently selected from the group consisting of a (meth)acrylate, acrylonitrile, (meth)acrylamide, maleimide, itaconimide, citroconimide, maleic anhydride, cyanoacrylate, maleate, fumarate, crotonate, alkylidene malonate and cinnamate and (ii) one or more non-activated olefins independently selected from the group consisting of an unsubstituted alkene, monosubstituted alkene, disubstituted alkene, trisubstituted alkene, allyl ether, allyl ester, allyl sulphide and allylamide, wherein said one or more non-activated olefins constitutes at least 30% of the polymer, said method comprising the steps of:
(a) preparing a solution containing said one or more of activated olefins and said one or more non-activated olefins, optionally in the presence of a solvent;
(b) precomplexing equimolar amounts of said one or more of activated olefins and a Lewis acid to form a mix and adding the mix to the solution in (a) to form a mixture;
(c) optionally adding a radical initiator; and
(d) polymerizing said mixture at temperatures of about −78° C. to about 80° C. for a time sufficient to obtain the desired polymer.
In another embodiment, the present invention discloses a process to prepare a copolymer with weight average molecular weight in the range 50,000-3.0 million, wherein said copolymer comprises, in its repeat unit, (i) an activated olefin independently selected from the group consisting of a (meth)acrylate, acrylonitrile, (meth)acrylamide, maleimide, itaconimide, citroconimide, maleic anhydride, cyanoacrylate, maleate, fumarate, crotonate, alkylidene malonate and cinnamate and (ii) a non-activated olefin independently selected from the group consisting of an unsubstituted alkene, monosubstituted alkene, disubstituted alkene, trisubstituted alkene, allyl ether, allyl ester, allyl sulphide and allylamide, wherein said non-activated olefin constitutes at least 30% of the polymer, said method comprising the steps of:
(a) preparing a solution containing said activated olefin and said non-activated olefin, optionally in the presence of a solvent;
(b) precomplexing equimolar amounts of said activated olefins and a Lewis acid to form a mix and adding the mix to the solution in (a) to form a mixture;
(c) optionally adding a radical initiator; and
(d) polymerizing said mixture at temperatures of about −78° C. to about 80° C. for a time sufficient to obtain the desired copolymer.
In yet another embodiment, the present invention discloses a process to prepare a terpolymer with weight average molecular weight in the range 50,000-3.0 million, wherein said terpolymer comprises, in its repeat unit, (i) one or more activated olefins independently selected from the group consisting of a (meth)acrylate, acrylonitrile, (meth)acrylamide, maleimide, itaconimide, citroconimide, maleic anhydride, cyanoacrylate, maleate, fumarate, crotonate, alkylidene malonate and cinnamate and (ii) one or more non-activated olefins independently selected from the group consisting of an unsubstituted alkene, monosubstituted alkene, disubstituted alkene, trisubstituted alkene, allyl ether, allyl ester, allyl sulphide and allylamide, wherein said one or more non-activated olefins constitutes at least 30% of the terpolymer, said method comprising the steps of:
(a) preparing a solution containing said one or more of activated olefins and said one or more non-activated olefins, optionally in the presence of a solvent;
(b) precomplexing equimolar amounts of said one or more of activated olefins and a Lewis acid to the solution to form a mix and adding the mix to the solution in (a) to form a mixture;
(c) optionally adding a radical initiator; and
(d) polymerizing said mixture at temperatures of about −78° C. to about 80° C. for a time sufficient to obtain the desired terpolymer.
In most of the instant polymerization reactions, high pressures were not found necessary. The reactions could be performed efficiently at atmospheric pressures. In most of the instant polymerization reactions, conventional polymerization equipment was found sufficient.
A free radical initiator was not always necessary in the polymerization reactions. While free radical initiators could be used, several of the reactions could be performed with substantially equal efficiency and equally desirable results without a free radical initiator.
It was also found that precomplexing of the Lewis acid with the activated olefin was not always necessary for the polymerization reaction to proceed equally efficiently to yield the desired polymer in desired yields and with desired high olefin content and high molecular weights. In such instances, the embodiments described herein for the precomplexing reaction are equally applicable to the non-precomplexing reaction. Thus, in another embodiment, the present invention discloses a process to prepare a polymer with weight average molecular weight in the range 50,000-3.0 million, wherein said polymer comprises, in its repeat unit, (i) one or more activated olefins independently selected from the group consisting of a (meth)acrylate, acrylonitrile, (meth)acrylamide, maleimide, itaconimide, citroconimide, maleic anhydride, cyanoacrylate, maleate, fumarate, crotonate, alkylidene malonate and cinnamate and (ii) one or more non-activated olefins independently selected from the group consisting of an unsubstituted alkene, monosubstituted alkene, disubstituted alkene, trisubstituted alkene, allyl ether, allyl ester, allyl sulphide and allylamide, wherein said one or more non-activated olefins constitutes at least 30% of the polymer, said method comprising the steps of:
(a) preparing a solution containing said one or more of activated olefins and said one or more non-activated olefins, optionally in the presence of a solvent;
(b) adding a Lewis acid to the solution to form a mixture;
(c) optionally adding a radical initiator; and
(d) polymerizing said mixture at temperatures of about −78° C. to about 80° C. for a time sufficient to obtain the desired polymer.
In another embodiment, the present invention discloses polymer compositions (such as, for example, copolymers, terpolymers and the like) with high molecular weight and high olefin content prepared by the inventive process.
In yet another embodiment, the present invention discloses polymers (such as, for example, copolymers, terpolymers and the like) with high molecular weight and high olefin content) containing crosslinkable functionalities. The crosslinkable functionalities are advantageous that they can be converted into products with useful applications. Non-limiting examples of such applications include adhesives, elastomers, tougheners, polymeric photoinitiators and the like. The crosslinkable functionalities can be present in the polymers as they are prepared or they can be introduced into the polymer by further reacting the polymer with suitable reactants.
In still another embodiment, the present invention discloses articles and materials comprising the inventive polymers discussed above.
DETAILED DESCRIPTION OF THE INVENTION
For purpose of this present invention, the following definitions will apply:
The terms “(meth)acrylate” or “(meth)acryloxy” will include methacrylate and acrylate and methacryloxy and acryloxy, respectively, as applicable.
The terms “halogen”, “halo”, or “hal” when used alone or part of another group mean chlorine, fluorine, bromine or iodine.
In an embodiment, the present invention discloses a process to prepare a polymer with weight average molecular weight in the range 50,000-3.0 million, wherein said polymer comprises, in its repeat unit, (i) one or more activated olefins independently selected from the group consisting of a (meth)acrylate, acrylonitrile, (meth)acrylamide, maleimide, itaconimide, citroconimide, maleic anhydride, cyanoacrylate, maleate, fumarate, crotonate, alkylidene malonate and cinnamate and (ii) one or more non-activated olefins independently selected from the group consisting of an unsubstituted alkene, monosubstituted alkene, disubstituted alkene, trisubstituted alkene, allyl ether, allyl ester, allyl sulphide and allylamide, wherein said one or more non-activated olefins constitutes at least 30% of the polymer, said method comprising the steps of:
(a) preparing a solution containing said one or more of activated olefins and said one or more non-activated olefins, optionally in the presence of a solvent;
(b) precomplexing equimolar amounts of said one or more of activated olefins and a Lewis acid to form a mix and adding the mix to the solution in (a) to form a mixture;
(c) optionally adding a radical initiator; and
(d) polymerizing said mixture at temperatures of about −78° C. to about 80° C. for a time sufficient to obtain the desired polymer.
In another embodiment, the activated olefin is a (meth)acrylate wherein said (meth)acrylate is represented by the formula H 2 C═C(G)CO 2 R 1 , where G may be hydrogen, halogen or alkyl of 1 to 6 carbon atoms, and R 1 may be selected from alkyl, cycloalkyl, alkenyl, cycloalkenyl, alkaryl, aralkyl or aryl groups of 1 to 16 carbon atoms, any of which may be optionally substituted or interrupted as the case may be with the moiety selected from the group consisting of silane, silicon, oxygen, halogen, carbonyl, hydroxyl, ester, carboxylic acid, urea, urethane, carbamate, amine, amide, sulfur, sulfonate and sulfone and combinations thereof.
Non-limiting examples of suitable (meth)acrylates are methyl(meth)acrylate, ethyl(meth)acrylate, butyl(meth)acrylate, isobutyl(meth)acrylate, 2-ethylhexyl(meth)acrylate, isooctyl(meth)acrylate, glycidyl(meth)acrylate, cyclohexyl(meth)acrylate, isobornyl(meth)acrylate, benzyl(meth)acrylate, 2-hydroxy(meth)acrylate, trimethoxybutyl(meth)acrylate, ethylcarbitol(meth)acrylate, phenoxyethyl(meth)acrylate, 2-hydroxyethyl(meth)acrylate, trimethylolpropanetri(meth)acrylate, tetramethylolmethane tetra(meth)acrylate, pentaerythritol hexa(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol monohydroxy penta(meth)acrylate, dipentaerythritol hexa(meth)acrylate, 1,4-butyleneglycol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate, polyethyleneglycol di(meth)acrylate and oligoester(meth)acrylate.
In one particularly useful aspect of the invention, the (meth)acrylate is methyl(meth)acrylate, ethyl(meth)acrylate, butyl(meth)acrylate, isobutyl(meth)acrylate, 2-ethylhexyl(meth)acrylate, isooctyl(meth)acrylate, glycidyl(meth)acrylate or cyclohexyl(meth)acrylate.
The non-activated olefin is selected from the group consisting of an unsubstituted alkene, a monosubstituted alkene, a disubstituted alkene and a trisubstituted alkene.
Non-limiting examples of suitable non-activated olefins are ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 2-methyl-pentene, 3-methyl-1-butene, isobutylene, diisobutylene, 2-methyl-1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1,1-dimethylpentene, vinylcyclohexane, cyclopropene, cyclobutene, cyclopentene, cyclohexene, norbornene, limonene, α-pinene, β-pinene, camphene, cis-cyclooctene and trans-cyclooctene.
In one particularly useful aspect of the invention, the non-activated olefin is selected from ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 2-methylpentene, 3-methyl-1-butene, isobutylene or diisobutylene.
In one particularly useful aspect of the invention, the activated olefin is selected from methyl acrylate or n-butyl acrylate, and the non-activated olefin is selected from 2-methylpentene, isobutylene or 1-octene.
A solvent is generally not necessary for the reaction to proceed if the reactants are liquid and soluble enough in each other as well as to dissolve the catalyst sufficiently for the reaction to proceed. However, if a solvent is desired, suitable solvent may be selected from a hydrocarbon, halogenated hydrocarbon, alkyl ester (e.g. ethyl acetate, butyl acetate and the like) or mixtures thereof. Non-limiting examples of suitable solvents are toluene, xylene, benzene, n-hexane, n-heptane, chlorobenzene, methylene chloride, 1,2-dichloroethane, cyclohexane, methyl cyclohexane and mixtures thereof. A particularly preferred solvent is toluene.
The reaction is performed in the presence of a Lewis acid catalyst. Non-limiting examples of suitable Lewis acids include EtAlCl 2 , ethyl aluminum sesquichloride, ZnCl 2 , AlCl 3 , AlBr 3 , BF 3 , TiCl 4 and combinations thereof. The choice of the Lewis acid depends on any solvent selected for the reaction since solubility of the Lewis acid in that particular solvent should be taken into consideration. A particularly preferred Lewis acid is EtAlCl 2 .
The activated olefin and the Lewis acid catalyst are ideally precomplexed to form a mix prior to the addition of the copolymerization reactant mixture.
A free radical initiator is not always necessary for the polymerization reaction to proceed. Thus, it was found that the polymerization reaction could be performed with an initiator as well as without initiator to satisfactory and desired yields, conversion and molecular weights. If an initiator is used, suitable radical initiators may be selected from the group consisting of benzoyl peroxide, methyl ethyl ketone peroxides, di-t-butyl peroxide, di-t-amyl peroxide, dicumyl peroxide, diacyl peroxide, decanoyl peroxide, lauroyl peroxide, 2,4-dichlorobenzoyl peroxide, t-butyl perbenzoate, cumene hydroperoxide (CHP), 2,5-bis(t-butylperoxy) 2,5-dimethylhexane, peroxydicarbonates, peroxyesters, dialkyl peroxides, hydroperoxide, peroxyketals, 4,4′-azobis(4-cyanovaleric acid), 1,1′-azobis(cyclohexanecarbonitrile), 2,2′-azobisisobutyronitrile (“AIBN”), and mixtures thereof. A particularly preferred initiator in such cases is benzoyl peroxide. Free radical initiators may be incorporated in any amounts useful to achieve the desired reaction or cure. Desirably, they are present in amounts of about 0.01% to about 10% by weight of the total composition. Combinations of the free-radical initiators are also useful.
The reaction temperature and duration may be selected as is suitable or sufficient to obtain the desired polymer in desired yields. Reaction temperatures, for example, may range generally from about −78° C. to about 80° C., specifically from about −78° C. to about 40° C. and more specifically from about −78° C. to about the room temperature (“RT”).
In an illustrative process of the invention, methyl acrylate (“MA”, 1 eq) and isobutylene (“IB”, 10 eq) were reacted in the presence of benzoyl peroxide (“BPO”, 0.01 eq) as radical initiator and EtAlCl 2 (0.2 eq) as Lewis acid in toluene solvent. The Lewis acid was complexed with equimolar amount of the acrylate prior to the addition of the copolymerization mixture. Several runs were performed and the copolymers in the molecular weight range 500,000-1.5 million were obtained (Table 1, entries 1 and 2). Higher molecular weights copolymers were also obtained even with higher alkene such as 1-octene (entry 3). 1,1-Disubstituted alkene such as 2-methyl pentene also gave higher molecular weight copolymer under similar conditions (entry 4). These results established that high molecular weight copolymers with high olefin content can be obtained under low temperature conditions in the presence of Lewis acids. The excess olefin can be distilled and recycled to make the process more economical.
TABLE 1
Copolymerization study of olefins (10 eq) and acrylates (1 eq) in
the presence of 0.01 eq of BPO and 0.2 eq of EtAlCl 2 in toluene
Acrylate:Olefin
Entry
Acrylate
Olefin
Mol. wt. Range
ratio
1
MA
Isobutylene
500,000-1.5 million
~1:1
2
n-BA
isobutylene
500,000-1.5 million
~1:1
3
n-BA
1-Octene
200,000-400,000
~1:1
4
n-BA
2-methyl
~250,000
~1:1
pentene
Table 2 lists the properties (e.g. mol. weights) of several other polymers prepared by the process of the invention, demonstrating the flexibility of the process as well as the feasibility to produce polymers with tailor-made properties by adjusting the reaction conditions suitably.
TABLE 2
Lewis
Non-activated
acid(eq)/initiator
Entry
Acrylate
Olefin
Temp.
Solvent
Initiator
(eq)
Mol. Wt.
1
n-BA
2-
RT
Toluene
BPO
0.2/0.01
90,000
methylpentene
2
n-BA
2-
−40° C.
Toluene
BPO
0.2/0.01
242,000
methylpentene
3
n-BA
1-Octene
RT
Toluene
BPO
0.2/0.01
183,000
4
n-BA
1-Octene
−40° C.
none
BPO
0.2/0.01
340,000
5
MA
1-Octene
RT
Toluene
BPO
0.2/0.01
127,634
6
MA
1-Octene
−40° C.
toluene
BPO
0.2/0.01
304,512
7
n-BA
1-Octene
−40° C.
None
BPO
0.4/0.02
260,000
8
n-BA
1-Octene
−40° C.
Toluene
BPO
0.4/0.02
150,000
9
n-BA
1-Octene
−40° C.
None
BPO
0.2/0.01
580,000
10
n-BA
1-Octene
−40° C.
Toluene
BPO
0.2/0.01
236,000
Characterization
1 H and 13 C NMR spectral techniques were used to establish % of alkene and acrylate present in the copolymer. The data indicated that all of these copolymers contained olefins and acrylates in approximately 1:1 ratio. A copolymerization experiment was performed by lowering the 1-octene reactant ratio from 10:1 to 4:1 with respect to acrylate. However, this did not appear to affect the 1-octene content in the copolymer significantly. GC/pyrolysis data of several copolymers indicated mostly alternating type sequence of alkene and acrylate in the copolymer. Alkene-acrylate dimeric and trimeric fragments appeared in the GC pyrolysis spectrum, which indicated mostly alternating type of sequence. The polymers obtained by the inventive process had high weight average molecular weights. Weight average molecular weights of about 50,000 to about 3.0 million could be routinely obtained in the polymers.
The reaction lends itself to the preparation of copolymers, terpolymers and the like with equal ease. Several such reactions are described in more detail in the Examples section. Functionalized polymers could be prepared as well. Polymers with suitable functionalities could be prepared. Non-limiting examples of such functionalities include functional groups such as epoxy, carboxylic acid, hydroxy, thiol, amide, oxazoline, acetoacetate, isocyanate, carbamate, aceto, amine, amine salt, quaternized amine, thioether, sulfide, sulfonium salt, acetophenone, acyl phosphine oxide, thioxanthone, benzoin ether, benzyl ketal, siloxy, cyano, cyanoacrylate, cyanoacetate, alkyl ether, reactive silanes such as alkoxy silanes, e.g., tetramethyoxysilane, epoxyether and vinyl ether and combinations thereof. The functional groups could be introduced by processes such as, for example, starting with a functional group-containing monomer as a reactant or preparing a non-functionalized polymer which is further reacted with suitable reagents to introduce the functional groups. Creating functional ends on the polymer may also be done by performing an end-capping reaction. For example, these groups may be added to one or more of the terminal ends of the inventive resin via reaction with compounds containing these functionalities.
In another embodiment, the present invention includes reaction products (polymers) formed by the inventive process described above. Thus, in an embodiment, the invention provides a reaction product prepared by a Lewis acid-catalyzed copolymerization reaction, wherein said product comprises, in its repeat unit, one or more activated olefins and at least 30% content of one or more non-activated olefins, and has a weight average molecular weight in the range 50,000-3.0 million, wherein said one or more activated olefins are independently selected from the group consisting of a (meth)acrylate, acrylonitrile, (meth)acrylamide, maleimide, itaconimide, citroconimide, maleic anhydride, cyanoacrylate, maleate, fumarate, crotonate, cinnamate and alkylidene malonate, and said one or more non-activated olefins are independently selected from the group consisting of an unsubstituted alkene, monosubstituted alkene, disubstituted alkene, trisubstituted alkene, allyl ether, allyl ester, allyl sulfide and allyl amide.
The reaction product can be a copolymer, terpolymer and the like. The copolymer, terpolymer and the like may also comprise one or more crosslinkable functionalities such as, for example, those described above.
In yet another embodiment, the present invention includes materials or articles formed using the reaction products of the invention. Non-limiting examples of such materials and articles include an adhesive, an elastomer, a toughener for a cyanoacrylate and/or epoxy, a polymeric photoinitiator or a personal care product.
The present invention is further described by the Examples shown below. The Examples are provided for illustrative purposes only and are not to be considered as limiting the scope of the invention or the claims in any way.
EXAMPLES
Example 1
Synthesis of Methyl Acrylate (MA) and Isobutylene Copolymer
In a 500 mL 4 necked round bottom flask equipped with a stainless steel stirrer with banana shaped blade, thermometer, cold finger condenser, nitrogen inlet and a cold finger condenser containing dry ice-acetone bath was taken 65.6 g of toluene. The reaction flask was purged with nitrogen while it was cooled using dry ice-o-xylene cooling mixture. 90 g of isobutylene was transferred to the flask.
In another separate flask 0.43 g of BPO in 13.3 g of methyl acrylate (MA) was dissolved and transferred to the reaction flask.
In a separate flask 2.1 g of MA and 2.4 g toluene were taken in a 100 mL 1 necked round bottom flask. Nitrogen was purged through the flask while it was cooled using an ice bath. 19.5 mL of 25 wt % ethyl aluminum dichloride was added to this flask dropwise with occasional swirling. After about 5 minutes, the solution containing the precomplex was transferred to the main reaction flask using a syringe. The mixture was stirred at −40° C. for 8 h and at RT overnight. Next day, the reaction was quenched using 20 g of isopropanol. The mixture was transferred to a separatory funnel, washed several times with water, and dried over anhydrous sodium sulfate. After filtering the solvent was evaporated using rotovap to give the copolymer (26 g). The composition was determined by proton NMR and the molecular weight was determined by GPC.
Example 2
Synthesis of n-butyl acrylate/1-Octene Copolymer
In a 500 mL 4 necked round bottom flask equipped with a stainless steel stirrer with banana shaped blade, thermometer, cold finger condenser, nitrogen inlet and a cold finger condenser containing dry ice-acetone bath were taken 40 g of toluene and 40 g of 1-octene. The reaction flask was purged with nitrogen while it was cooled using dry ice-o-xylene cooling mixture.
In a separate flask 86 mg of BPO in 3.66 g of butyl acrylate (BA) was dissolved and transferred to the reaction flask.
In another separate flask 0.91 g of BA and 2 g toluene were taken in a 100 mL 1 necked round bottom flask. Nitrogen was purged through the flask while it was cooled using an ice bath. 3.9 mL of 25 wt % toluene solution of ethyl aluminum dichloride was added to this flask drop wise with occasional swirling. After about 5 minutes, the solution containing the precomplex was transferred to the main reaction flask using a syringe. The mixture was stirred at −40° C. for 8 h and at RT overnight. Next day, the reaction was quenched using 20 g of isopropanol. The mixture was transferred to a separatory funnel, washed several times with water, and dried over anhydrous sodium sulfate. After filtering the solvent was evaporated using rotovap to give the copolymer (8 g). The composition was determined by proton NMR and the molecular weight was determined by GPC.
Example 3
Synthesis of Butyl Acrylate and Isobutylene Copolymer
In a 500 mL 4 necked round bottom flask equipped with a stainless steel stirrer with banana shaped blade, thermometer, cold finger condenser, nitrogen inlet and a cold finger condenser containing dry ice-acetone bath was taken 110.8 g of toluene. The reaction flask was purged with nitrogen while it was cooled using dry ice-o-xylene cooling mixture. 150 g of isobutylene was transferred to the flask.
In a separate flask 0.72 g of BPO in 30.46 g of butyl acrylate (BA) was dissolved and transferred to the reaction flask.
In another separate flask 7.61 g of BA and 8 g toluene were taken in a 100 mL 1 necked round bottom flask. Nitrogen was purged through the flask while it was cooled using an ice bath. 32.54 mL of 25 wt % toluene solution of ethyl aluminum dichloride was added to this flask dropwise with occasional swirling. After about 5 minutes, the solution containing the precomplex was transferred to the main reaction flask using a syringe. The mixture was stirred at −40° C. for 8 h and at RT overnight. Next day, the reaction was quenched using 20 g of isopropanol. The mixture was transferred to a separatory funnel, washed several times with water, and dried over anhydrous sodium sulfate. After filtering the solvent was evaporated using rotovap to give the copolymer (58.5 g). The composition was determined by proton NMR and the molecular weight was determined by GPC.
Example 4
Synthesis of Butyl Acrylate (BA), Ethyleneglycol Phenylether Acrylate and 1-Octene Terpolymer
(m and n indicate the amount of each monomer moiety incorporated into the repeat unit of the polymer.)
In a 500 mL 4 necked round bottom flask equipped with a stainless steel stirrer with banana shaped blade, thermometer, cold finger condenser, nitrogen inlet and a cold finger condenser containing dry ice-acetone bath were taken 130 g of toluene and 175 g of 1-octene. The reaction flask was purged with nitrogen while it was cooled using dry ice-o-xylene cooling mixture.
In a separate flask 0.76 g of BPO in 34 g of butyl acrylate (BA) was dissolved and transferred to the reaction flask.
In another separate flask 6 g of BA, 3 g of ethyleneglycol phenyl ether acrylate and 8 g toluene were taken in a 100 mL 1 necked round bottom flask. Nitrogen was purged through the flask while it was cooled using an ice bath. 34.2 mL of 25 wt % toluene solution of ethyl aluminum dichloride was added to this flask drop wise with occasional swirling. After about 5 minutes, the solution containing the precomplex was transferred to the main reaction flask using a syringe. The mixture was stirred at −40° C. for 8 h and at RT overnight. Next day, the reaction was quenched using 20 g of isopropanol. The mixture was transferred to a separatory funnel, washed several times with water, and dried over anhydrous sodium sulfate. After filtering the solvent was evaporated using rotovap to give the terpolymer (crude 67.8 g). The composition was determined by proton NMR and the molecular weight was determined by GPC.
Example 5
Synthesis of Copolymer of Methyl Methacrylate (MMA) and 1-Octene
In a 500 mL 4 necked round bottom flask equipped with a stainless steel stirrer with banana shaped blade, thermometer, cold finger condenser, nitrogen inlet and a cold finger condenser containing dry ice-acetone bath were taken 40 mL of toluene and 56.1 g of 1-octene. The reaction flask was purged with nitrogen while it was cooled using dry ice-o-xylene cooling mixture.
In a separate flask 0.24 g of BPO in 8 g of methyl methacrylate (MMA) was dissolved and transferred to the reaction flask.
In another separate flask 2 g of MMA and 2 mL toluene were taken in a 100 mL 1 necked round bottom flask. Nitrogen was purged through the flask while it was cooled using an ice bath. 11 mL of 25 wt % toluene solution of ethyl aluminum dichloride was added to this flask drop wise with occasional swirling. After about 5 minutes, the solution containing the precomplex was transferred to the main reaction flask using a syringe. The mixture was stirred at −40° C. for 8 h and at RT overnight. Next day, the reaction was quenched using 20 g of isopropanol. The mixture was transferred to a separatory funnel, washed several times with water, and dried over anhydrous sodium sulfate. After filtering the solvent was evaporated using rotovap to give the copolymer (2 g). The composition was determined by proton NMR and the molecular weight was determined by GPC.
Example 6
Synthesis of Butyl Acrylate (BA), Benzylacrylate and 1-Octene Terpolymer
In a 500 mL 4 necked round bottom flask equipped with a stainless steel stirrer with banana shaped blade, thermometer, cold finger condenser, nitrogen inlet and a cold finger condenser containing dry ice-acetone bath were taken 115 g of toluene and 87.6 g of 1-octene. The reaction flask was purged with nitrogen while it was cooled using dry ice-o-xylene cooling mixture.
In a separate flask 0.38 g of BPO in 16 g of butyl acrylate (BA) and 1.27 g of benzyl acrylate was dissolved and transferred to the reaction flask.
In another separate flask 4 g of BA and 5 mL toluene were taken in a 100 mL 1 necked round bottom flask. Nitrogen was purged through the flask while it was cooled using an ice bath. 17.1 mL of 25 wt % toluene solution of ethyl aluminum dichloride was added to this flask drop wise with occasional swirling. After about 5 minutes, the solution containing the precomplex was transferred to the main reaction flask using a syringe. The mixture was stirred at −40° C. for 8 h and at RT overnight. Next day, the reaction was quenched using 20 g of isopropanol. The mixture was transferred to a separatory funnel, washed several times with water, and dried over anhydrous sodium sulfate. After filtering the solvent was evaporated using rotovap to give the terpolymer (36.9 g, crude). The composition was determined by proton NMR and the molecular weight was determined by GPC.
Example 7
Synthesis of Butyl Acrylate (BA) and Diisobutylene Copolymer
In a 500 mL 4 necked round bottom flask equipped with a stainless steel stirrer with banana shaped blade, thermometer, cold finger condenser, nitrogen inlet and a cold finger condenser containing dry ice-acetone bath was taken 80 g of toluene and 87.6 g of diisobutylene. The reaction flask was purged with nitrogen while it was cooled using dry ice-o-xylene cooling mixture.
In another separate flask 0.38 g of BPO in 20 g of butyl acrylate (BA) was dissolved and transferred to the reaction flask.
In a separate flask 4 g of BA and 4 mL of toluene were taken in a 100 mL 1 necked round bottom flask. Nitrogen was purged through the flask while it was cooled using an ice bath. 17.1 mL of 25 wt % ethyl aluminum dichloride was added to this flask dropwise with occasional swirling. After about 5 minutes, the solution containing the precomplex was transferred to the main reaction flask using a syringe. The mixture was stirred at −40° C. for 8 h and at RT overnight. Next day, the reaction was quenched using 20 g of isopropanol. The mixture was transferred to a separatory funnel, washed several times with water, and dried over anhydrous sodium sulfate. After filtering the solvent was evaporated using rotovap to give the copolymer (26.6 g, crude). The composition was determined by proton NMR and the molecular weight was determined by GPC.
Example 8
Synthesis of butyl acrylate (BA), 4[2-acryloxyethoxy]benzophenone and 1-Octene Terpolymer
In a 500 mL 4 necked round bottom flask equipped with a stainless steel stirrer with banana shaped blade, thermometer, cold finger condenser, nitrogen inlet and a cold finger condenser containing dry ice-acetone bath were taken 40 g of toluene and 40 g of 1-octene. The reaction flask was purged with nitrogen while it was cooled using dry ice-o-xylene cooling mixture.
In a separate flask 0.17 g of BPO in 7.34 g of butyl acrylate (BA) was dissolved and transferred to the reaction flask.
In another separate flask 1.34 g of BA, 1.05 g of 4[2-acryloxyethoxy]benzophenone and 2 g toluene were taken in a 100 mL 1 necked round bottom flask. Nitrogen was purged through the flask while it was cooled using an ice bath. 7.81 mL of 25 wt % toluene solution of ethyl aluminum dichloride was added to this flask drop wise with occasional swirling. After about 5 minutes, the solution containing the precomplex was transferred to the main reaction flask using a syringe. The mixture was stirred at −40° C. for 8 h and at RT overnight. Next day, the reaction was quenched using 20 g of isopropanol. The mixture was transferred to a separatory funnel, washed several times with water, and dried over anhydrous sodium sulfate. After filtering the solvent was evaporated using rotovap to give the terpolymer (8 g). The composition was determined by proton NMR (benzophenone protons at 6-8.8 ppm) and the molecular weight was determined by Gel Permeation Chromatography (“GPC”). The GPC analysis was performed using both RI and UV techniques. UV GPC indicated the presence of UV active polymer peaks similar to those indicated by the RI detector. This established the incorporation of 4-[2-acryloxyethoxy]benzophenone unit in the terpolymer.
Example 9
Synthesis of Butyl Acrylate (BA) and 1-Octene Copolymer in the Absence of Radical Initiator
In a 500 mL 4 necked round bottom flask equipped with a stainless steel stirrer with banana shaped blade, thermometer, cold finger condenser, nitrogen inlet and a cold finger condenser containing dry ice-acetone bath were taken 40 g of toluene and 40 g of 1-octene. The reaction flask was purged with nitrogen while it was cooled using dry ice-o-xylene cooling mixture. 3.66 g of butyl acrylate (BA) was transferred to the reaction flask.
In another separate flask 0.91 g of BA and 2 g toluene were taken in a 100 mL 1 necked round bottom flask. Nitrogen was purged through the flask while it was cooled using an ice bath. 3.9 mL of 25 wt % toluene solution of ethyl aluminum dichloride was added to this flask drop wise with occasional swirling. After about 5 minutes, the solution containing the precomplex was transferred to the main reaction flask using a syringe. The mixture was stirred at −40° C. for 8 h and at RT overnight. Next day, the reaction was quenched using 20 g of isopropanol. The mixture was transferred to a separatory funnel, washed several times with water, and dried over anhydrous sodium sulfate. After filtering the solvent was evaporated using rotovap to give the copolymer (4 g). The composition was determined by proton NMR and the molecular weight was determined by GPC.
By following a similar method, a copolymer of MA and 1-octene was also synthesized in the absence of a free radical initiator.
The polymers were found to have the following data
Non-activated
Acrylate:Octene
Entry
Acrylate
Olefin
Mol. Wt.
ratio by 1 HNMR
1
n-BA
1-octene
242,000
50:50
2
MA
1-Octene
300,000
53:47
Example 10
Synthesis of Methyl Acrylate/1-Octene Copolymer at Room Temperature
In a 500 mL 4 necked round bottom flask equipped with a stainless steel stirrer with banana shaped blade, thermometer, cold finger condenser, nitrogen inlet and a cold finger condenser containing dry ice-acetone bath were taken 94 g of toluene and 150 g of 1-octene. The reaction flask was purged with nitrogen.
In a separate flask 81 mg of BPO in 23 g of methyl acrylate (MA) was dissolved and transferred to the reaction flask.
In another separate flask 5.75 g of MA and 6 g toluene were taken in a 100 mL 1 necked round bottom flask. Nitrogen was purged through the flask while it was cooled using an ice bath. 36.6 mL of 25 wt % toluene solution of ethyl aluminum dichloride was added to this flask drop wise with occasional swirling. After about 5 minutes, the solution containing the precomplex was transferred to the main reaction flask using a syringe. The mixture was stirred at −40° C. for 8 h and at RT overnight. Next day, the reaction was quenched using 20 g of isopropanol. The mixture was transferred to a separatory funnel, washed several times with water, and dried over anhydrous sodium sulfate. After filtering the solvent was evaporated using rotovap to give the copolymer (44 g). The composition was determined by proton NMR and the molecular weight was determined by GPC.
BA and 1-Octene compositions were also synthesized at room temperature.
Example 11
Synthesis of Methyl Acrylate (MA) and 1-Octene Copolymer in the Absence of Radical Initiator
In a 500 mL 4 necked round bottom flask equipped with a stainless steel stirrer with banana shaped blade, thermometer, cold finger condenser, nitrogen inlet and a cold finger condenser containing dry ice-acetone bath were, taken 94 g of toluene and 150 g of 1-octene. The reaction flask was purged with nitrogen while it was cooled using dry ice-o-xylene cooling mixture. 23 g of methyl acrylate (MA) was transferred to the reaction flask.
In another separate flask 5.75 g of MA and 6 g toluene were taken in a 100 mL 1 necked round bottom flask. Nitrogen was purged through the flask while it was cooled using an ice bath. 36.6 mL of 25 wt % toluene solution of ethyl aluminum dichloride was added to this flask drop wise with occasional swirling. After about 5 minutes, the solution containing the precomplex was transferred to the main reaction flask using a syringe. The mixture was stirred at −40° C. for 8 h and at RT overnight. Next day, the reaction was quenched using 20 g of isopropanol. The mixture was transferred to a separatory funnel, washed several times with water, and dried over anhydrous sodium sulfate. After filtering the solvent was evaporated using rotovap to give the copolymer (16.5 g). The composition was determined by proton NMR and the molecular weight was determined by GPC.
Example 12
Synthesis of Butyl Acrylate (BA), 4-Allyloxy Benzophenone and 1-Octene Terpolymer
Example 8 described the synthesis of a terpolymer where the benzophenone moiety was part of the acrylate unit. Conversely, the terpolymer where the benzophenone moiety is part of the olefin (and not the acrylate) could also be prepared by a similar process where n-BA, 1-octene and 4-allyloxy benzophenone were polymerized at RT as shown below.
In a 500 mL 4 necked round bottom flask equipped with a stainless steel stirrer with banana shaped blade, thermometer, cold finger condenser, nitrogen inlet and a cold finger condenser containing dry ice-acetone bath were taken 171 g of toluene, 20 g 4-allyloxy benzophenone and 37.5 g of 1-octene. The reaction flask was purged with nitrogen while it was cooled using dry ice-o-xylene cooling mixture.
In a separate flask 0.41 g of BPO in 17 g of butyl acrylate (BA) was dissolved and transferred to the reaction flask.
In another separate flask 4 g of BA and 4 g toluene were taken in a 100 mL 1 necked round bottom flask. Nitrogen was purged through the flask while it was cooled using an ice bath. 18.3 mL of 25 wt % toluene solution of ethyl aluminum dichloride was added to this flask drop wise with occasional swirling. After about 5 minutes, the solution containing the precomplex was transferred to the main reaction flask using a syringe. The mixture was stirred at −40° C. for 8 h and at RT overnight. Next day, the reaction was quenched using 20 g of isopropanol. The mixture was transferred to a separatory funnel, washed several times with water, and dried over anhydrous sodium sulfate. After filtering the solvent was evaporated using rotovap to give the crude terpolymer. The crude terpolymer was purified by precipitating it from methanol. Purified terpolymer (27 g) was obtained. The molecular weight was determined by GPC. 1 H NMR analysis of the terpolymer after purification clearly showed the incorporation of 5 mol % of benzophenone. Absence of allylic protons in the NMR confirmed that the benzophenone moiety was polymer bound.
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The present invention discloses polymers prepared from polar vinyl monomers and non-polar olefin monomers with the polymers having high olefin content and high weight average molecular weights as well as methods of preparing them. The inventive polymers possess interesting properties that make them particularly attractive in several industrial applications.
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[0001] This application claims the benefit of U.S. Provisional Application No. 60/239,311 filed on Oct. 10, 2000 in the names of T. O. Fanta et al.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to a compact operating mechanism for switches and circuit interrupters with improved input drive arrangement and more particularly to a quick-make quick-break operating mechanism for electrical circuit interrupters, i.e. load-interrupter switches and fault interrupters, the drive input arrangement being capable of either power or manual operation without the necessity of any coupling/decoupling or mode selection.
[0004] 2. Description of Related Art
[0005] Various operating mechanisms for electrical switches and circuit interrupters provide multiple operational states at an output corresponding to the desired operational states of the switch controlled by the mechanism. For example, U.S. Pat. Nos. 5,895,987 and 6,025,657 are directed to a power operator capable of manual or power operation without decoupling. Additionally, U.S. Pat. No. 4,146,764 is directed to a spring-operated closing mechanism for a circuit breaker that does not require coupling/decoupling, the arrangement including side-by-side ratchet control plates with multiple rods passing therethrough that function as pawls. A separate opening spring is utilized for the opening function. Considering other operating mechanisms, U.S. Pat. No. 3,563,102 discloses a quick-make quick-break mechanism for operating a switch between open and closed positions. Other operating mechanisms are shown in the following U.S. Pat. Nos. 3,845,433; 4,293,834; 5,140,117; and 5,224,590.
SUMMARY OF THE INVENTION
[0006] Accordingly, it is a principal object of the present invention to provide a compact operating mechanism for switches and circuit interrupters with improved input drive arrangement and more particularly to a quick-make quick-break operating mechanism for electrical circuit interrupters, i.e. load-interrupter switches and fault interrupters, the drive input arrangement being capable of either power or manual operation without the necessity of any coupling/decoupling or mode selection.
[0007] It is another object of the present invention to provide a compact operating mechanism that incorporates manual and power drive inputs without the necessity of coupling/decoupling functions.
[0008] These and other objects of the present invention are achieved by a compact operating mechanism for switches and circuit interrupters with improved input drive arrangement and more particularly to a quick-make quick-break operating mechanism for electrical circuit interrupters, i.e. load-interrupter switches and fault interrupters, the drive input arrangement being capable of either power or manual operation without the necessity of any coupling/decoupling or mode selection.
BRIEF DESCRIPTION OF THE DRAWING
[0009] The invention, both as to its organization and method of operation, together with further objects and advantages thereof, will best be understood by reference to the specification taken in conjunction with the accompanying drawing in which:
[0010] [0010]FIG. 1 is a front elevational view of a switch incorporating the operating mechanism in accordance with the principles of the present invention;
[0011] [0011]FIGS. 2 and 3 are front elevational views of the operating mechanism of FIG. 1 with parts cut away and removed for clarity;
[0012] [0012]FIG. 4 is an enlarged elevational view of the operating mechanism of FIGS. 2 and 3 and illustrating a different operative position;
[0013] [0013]FIG. 5 is an elevational view of the ratchet wheel of the operating mechanism of FIGS. 2 - 4 ; and
[0014] [0014]FIGS. 6 and 7 are partial views on an enlarged scale of portions of the operating mechanism of FIGS. 2 - 4 and illustrating operating control features thereof.
DETAILED DESCRIPTION
[0015] Referring now to FIG. 1, an operating mechanism 10 of the present invention is of the quick-make, quick-break variety and is useful to provide operation of a circuit interrupter, e.g. in a specific application, a group-operated switch 12 as shown in FIG. 1 and in U.S. Pat. Nos. 4,938,792, 5,075,521, 5,091,616 and 5,103,111. In response to power supply connections and control signals, the operating mechanism 10 charges a stored energy mechanism and controls operation thereof between an open position and a closed position. Additionally, the operating mechanism 10 in response to a manual input at 20 , operates between open and closed positions. The operating mechanism 10 includes a housing 16 having a removable cover portion 18 . Referring now additionally to FIGS. 2 - 5 , the operating mechanism 10 includes a stored-energy mechanism 24 , that is rotated via a drive input 26 . The operating mechanism 10 via a drive output lever 29 at an output at 27 operates the drive linkage of the switch, e.g. at 31 in FIG. 1 and at 93 , 95 of FIG. 5 in U.S. Pat. No. 5,091,616. The stored energy mechanism 24 is of the general type shown in U.S. Pat. Nos. 3,563,102 and 5,075,521. The drive input 26 is driven through a linkage 28 which in turn is connected to be driven at 30 from a drive arrangement 32 . The drive arrangement at 32 includes a ratchet wheel 34 that fixedly carries a drive lever 36 , a distal end 38 of the drive lever 36 including a pin 40 to provide connection to the linkage 28 at 30 . The ratchet wheel 34 is rotatably carried about an output shaft 50 of a motor drive 52 . As seen in FIG. 5, the ratchet wheel 34 is driven by a pair of pawls 42 , 44 mounted within a hub 46 carried within the ratchet wheel 34 having internal ratchet teeth 48 , the hub 46 being keyed to the output shaft 50 and being spring-biased at 54 in an outward direction. For manual operation, a manual drive lever 60 is provided that includes a manual drive pawl 62 pivotally carried by the manual drive lever 60 , the manual drive pawl 62 also being characterized as an indexing pawl since multiple strokes of the manual drive lever 60 are required as will be explained in detail hereinafter. The manual drive lever 60 is pivotally mounted at 50 and includes a bumper at 64 . The ratchet wheel 34 includes external ratchet teeth 37 arranged about the outer periphery 35 of the ratchet wheel 34 . The drive pawls 42 , 44 are overdriven during the manual driving of the ratchet wheel 34 via the indexing pawl 62 thereby not backdriving the motor drive 52 . Correspondingly, during power operation, the manual drive pawl 62 is overdriven as the ratchet wheel 34 is rotated by the pawls 42 , 44 . A holding pawl 70 is provided to prevent backdriving of the stored energy mechanism 24 and the ratchet wheel 34 .
[0016] In normal operation where a power supply is present, the operating mechanism 10 charges the stored energy mechanism 24 to a predetermined pre-charged point prior to an opening or closing operation such that the operating mechanism 10 is always ready for a fast open or close operation upon command. When it is desired to change the state of the operating mechanism 10 , e.g. from open to closed or closed to open, the operating mechanism 10 is controlled via the output shaft 50 of the motor drive 52 to drive the stored-energy mechanism 24 beyond the pre-charged state and past the release point of the stored-energy mechanism 24 thereby causing operation. The motor drive 52 immediately recharges the stored-energy mechanism 24 to the pre-charged state for the next operation.
[0017] When a power supply is not present, manual operation is available via the manual input at 20 to operate the operating mechanism 10 to change the state of the driven switch. Specifically, a manually operable arrangement 100 including a pull ring 102 that is reciprocated between the positions of FIGS. 2 and 3 a number of times to charge and operate the stored-energy mechanism 24 . The manually operable arrangement 100 includes a pull rod 104 biased by a spring 106 with the spring being retained between the cover 18 and the pull rod 104 and being compressed upon each downward stroke of the pull ring 102 . Thus, the pull rod is returned under the bias of the spring 106 . The pull rod 104 is connected at 108 to pivot the manual drive lever 60 .
[0018] For normal operation where a power supply is present and considering now the arrangement of the operating mechanism 10 to charge the stored energy mechanism 24 to the predetermined pre-charged point and referring specifically now to FIGS. 4, 6 and 7 , two control grooves 120 , 122 arranged on the periphery of an outside hub 39 of the ratchet wheel 34 cooperate with a limit switch assembly 124 . The limit switch 124 is arranged to control power to the motor drive 52 . The limit switch assembly 124 includes an intermediate lever 126 that is biased toward the ratchet wheel 34 via a spring 128 and that is positioned to ride on the outside hub 39 of the ratchet wheel 34 . When the motor drive 52 has charged the stored energy mechanism 24 to the pre-charged state, the intermediate lever 126 moves into one of the control grooves 120 , 122 actuating the limit switch 124 which turns off the motor drive 52 as illustrated in FIG. 7. Thus, the operating mechanism 10 is maintained in the pre-charged position for either opening or closing upon command. The positions illustrated in FIG. 6 depicts the position of the intermediate lever 126 just prior to actuation of the limit switch 124 before reaching the pre-charged position. The expanse and shape of the control grooves 120 , 122 permit back driving and coasting of the motor drive 52 without deactuating the limit switch 124 .
[0019] Considering now an interlock feature of the operating mechanism 10 to prevent manual operation when a disconnect switch of the group-operated switch 12 is in an open position, a movable cam surface 130 is provided to lift the manual indexing pawl 62 via contact thereof away from engagement with the ratchet wheel 34 as shown in FIG. 4. Thus, operation of the manual drive lever 60 will neither charge nor trip the operating mechanism 10 . Movement of the disconnect operating linkage 17 (FIG. 1) is communicated to the operating mechanism 10 via a connecting member 19 .
[0020] While there have been illustrated and described various embodiments of the present invention, it will be apparent that various changes and modifications will occur to those skilled in the art. Accordingly, it is intended in the appended claims to cover all such changes and modifications that fall within the true spirit and scope of the present invention.
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A compact operating mechanism for switches and circuit interrupters provides improved input drive arrangement and more particularly to a quick-make quick-break operating mechanism for electrical circuit interrupters, i.e. load-interrupter switches and fault interrupters, the drive input arrangement being capable of either power or manual operation without the necessity of any coupling/decoupling or mode selection.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention concerns a dispenser for vertically stacked uniformly sized packages, and more particularly relates to a lockable wall-mounted dispenser for packages of cigarettes.
2. Description of the Prior Art
Vending machines for packages of cigarettes are well known. As disclosed in U.S. Pat. Nos. 4,130,326; 5,351,854; 5,397,016; 5,407,094 and elsewhere, such machines comprise a locked chamber for holding a multitude of cigarette packages in a stacked array, means for receiving payment, and means for sequentially dispensing the packages, usually by a gravity fall technique.
Adults who enjoy cigarette smoking often do not want their children to take up the cigarette-smoking pastime. In the home environment therefore, the smoking adults would like to have ready access to packages, but would prefer to deny such access to their children or other unauthorized persons.
U.S. Pat. No. D 249,764 to Burklacish discloses a wall-mounted dispenser for vertically stacked packages of cigarettes. Although well suited for use in a residential dwelling, the Burklacish dispenser has no provision for preventing unauthorized removal of packages.
It is accordingly an object of the present invention to provide wall-mounted apparatus for the storage and dispensing of packages of cigarettes.
It is a further object of this invention to provide apparatus as in the foregoing object which can be secured with respect to unauthorized dispensation.
It is another object of the present invention to provide apparatus of the aforesaid nature which is easy to use and of durable simple construction amenable to low cost manufacture.
These objects and other objects and advantages of the invention will be apparent from the following description.
SUMMARY OF THE INVENTION
The above and other beneficial objects and advantages are accomplished in accordance with the present invention by a wall-mountable apparatus for securably dispensing packages of cigarettes, said apparatus comprising:
1) a vertically elongated interior casing comprised of a top portion, opposed side panels and a flat rear panel having means for attachment to a vertical wall,
2) an exterior shell comprised of a sidewall panel having a front portion, a horizontally disposed lower edge, vertically disposed rear edges, an upper panel portion, and a vertical slot in said front portion that opens onto said lower edge, said exterior shell configured to embrace said interior casing and joined thereto by way of pivot means which permit swinging movement of said exterior shell in a vertical path between an upper position which encloses said interior casing and a lower position which exposes said interior casing,
3) a basket tray disposed within said interior casing and adapted to hold a vertically stacked multitude of packages of cigarettes, said basket tray comprised of opposed vertical retaining walls, an upper extremity having a horizontally disposed abutment panel, and a lower extremity having a horizontally disposed serving panel,
4) means for permitting reciprocal vertical movement of said basket tray between a dispensing lower state wherein said serving panel is disposed below the lower edge of said exterior shell to a sufficient extent to permit removal of a package of cigarettes from said basket tray, and a locked upper state wherein said serving panel is spaced too close to said lower edge to permit removal of a package of cigarettes from said basket tray,
5) first locking means for preventing unauthorized movement of said basket tray to its dispensing state, and
6) second locking means for securing said exterior shell in said upper position.
BRIEF DESCRIPTION OF THE DRAWING
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawing forming a part of this specification and in which similar numerals of reference indicate corresponding parts in all the figures of the drawing:
FIG. 1 is a front and side perspective view of an embodiment of the dispenser of the present invention shown in its dispensing state.
FIG. 2 is an exploded perspective view of the embodiment of FIG. 1.
FIG. 3 is a vertical sectional side view of the embodiment of FIG. 1.
FIG. 4 is a sectional view taken in the direction of the arrows upon the line 4--4 of FIG. 3.
FIG. 5 is a sectional view taken in the direction of the arrows upon the line 5--5 of FIG. 4.
FIG. 6 is an enlarged fragmentary view of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1-6, an embodiment of the dispensing device 10 of the present invention is shown comprised of interior casing 12, exterior shell 13 adapted to pivotally embrace said interior casing, and basket tray 14 adapted to reside within said interior casing.
Interior casing 12 is vertically elongated between upper and lower extremities 15 and 16, respectively, and is further comprised of top portion 17, left and right side panels 18 and 19, respectively, having interior and exterior surfaces 54 and 55, respectively, and flat rear panel 20 equipped with keyhole-type apertures 21 to facilitate mounting to a vertical wall surface. At least two of said apertures are employed in symmetric disposition with respect to a center vertical plane of symmetry 69. Said interior casing is preferably fabricated of plastic, and may be of monolithic construction by virtue of a molding operation. One of said side panels, such as right side panel 19, may be provided with an arcuate slot 22 to accommodate a locking mechanism associated with exterior shell 13, as will be described.
Lower extremity 16 of said interior casing is provided with opposed horizontal lower abutment shelves 23 inwardly directed with respect to the interior region of said casing. The top portion 17 of said interior casing is provided with a vertically oriented control panel 24 extending between said side panels in parallel relationship to rear panel 20, and opposed horizontal retaining shelves 25 attached to said side panels. Opposed horizontal upper abutment shelves 53 are secured to interior surfaces 54 at equal distances below shelves 25.
Said exterior shell is comprised of a sidewall panel 27 shown to be of arcuate curved contour having a front portion 50, left and right side portions 29 and 30, respectively, which terminate downwardly in horizontally disposed lower edge 48, and flat upper panel 28. Front portion 50 is shown to be convex outwardly with respect to interior casing 12. Said exterior shell is configured to embrace said interior casing, and is attached thereto by pivot means in the form of rivet pins 31. Such manner of attachment enables said exterior shell to have swinging movement in a vertical path between an upper position, as shown in FIG. 1, which encloses said interior casing, and a lower position, as shown in FIG. 2, which exposes said interior casing. Front portion 50 of said exterior shell is preferably provided with a centered vertical slot 32 which permits the viewing of individual packages of cigarettes 33 held within the dispenser apparatus. A lock 34 is associated with right side panel 30 and adapted to ride within arcuate slot 22 of interior casing 12, whereby locked engagement between said exterior shell and interior casing is secured. A push-button 35 is associated with front portion 50 above slot 32, said button being a component of first locking means 51, as will be detailed hereinafter. A keylock 36 is disposed upon upper panel 28 as another component of said first locking means.
Basket tray 14, adapted to be removably disposed within said interior casing, is comprised of flat back panel 49, horizontal top panel 39, and opposed vertical retaining walls 37, which, at their upper extremities join top panel 39. The lower extremities of said retaining walls joint horizontal serving panel 41 whose length extends from back panel 49 to close proximity with the front portion of said exterior shell. Exteriorly directed lower tabs 42 are disposed upon the exterior surfaces 44 of both retaining walls 37. Said lower tabs contain apertures 45 which are in vertical alignment with corresponding apertures 43 in panel 39, and with apertures 52 in upper shelves 53 of said interior casing. Retaining walls 37 are adapted to hold at least ten packages of cigarettes oriented orthogonally lengthwise with respect to back panel 49. Said back panel may be equipped with means for adjusting the effective length of serving panel 41 so as to accommodate cigarette packages of varied lengths. In one embodiment, such length-adjusting means may simply be an elongated flat vertical bar adjustably secured by aligned slots in top panel 39 and serving panel 41.
A control rod 46 engages each set of vertically aligned apertures 43, 45 and 52. The upper extremity of each rod 46 is secured in retaining shelf 25, and each lower extremity is secured in lower abutment shelves 23. A coil spring 47 is seated upon the upper extremity of each rod. By virtue of such interaction of components, the basket can undergo spring-driven downward movement between a dispensing lower state, as shown in FIG. 1, wherein said serving panel is disposed below the lower edge 48 of said outer shell to a sufficient extent to permit removal of a package of cigarettes from said basket tray. Said basket tray may be manually pushed upwardly to its locked upper state, as shown in FIG. 3, wherein said serving panel is spaced too close to said lower edge 48 to permit removal of a package of cigarettes.
The extent of downward movement of said basket tray is limited by the impingement of top panel 39 with upper shoulders 53 of said interior casing. The extent of upward movement of said basket tray is limited by the compression of springs 47 and interaction with first locking means 51. Said first locking means, as best shown in FIG. 6 is comprised of apertured guide post 56 upwardly directed from top panel 39, and a first activation rod 57, slideably held by said post and extending to a forward extremity 58 that partially enters securing bore 59 of control panel 24. A second activation rod 61 extends from push button 35 to a rear extremity that partially enters bore 59 in facing relationship with rod 57. The rear extremity of activation rod 57 is provided with a washer 62 that retains coil spring 63 in interaction with post 56. A restoring spring 68 urges push button 35 and rod 61 to a normally outwardly directed position.
In operation, depression of button 35 causes rod 61 to push rod 57 out of securing bore 59. Such action enables paired springs 47 to drive basket tray 14 downwardly to the dispensing state of the apparatus while causing rod 57 to ride against the rear surface of control panel 24. Following removal of a cigarette package 33, manual force directed by the user upwardly against serving panel 41 causes basket tray 14 to return to its uppermost position against the urging of springs 47. Such action causes activation rod 57 to re-enter bore 59 to secure said basket tray in its locked state. Keylock 36 rotatively controls shaft 65 having distal locking elbow 66. When elbow 66 is rotated to the position shown in FIG. 6 where it is in abutment with washer 62 it is impossible to dislodge forward extremity 58 of rod 57 from bore 59, and accordingly, basket tray 14 will remain in its uppermost, locked state. When shaft 65 is rotated 180 degrees, as shown by the phantom lines in FIG. 6, elbow 66 does not impede rearward displacement of rod 57, and accordingly, depression of button 35 will achieve release of basket tray 14 to its lowermost, dispensing state.
While particular examples of the present invention have been shown and described, it is apparent that changes and modifications may be made therein without departing from the invention in its broadest aspects. The aim of the appended claims, therefore is to cover all such changes and modifications as fall within the true spirit and scope of the invention.
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A wall-mountable apparatus for securably dispensing packages of cigarettes includes a vertically elongated interior casing, and an exterior shell configured to embrace the interior casing and pivotally jointed thereto in a manner to permit swinging movement of the shell in a vertical path between a lockable upper position which encloses the interior casing, and a lower position which exposes the interior casing. A basket tray disposed within the interior casing holds a multitude of vertically stacked packages of cigarettes which descend by gravity effect to a serving panel which may be adjustably disposed in a lower, dispensing position or in an upraised, non-dispensing and locked position.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Priority of U.S. Provisional Patent Application Ser. No. 61/825,325 filed 20 May 2013, which is hereby incorporated herein by reference, is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
Not applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The system of the present invention relates to over-pressured coal seams and coal bed methane drilling and completion. More particularly, the present invention relates to a continuous circulating concentric casing system for controlled bottom hole pressure for coal bed methane drilling without the use of weighted drilling fluids containing chemicals utilizing annular friction control and or in conjunction with surface choking to provide the required hydrostatic pressure within the bore hole.
2. General Background
In over-pressured coal (CBM) seams and in circumstances when drilling in the direction perpendicular to the face cleats in the coal seams, which has the highest permeability, but in the lowest borehole stability direction, coal seam permeability is easily damaged by the addition of any chemicals or weighting agents as it becomes necessary to have a fluid in the hole with a higher specific gravity heavier than water. In the prior art, to obtain a specific gravity heavier than water, weighting agents and chemicals have been added to water to obtain a desired hydrostatic weight. What happens in coal is that coal has a unique ability to absorb, and to adsorb a wide variety of chemicals that irreversibly reduce the permeability by as much as 85%.
An objective of the present invention is to eliminate a need to add weighting agents and chemicals. The method of the present invention creates back pressure thru the use of either friction on the return annulus or to choke the return annulus, creating back pressure on the formation, or to use a combination of both to create, thru continuous circulating, an induced higher Equivalent Circulating Density (ECD) on the formation. Thus the formation thinks it has a heavier fluid in the hole but only has water in the annulus. This way formation damage is eliminated and higher pressures are exerted in the wellbore creating a reduced collapse window and reduced wellbore collapse issue.
BRIEF SUMMARY OF THE INVENTION
The present invention solves the problems faced in the art in a simple and straightforward manner. The present invention provides a method of drilling multiple boreholes within a single caisson, to recover methane gas from coal seams, including the steps of drilling first and second vertical boreholes from a single location within a single caisson; drilling at least one or more horizontal wells from the several vertical bore hole, the horizontal wells drilled substantially parallel or at a 45 degree angle to a face cleat in the coal bed; drilling at least one or more lateral wells from the one or more horizontal wells, the lateral wells drilled substantially perpendicular to one or more face cleats in the coal seam or seams; continuously circulating water through the drilled vertical, horizontal and lateral wells to recover the water and cuttings from the coal seam; applying friction or choke manifold to the water circulating down the well bores so that the water creates an Equivalent Circulating Density (ECD) pressure within the well bore sufficient to maintain an equilibrium with the hydrostatic pressure in the coal bed formation; and drilling at least a third vertical borehole within the single caisson, with one or more horizontal boreholes and one or more lateral boreholes for returning water obtained from the lateral producing wells into a water zone beneath the surface for water injection during the production phase.
In the system of the present invention, the present invention would enable the prevention of pressured CBM (over-pressured coal) reservoir damage. This may be done through the use of concentric casing string for annular friction control and in combination with surface choking systems control of bottom hole pressures, which allows the reservoir to be drilled and completed in a non-invasive and stable bore hole environment. Manage Pressure Drilling (MPD) may be accomplished by many means including combinations of backpressure, variable fluid density, fluid rheology, circulating friction and hole geometry. MPD can overcome a variety of problems, including shallow geotechnical hazards, well bore instability, lost circulation, and narrow margins between formation pore pressure and fracture gradient.
In an embodiment of the method of the present invention, the method comprises drilling multiple boreholes within a single caisson, to recover methane gas from a coal bed, comprising the following steps: (a) drilling a first vertical borehole from a single location within a single caisson; (b) drilling at least one horizontal well from the vertical bore hole, the horizontal well drilled substantially parallel to a face cleat in the coal bed; (c) drilling at least one or more lateral wells from the horizontal well, the lateral wells drilled substantially perpendicular to one or more face cleats in the coal bed; (d) continuously circulating water through the drilled wells to circulate water and cuttings from the coal bed; and (e) applying friction and or choke methods or a combination of both to the water circulating so that the water attains a hydrostatic pressure within the well sufficient to maintain an equilibrium with the hydrostatic pressure in the coal bed formation to prevent collapse of the well.
In another embodiment of the method of the present invention, there is drilled at least a second vertical borehole within the single caisson, with one or more horizontal boreholes and one or more lateral boreholes for recovering methane gas and water from the second borehole using the continuous circulating process and maintaining the water under a certain hydrostatic pressure equal to the pressure within the coal bed.
In another embodiment of the method of the present invention, there is drilled at least a third vertical borehole within the single caisson, with one or more horizontal boreholes and one or more lateral boreholes for returning water received from the first and second wells into a waste water zone beneath the surface.
In another embodiment of the method of the present invention, the water recovered from the coal bed seam is separated removing solids, filtered and returned down the third borehole into the waste water zone, while the methane gas is stored above the surface.
In another embodiment of the method of the present invention, imparting a friction component to the flow of the water as it is circulated within the drilled wells provides a greater hydrostatic pressure to the water equal to the hydrostatic pressure obtained by using chemicals in the water that may be harmful to the coal bed and impede recovery of the methane gas.
In another embodiment of the method of the present invention, circulating fresh untreated water with greater hydrostatic pressure obtained by friction or a choke manifold down the drilled wells to recover the methane gas eliminates the use of chemicals in the water which would reduce or stop the flow of methane gas from the coal bed formation.
In another embodiment of the method of the present invention, the recovery of the methane gas from the coal formation would be done through lateral wells being drilled perpendicular to face cleats in the coal bed formation for maximum recovery of methane gas.
Another embodiment of the method of the present invention comprises a method of drilling multiple boreholes within a single caisson, to recovery methane gas from a coal bed, comprising the following steps: (a) drilling first and second vertical boreholes from a single location within a single caisson; (b) drilling at least one or more horizontal wells from the several vertical bore holes, the horizontal wells drilled substantially parallel to a face cleat in the coal bed; (c) drilling at least one or more lateral wells from the one or more horizontal wells, the lateral wells drilled substantially perpendicular to one or more face cleats in the coal bed; (d) continuously circulating water through the drilled vertical, horizontal and lateral wells to recover the water and entrained methane gas from the coal bed; e) applying friction or choke manifold to the water circulating down the well bores so that the water attains a hydrostatic pressure within the well sufficient to maintain an equilibrium with the hydrostatic pressure in the coal bed formation; and (f) drilling at least a third vertical borehole within the single caisson, with one or more horizontal boreholes and one or more lateral boreholes for returning the water circulated from the lateral wells into a waste water zone beneath the surface.
In another embodiment of the method of the present invention, the recovery of the methane gas from the coal formation would be done through lateral wells being drilled perpendicular to face cleat fractures in the coal bed formation for maximum recovery of methane gas.
In another embodiment of the method of the present invention, one or more horizontal wells are drilled from the vertical well, each horizontal well drilled parallel to the face cleat fractures in the coal bed and one or more lateral wells are drilled from the horizontal wells, each lateral well drilled perpendicular to the face cleat fractures to provide a maximum recovery of methane gas as the laterals wells penetrate a plurality of face cleat fractures.
Another embodiment of the method of the present invention comprises a method of drilling multiple boreholes within a single caisson, to recovery methane gas from a coal bed, comprising the following steps: (a) drilling first and second vertical boreholes from a single location within a single caisson; (b) drilling at least one or more horizontal wells from the several vertical bore holes, the horizontal wells drilled substantially parallel to a face cleat in the coal bed; (c) drilling at least one or more lateral wells from the one or more horizontal wells, the lateral wells drilled substantially perpendicular to one or more face cleats in the coal bed; (d) continuously circulating water through the drilled vertical, horizontal and lateral wells to recover the water and entrained methane gas from the coal bed; (e) applying friction or choke manifold to the water circulating down the well bores so that the water appears to have a hydrostatic pressure within the well sufficient to maintain an equilibrium with the hydrostatic pressure in the coal bed formation; and (f) drilling at least a third vertical borehole within the single caisson, with one or more horizontal boreholes and one or more lateral boreholes for returning water obtained from the lateral wells into a waste water zone beneath the surface.
In another embodiment of the method of the present invention, imparting friction or choke to the circulating water, increases the hydrostatic effects of the water from a weight of 8.6 lbs/gal to at least 12.5 lbs/gal, substantially equal to the hydrostatic pressure of the coal formation.
Another embodiment of the present invention comprises a method of recovering methane gas from a pressurized coal bed through one or more wells within a single caisson by continuously circulating untreated water having an effective hydrostatic pressure equal to the coal bed formation, so that methane gas entrained in the formation can flow into the circulating water and be recovered from the circulating water when the water is returned to the surface, and the water can be recirculated into a waste water zone beneath the surface through a separate well within the caisson.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
FIG. 1 illustrates an overall view of multiple wells being drilled out of a single caisson from a single location in the method of the present invention;
FIG. 2 illustrates a cross-section view of the multiple wells within the caisson as illustrated in FIG. 1 in the method of the present invention;
FIG. 3A illustrates a water injection well to return waste water into the formation utilizing a vertical well in the method of the present invention;
FIG. 3B illustrates a water injection well returning waste water into the formation through a use of a horizontal well extending from the vertical well in FIG. 3A in the method of the present invention;
FIG. 4 illustrates yet another embodiment of the water injection well in FIGS. 3A and 3B , where there are multiple lateral wells extending out from the horizontal well in the method of the present invention;
FIG. 5 illustrates a depiction of the drilling of the lateral wells perpendicular to the face cleats in the coal seam to recover maximum of methane gas from the coal seam in the method of the present invention;
FIG. 6 illustrates the single pass continuous circulation drilling utilized in the method of the present invention;
FIG. 7 illustrates the continuous circulating concentric casing pressure management with friction and choke methods in the method of the present invention;
FIG. 8 illustrates a wellhead for continuous circulation in the method of the present invention;
FIG. 9 illustrates a plurality of lateral wells which have been lined with liners as the methane gas is collected from the coal seam in the method of the present invention;
FIG. 10 illustrates an overall view of the methane gas collection from the coal seam utilizing a plurality of lateral wells and the water injection well returning used water into the underground, all through the same caisson in the method of the present invention;
FIG. 11 illustrates a depiction of a plurality of horizontal wells having been drilled parallel to the face cleats and a plurality lateral wells having been drilled perpendicular to the face cleats in the coal seam for obtaining maximum collection of methane gas; and
FIG. 12 illustrates a continuous circulating concentric casing in the method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 through 11 illustrate the preferred method of the present invention, which in summary is a plurality of wells being drilled through a single caisson from the rig floor, at least two of the wells drilled for the ultimate collection of methane gas from a coal seam, and a third well drilled to return waste water used in the process to a water collection zone beneath the surface.
Turning now to the individual Figures, as seen in overall view in FIG. 1 , and in cross-section view in FIG. 2 , there is illustrated in overall view in FIG. 1 , a drilling rig 20 having a single caisson 22 with three wells 24 , 26 , 28 within the single caisson 22 . As seen, each of the wells include a vertical well section 29 , which terminates in at least one or more horizontal wells 30 , which branch off into a plurality of lateral wells 32 , for reasons stated herein. Of the three wells depicted, two of the wells 24 , 26 are multilateral wells to produce water and methane gas, while the third well 28 comprises an injection well 28 that can inject waste water back into one of the underground reservoirs.
The two producing wells 24 , 26 would produce the water and methane gas after completion, where the recovery from these wells would be run thru a centrifuge 82 (as seen in FIG. 7 ) to remove the fine particles during the drilling phase and additionally a centrifuge would be used after completion to remove the coal fines for re-injection, while for the third well 28 , water would be re-injected back into the earth in a water bearing zone. The configuration of the three wells 24 , 26 , 28 within a single conduit or caisson 22 is important and novel since this allows the single site to produce gas through the circulated water in wells 24 , and 26 , and send waste water down into the water bearing zone via well 28 , rather than on site collection ponds, which may be required in some jurisdictional legal guidelines.
As further illustrated in FIGS. 3A and 3B , water 36 is being injected into a vertical well section 29 ( FIG. 3A ), or into a horizontal well 30 ( FIG. 3B ) or into a horizontal with multiple laterals 32 , as seen in FIG. 4 for sending the water into water bearing zones in formation 31 . FIG. 4 depicts injection down the hole of produced water or produced waste water 37 that has been run thru solids removal equipment.
In understanding the nature of a coal seam, coal seams contain face cleats and butt cleats. All of the face cleats comprise cracks in the coal seam which are in a certain direction and comprise the pathway for gas movement thru the coal seam, while the butt cleats connect the face cleats. In a coal seam all major fractures, or face cleats, are in the same direction. Therefore, if one drills in parallel to the face cleats, and only connects two of them, this is the most stable direction. But, if one drills perpendicular to the face cleats, and connects all of the fractures, the recovery is very good, which has, in effect, created a new mechanical induced butt cleat, i.e., connecting one or more face cleats. Drilling from parallel to perpendicular requires more hydrostatic pressure, i.e. mud weight, going from stable to unstable. Most drillers want to drill parallel to the face cleats to avoid the instability in the well. For example, the mine shaft in a coal mine may be mined parallel to the face cleats, to avoid collapse of the mine shaft. However, in coal bed drilling for methane gas, the recovery, when one drills perpendicular to the face cleats is 10 to 20 times more productive; therefore, the most productive direction is to drill perpendicular.
With that in mind, turning now to FIG. 5 , it has been determined that if there is a fracture in the coal seam, referenced as face cleat fractures 50 , that these face cleat fractures 50 would all be parallel one another in the coal seam. One would drill a vertical well, such as well 24 , and drill the horizontal well 30 parallel to the fractures 50 for attaining the most stable well bore, which means the less likely to collapse under downhole pressures. Drilling parallel to the fractures 50 is the most stable direction, but it is the least productive of the drilling. One would want to be able to drill perpendicular to the fractures 50 for maximum production of methane gas through the lateral wells 32 . As stated earlier, drilling perpendicular to the fractures is useful because production of methane gas is ten to twenty times greater when the production wells are perpendicular to the fractures 50 rather than parallel to the fractures 50 .
In an embodiment of the present invention, to drill perpendicular to the face cleat fractures 50 in a stable environment, one would provide higher hydrostatic pressure by higher mud weight or, with water alone, having the water exhibit characteristics which renders its weight or ECD from 8.6 to 12.6 lbs/gal, for example. An embodiment of the present invention provides the desired weight or ECD thru creating mechanical friction, since fluid has resistance, which creates back pressure. In another embodiment, using fresh water, the method comprises use of chokes on surface. For example, one would pump in 100 gallons, but only let out 90 gallons, therefore creating back pressure. The back pressure caused by this process would give greater weight effect or ECD to the water, and increase sufficient hydrostatic pressure in the well bore.
In an embodiment of the present invention, one would use treated water free from any chemicals and bacteria. An object of the present invention is to enable a cleaner formation with no damage by chemicals. However, because the perpendicular drilled wells create instability, in order to minimize that problem, a higher bottom hole pressure is useful, when the coal seam is pressurized down hole. As discussed earlier, in order to minimize a coal seam from being damaged by mud additives added to water in order to create a greater hydrostatic pressure, in a preferred embodiment one would drill with clear water. However, it is difficult to obtain the proper hydrostatic pressure to keep the well from collapsing with just water, without increasing the hydrostatic pressure in some manner. In coal reservoirs which are pressured, there is a need for a process to obtain instantaneous increases of hydrostatic pressure from 8.6 to 12.6 lbs per gallon mud or higher, such as barite or other chemicals added to the water. These chemicals damage the permeability in the formation, actually holding back the pressure, and reduce the opportunity for desorption of methane gas from the formation. Therefore, in a preferred embodiment pure or clear water (containing less than 4 microns of solids drilling fluid, for example) is used, which has a weight of 8.6, but has the effect as the heavier mud, at possibly 12 lbs/gal. In a preferred embodiment of the present invention, to address this problem, one would drill the wells from the parallel or sub-parallel to the perpendicular, without agents, such as chemicals, and with use of friction or back pressure, or a combination of both, as discussed earlier. These means, i.e. the friction or back pressure, can increase the circulating density of the fluid, which is only water in a preferred embodiment.
Turning therefore to FIGS. 6 through 8 , these figures show that on the surface systems may be used to increase friction within the well or through the use of a choke manifold, or a combination of both circulated continuously down the concentric annulus, both of which would cause the water to exhibit a greater hydrostatic pressure, of a suitable magnitude, without the use of chemical or surfactants. By creating the higher equivalent of back pressure, through friction or a choke manifold, one is able to drill the wells perpendicular, for greater recovery of methane gas. That allows one to drill perpendicular and have a higher effective bottom hole pressure without having the bore collapse. There are no chemical agents, such as surfactants involved, which can cause the clay to swell and choke off the flow of gas out of the formation.
It should be noted that as seen in FIGS. 6 through 8 , the system, in a preferred embodiment, would be a continuous circulating system for reducing the likelihood of the formation collapsing under pressure, wherein the water through either friction or the choke valve maintains a 10 lb. per sq. inch pressure down hole, for example, without the use of chemicals.
In FIG. 6 , water is pumped from pumps 70 and 72 via line 74 to the stand pipe 76 and circulated down the borehole. While circulating, due to the hydrostatic pressure of the water and choking effects, for reasons described earlier, the formation remains stable. The water is then returned from the borehole, and after cleansing through the shale shaker 78 , de-silter 80 , and decanting centrifuge 82 , the water returns to pumps 70 and 72 .
In FIGS. 7-8 , the water is being pumped from pump 70 via line 74 to stand pipe 76 returning up bore 90 . Simultaneously pumping with pump 70 from pump 72 via line 103 , then down annulus 104 thru perforations 100 , and returns commingled with fluid from pump 70 up the inner annulus 98 of the well, and goes to the rig choke manifold 94 . This creates both friction control of the annulus and choking to increase the hydrostatic ECD control of bottom hole pressure. The water is then cleansed and returns to pumps 70 and 72 . FIG. 8 illustrates a view of a well head 102 , with the water being pumped down an inner bore 96 , and returned up an annulus 98 where the water from pump 70 and pump 72 are commingled creating the friction effect for hydrostatic friction which then returns to the rig floor for additional choking effect and separation. In a preferred embodiment the present invention is a continuous circulation system, if circulation stops, i.e., turn the pumps off, this can create a loss of friction and choking, so that the formation may collapse. Pump 72 during connections can increase its flow to match the gallons per minute of both pumps 70 and 72 to maintain the friction effect. After a connection is made and flow is re-established to pump 70 , pump 72 can slow to the commingled volume and maintain the friction effect.
As illustrated in FIG. 9 , at some point in time during the process, one may wish to case the laterals 32 off. FIG. 9 illustrates slotted liners 60 which have been inserted into each of the laterals 32 . This is useful to help maintain the integrity of the laterals 32 during the method of the invention.
In FIG. 10 , there is again depicted an overall view of a drilling rig 20 with multiple wells from a single caisson 22 , where some of the laterals 32 from wells 24 , 26 are collecting methane gas by continuously circulating water into the formation, while laterals 32 from a third well 28 are returning waste water to the water bearing zones beneath the surface. In FIG. 11 , there is depicted the vertical wells extending from the single caisson 22 , where there are a plurality of horizontal wells 30 drilled in the same direction as the face cleat fractures 50 , to maintain stability, but where there are a plurality of lateral wells 32 being drilled perpendicular to the horizontal wells 30 through multiple face cleats 50 of the coal seam, to obtain maximum methane gas recovery. In an embodiment of the present invention, cased hole or open hole may be used, wherein the hydrostatic pressure is maintained through the continuous circulation of the water through the system under friction or through a choke at the surface, for maintaining the hydrostatic pressure of the water sufficiently high to prevent collapse of the formation at all times.
In an embodiment of the present invention, the novel system for recovering methane gas from coal seams involves a continuously circulating concentric pressure drilling program which may be adapted to include a splitter wellhead system for purposes of using a single borehole with three wells, or conduits, in the single borehole, with two of the conduits used for completing coal bed methane wells, and the third used as a water disposal well all within a single well caisson.
An embodiment of the present invention, involves a process for recovering methane from coal seams through the following steps: drilling and installing a caisson with multiple conduits; drilling a well bore through the conduit into a coal seam; using a continuous circulating process to drill and complete those wells within the coal seam with the lateral wells being perpendicular to the face cleats of the coal seam so that the well extends through multiple face cleats for maximum recovery of methane gas; completing each well either open or cased hole; next, drill the second well, and complete a series of multi-lateral wells into the coal seam perpendicular to the face cleat fractures as described earlier; then, in the third conduit, drill a vertical or horizontal or multilateral well for disposing the water produced from the other two conduits. The water would be returned through a pumping mechanism from conduits 1 and 2 , filtered for solids removal, and re-injected into the well bore via the borehole in conduit 3 . The present invention overcomes problems in the prior art thru use of multiple wells drilled from a single caisson in a coal bed methane system, using friction and choking methods to maintain the proper hydrostatic pressure of pure water, for coal bed methane recovery in at least two of the wells, and injecting water down hole, all within the same vertical well bore.
In an embodiment of the method of the present invention for a continuous circulating concentric casing managed equivalent circulating density (ECD) drilling method, the method involves a continuous circulating concentric casing using less than conventional mud density. Using less than conventional mud density, the well will be stable and dynamically dead, but may be statically underbalanced (see FIG. 12 ). As stated earlier, in an embodiment of the invention and in the well planning, one would drill wells perpendicular to the face cleats of the coal. From the face cleat direction, there would be a single fracture, reorientation and a single t-shaped multiple 105 provided as seen in FIG. 5 .
For purposes of the below paragraph, the following abbreviations will apply:
Equivalent Circulating Density (ECD)
Managed Pressure Drilling (MPD)
Bottom Hole Pressure (BHP)
Bottom Hole Circulating Pressure (BHCP)
Mud Weight (MW)
The MPD advantage as seen is at under conventional drilling MPD=MW+Annulus Friction Pressure. BHP control=only pump speed and MW change, because it is an “Open to Atmosphere” system; whereas in Managed Pressure Drilling (MPD), the MPD=MW+Annulus Friction Pressure+Backpressure. BHP control=pump speed, MW change and application of back pressure, because it is an enclosed, pressured system.
In the continuous circulating concentric casing pressure management, there is provided an adaptive drilling process used to precisely control the annular pressure profile throughout the wellbore. The objectives are to ascertain the downhole pressure environment limits and to manage the annular hydraulic pressure profile accordingly. It is an objective of the system to manage BHP from a specific gravity of 1 to 1.8 utilizing clean, less than 4 microns of solids, for example, in the drilling fluid. The drilling fluid may be comprised of produced water from other field wells. Any influx incidental to the operation would be safely contained using an appropriate process.
FIG. 12 illustrates a continuous circulating concentric casing where using less than conventional mud density, the well will be stable and dynamically dead, but may be statically underbalanced.
The following is a list of parts and materials suitable for use in the present invention:
PARTS LIST
PART NUMBER
DESCRIPTION
20
drilling rig
22
caisson
24, 26, 28
wells
29
vertical well section
30
horizontal wells
31
formation
32
lateral wells
36
water
37
produced waste water
50
face cleat fractures
60
slotted liners
70, 72
pumps
74
line
76
stand pipe
78
shale shaker
80
de-silter
82
centrifuge
90
bore
94
rig manifold
96
inner bore
98
annulus
100
perforations
102
well head
103
line from pump 72
104
inner annulus
105
t-shaped multiple
All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise.
The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
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A method of drilling multiple boreholes within a single caisson, for recovery of methane gas from a coal bed, including the steps of drilling first and second vertical boreholes from a single location within a single caisson; drilling at least one or more horizontal wells from the several vertical bore hole, the horizontal wells drilled substantially parallel to a face cleat in the coal bed; drilling at least one or more lateral wells from the one or more horizontal wells, the lateral wells drilled substantially perpendicular to one or more face cleats in the coal bed; continuously circulating water through the drilled vertical, horizontal and lateral wells to recover the water and entrained methane gas from the coal bed; applying friction or choke manifold to the water circulating down the well bores so that the water appears to have a hydrostatic pressure within the well sufficient to maintain an equilibrium with the hydrostatic pressure in the coal bed formation; and drilling at least a third vertical borehole within the single caisson, with one or more horizontal boreholes and one or more lateral boreholes for returning water obtained from the lateral wells into a water zone beneath the surface.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to microphone audio signal processing, particularly related to multiplexed microphone signals with multiple signal processing paths.
[0003] 2. Description of the Related Art
[0004] A microphone is a basic and essential element in an audio system. There are many different applications to a variety of audio systems. The most common audio systems include, at least, the following types: a teleconference system, a public addressing (PA) system, a recording studio, or some combination of the above three.
[0005] A simplest teleconference system is a telephone. Two people at two physically separate locations may talk to each other through a telephone network and two telephone sets. FIG. 1 illustrates a simplest teleconference system 100 . The teleconference system 100 has two sites, a near site and a far site. At each site, there is a telephone, 110 and 150 respectively. The two telephones are connected through a network 130 , typically a Public Switched Telephone Network (PSTN), sometime referred to as Plain Old Telephone Service (POTS). The near site telephone 110 has at least a microphone 102 and a loudspeaker 104 . Typically, the telephone also has a circuitry or processor module 106 to perform some signal processing. For example, most touch-tone phones can make different tones to represent different number keys, making artificial ring tones that can be changed by a user. The telephone 150 at the far site may or may not have the same components at in the telephone 110 . For simplicity, it is assumed that the telephone 150 has at least a microphone 152 , a loudspeaker 154 and a processing module 156 .
[0006] In a more advanced telephone, the processor module 106 may have more circuitry or more processing power to perform many functions. One state of the art telephone is a Polycom SoundStation® VTX-1000 speakerphone, available from the assignee of the current invention. The VTX-1000 has many more features and functions. For example, it is a speakerphone that allows full-duplex mode of operation. In full-duplex mode, talkers at both sites of the conference call can speak at the same time. To allow full-duplex mode of operation, the VTX-1000 has an advanced acoustic echo canceller (AEC). Without an AEC, annoying echo-like sounds will circulate between the two sites. If AEC is not implemented, then the speech signal 172 from a talker at the far site is transmitted through the network 130 to the near site telephone 110 as signal 134 . The speech signal 134 is reproduced by the loudspeaker 104 . Since the telephone is operating in full-duplex mode, the microphone 102 is active when loudspeaker 104 is working. The microphone 102 generates a signal 132 , which contains contributions due to the far end speech signal 172 from the loudspeaker 104 . This far end signal embedded in signal 132 is transmitted back to the far end together with the near site speech signal also in signal 132 . The entire signal 132 becomes a loudspeaker signal 174 at the far end and reproduced by loudspeaker 154 . This way, the far end talker will hear his voice back from the loudspeaker 154 , like an echo. This echo speech signal produced by the loudspeaker 154 can again be picked up by microphone 152 , transmitted through network 130 , reproduced by loudspeaker 104 , picked up by microphone 102 and transmitted back to loudspeaker 154 . If nothing is done to it, the echo signal can circulate between the two sites for a long time until dissipated into background noise, which is increased due to such echoes. Without AEC, full-duplex mode operation in a speakerphone is not practical due to the echoes and the noise.
[0007] When a process module 106 performs echo cancellation, it estimates the contribution of echo in the microphone signal 132 and subtracts that portion from the microphone signal 132 . This way, signal 132 only contains signals due to the speech of near site talkers. Therefore, what a far end talker can hear is the speech of near site talkers alone, without echo of his own voice. At the far end, another process module 156 may perform the similar acoustic echo cancellation. To achieve optimal goal of solving the echo problem, besides acoustic echo cancellation, echo suppression and noise fill may also be used. That is to minimize the residual echo heard by participants at the far site.
[0008] The process modules 106 and 156 may also perform other audio signal processing. For example, such processing may include parametric equalization. A particular microphone element may not respond to sound with uniform gain for all frequencies. To compensate for this non-uniformity, the process module may apply different filters on different frequencies to enhance or attenuate the frequency to achieve the uniform gain across the spectrum. The process module may also adjust the gain to change the characteristic of the speech or to achieve other acoustic objectives.
[0009] The process modules may also include automatic gain control (AGC) to accommodate the different loudness of speech from different talkers. There are various factors that may affect the gain of a microphone to speech, such as the loudness of the talker, the distance between the talker and the microphone or the orientation of the microphone and the talker. The use of AGC can avoid the wide fluctuation of the speech reproduced by a loudspeaker.
[0010] Another application of microphone signals is a public addressing system or a sound reinforcement system, as illustrated in FIG. 2 . Such a system is typically used in theatres, auditoriums or large classrooms. One of the main differences of system 200 and system 100 is that system 200 is typically used at one site. The microphone 202 and loudspeaker 204 are located at the same general location such that sound from the loudspeaker 204 is picked up by the microphone 202 . The microphone 202 , process module 206 and loudspeaker 204 can form a closed loop. Unlike system 100 , system 200 does not have two sites and cannot have the echo problem. There is no need for acoustic echo cancellation. But it has its own problem, a feedback problem. If the closed loop has an overall gain above unity for a particular frequency, then for that frequency, system 200 has a positive feedback loop which reinforces itself until it makes a very loud squeaky noise, typically referred to as howling. The howling is very disruptive to meetings, lectures or artistic performances. It may also be destructive to acoustic equipment involved in the loop. Eliminating or avoiding feedback is a major concern in making and operating an audio reinforcement system 200 . In doing so, a slight degradation of the acoustic performance is acceptable. A typical method for eliminating feedback is to reduce the overall gain below unity for all frequencies. This may limit the amount of amplification in the reinforcement system, which is the main purpose of using such a system in the first place. More advanced methods to avoid feedback can dynamically detect and attenuate only the frequency that is likely to cause the howling, while keeping the gain for other frequencies intact, i.e., the gain for other frequencies possibly can be above unity. The selective attenuation of some frequencies can affect the sound quality, due to the missing portion of the spectrum and the artificial distortion.
[0011] As illustrated in FIG. 2 , process module 206 may also perform many microphone signal processes 212 , including parametric equalization (PEQ), noise cancellation (NC), feedback elimination (FBE), dynamic process compression (DP), automatic gain control (AGC), and automatic mixing (AM). After performing desired processes on the microphone signal, the signal may be amplified by an amplifier 214 to form a loudspeaker signal 234 . Loudspeaker signal 234 is reproduced by a loudspeaker 204 .
[0012] FIG. 3 illustrates another system 300 , typically used in sound recording studios, radio broadcasting stations or court recorders. System 300 has a microphone 302 , a process module 306 and a recorder or other equipment 304 . The main difference between system 300 and systems 100 and 200 discussed earlier is that there is no closed loop in system 300 . The microphone 302 generates a signal 332 , processed by process module 306 , sent to recorder 304 (or other equipment for signal disposal) and that is the end of the system. There is no feedback from the processed signal to microphone 302 . Therefore, there is no need to perform some of the processes discussed in systems 100 and 200 , namely the echo cancellation, echo suppression and feedback elimination. Without the limitations imposed by the AEC and FBE processes, system 300 is typically focused on achieving the best sound quality possible, which is a requirement in a typical sound recording studio for recording a music performance or for a radio broadcasting stations for transmitting a live performance. When such a system is used for a court recorder, reliability is paramount, i.e., all words spoken or sounds must be recorded. In a typical system 300 , the microphone signal processes 312 may include PEQ, NC, DP and AGC etc.
SUMMARY OF THE INVENTION
[0013] As discussed above, different applications of microphone signals may require different processes. Some of the processes are similar, for example, most of the systems use AGC and PEQ. Some processes are different, for example AEC, FBE etc. Some processes necessary for one application may be in conflict with the purpose of another application. For example, feedback elimination is necessary for sound reinforcement application, but can degrade the acoustic quality. Feedback elimination should not be used in a sound recording application.
[0014] For clarity, systems 100 , 200 and 300 are described separately and apply to different applications. But in actual applications, these systems may be used together in a single setting. For example, in a distance learning application as illustrated in FIG. 5 , there is a local site and a far site. A professor is speaking at the local site. Students at both the local site and the far site can ask questions or otherwise interact with each other and the professor. The lecture is also recorded for use by students who do not have access to either the local classroom or a teleconference unit. In this case, the teleconference between the local site and the far site prefers the use of a conference system, similar to system 100 as shown in FIG. 1 . But the interaction between the professor and the students at the local site prefers a sound reinforcement system as shown in FIG. 2 such that speech of the professor and questioning student can be heard by all people. The recording for non-participating students prefers a recording system 300 as shown in FIG. 3 . The currently available audio systems cannot satisfy all desires for the three applications. Most of the time, only one of the desires is satisfied and the other two desires are ignored. Sometimes, none of the desired goals is achieved.
[0015] Currently, even if a microphone system or audio system is installed for one particular application, the system still has to be modified or adjusted extensively for that particular application. It is time consuming, costly and confusing. To custom-manufacture or configure a microphone system or audio system useful for only one particular application is possible, but it increases the cost and is not desirable.
[0016] It is more to desirable have a system or method that can adapt to a particular application easily. It is very desirable to have a system that can accommodate all application goals at the same time and avoid the apparent conflicts between them.
[0017] The current invention uses a process module that can route a microphone signal to different processing paths. Each path is customized to achieve the goal for a particular application. The identical processes within different paths may be performed by the same process module to avoid duplication and save processing power. When installing the system, a process path is selected for a particular application. No complicated configuration is required. All potentially conflicting processes are accommodated within the same processor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] A better understanding of the invention can be obtained when the following detailed description of the preferred embodiment is considered in conjunction with the following drawings, in which:
[0019] FIG. 1 illustrates a prior teleconference system.
[0020] FIG. 2 illustrates a prior art sound reinforcement system.
[0021] FIG. 3 illustrates a prior art sound recording system.
[0022] FIG. 4 illustrates a microphone processing system according to an embodiment of the current invention.
[0023] FIG. 5 illustrates a situation where all three applications are used.
[0024] FIG. 6 illustrates a signal routing in one embodiment with multiple microphones.
[0025] FIG. 7 illustrates another signal routing in an embodiment that makes use of an existing prior art audio system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] The current invention includes devices and methods to multiplex microphone signals, where each signal is used for a particular application. Each signal path is independent from another signal, so conflicting signal processes may be applied for the different signals. Some processes are used in several signal paths, then such processes may be shared among the signal paths.
[0027] FIG. 4 illustrates one embodiment of the current invention. A microphone 402 generates microphone signal 404 . The signal is processed by parametric equalizer (PEQ) 412 , acoustic echo cancellation (AEC) 414 and noise cancellation (NC) 416 . These processes are common in all applications. Accordingly, they are shared among all signal processing paths. The resulting signal is 406 . Then the signal processing path splits into several paths. In this example, four paths are shown: an ungated path, a gated path, a sound reinforcement path and a user defined path, as denoted by the output signals 433 , 453 , 473 and 493 . The ungated path includes auto gain control (AGC) 424 , dynamic process compression (DP) 426 and fader mute (FM) 431 . The gated path includes echo suppression and noise fill (SNF) 442 , ACG 444 , DP 446 , automatic microphone mixing (AM) 448 and FM 451 . Similarly, the sound reinforcement path includes feedback elimination (FBE) 462 , AGC 464 , DP 468 , AM 468 and FM 471 . The customized path may have some of the above mentioned processes or user customized processes 482 , 484 , 486 , 488 and 491 . This path allows a user of the system to mix and match pre-defined processes. It also allows the user to create his unique processes. It is noted that AGC 424 , 444 and 464 , DP 426 , 446 and 466 , AM 448 and 468 , and FM 431 , 451 and 471 are similar process in each path, so the processor is the same among the different paths and is shared among them. This way, computational power is shared by the different paths.
[0028] The ungated signal 433 is configured to be used in an open-loop system, such as a sound recording system. The signal 433 is processed to achieve the highest quality and reliability. Any sound picked up by the microphone 402 is presented at signal 433 with high fidelity. Typically, only one or a few microphone signals are mixed for each output 433 . Signal 433 may be recorded by a high quality sound recorder or broadcasted to others.
[0029] A second path generates a gated signal 453 . The gated signal 453 is configured to be used in a closed-loop system, more particularly, a conferencing system. The echo suppression and noise fill process (SNF) 442 complements an AEC 414 to reduce echo heard by people at a far site. A noise fill is typically necessary to avoid dead silence at the far site, when people at the near site are not talking. Because of the echo suppression and noise fill process, the gain of the local microphone can vary dynamically depending on whether there are any people talking. In a conference setting, local speech is not reproduced in local loudspeaker, so it does not matter whether the gain varies. If a gated signal 453 is reproduced in a local loudspeaker, such as in a local sound reinforcement system, then the SNF 442 -caused variation can be noticeable and sometimes annoying.
[0030] A third signal path generates a sound reinforcement signal 473 . The sound reinforcement signal 473 is configured for use in a sound reinforcement system. SNF 442 is not used. The main reason for this is the doubletalk problem. In an audio conference, there are times when only people at one conference site are talking, i.e., single-talk, and there are times when people at more than one site are talking, i.e., doubletalk. SNF 442 works differently depending on whether there is single-talk or doubletalk in the conference. It is not a problem in a conference application, as discussed above related to the second signal path. But when the amplitude of local speech is reproduced by local loudspeakers, the fluctuation in the gain of the local speech can be noticeable and problematic. It is as if someone is mischievously turning the amplifier volume dial down or up as soon as you start speaking or stop speaking. By removing SNF 442 , the associated doubletalk problem is eliminated. The gain of the speech remains stable. Instead, FBE 462 is used. FBE reduces the feedback problem by attenuating a frequency that the FBE predicts to be likely to cause howling. Because of this attenuation, the sound spectrum is artificially altered. The resulting sound quality is lower. The particular frequency which is attenuated may vary with time, so the overall degradation of the sound quality may be minor. Even so, at any particular time and at a particular frequency, the distortion can be substantial. If that particular frequency at that time is significant for some reason, then the signal 473 could be unacceptable. That is why signal 473 is not suitable for use in a court reporting application, where reliability is paramount.
[0031] In both the gated and sound reinforcement paths, automatic microphone mixing (AM) 448 and 468 are used. In a case of multiple microphones generating a single signal, an AM shuts off the microphone where no speech is detected and only opens the microphone where speech is detected. This way, noise signals from microphones that do not have speech signals are not mixed into the final speech signal. The SNR of the resulting mixed speech signal is improved. In a single signal processing situation, AM is essentially an on/off switch. When there is no speech signal detected at the microphone, the AM turns the signal off, such that the noise from this microphone is not supplied to downstream signal processing. When there is speech signal, then the signal is turned on and supplied to downstream processes. This improves signal quality for both versions. It improves gain before feedback in the sound reinforcement version. AM is not used in the ungated version to avoid possible attenuation of the local speech. And by definition, the ungated version is typically used for an application where there is minimum background noise (i.e. recording studio) or where all “noises” are, “signals” (i.e. court reporting).
[0032] FIG. 4 only illustrates the audio signal processing part of an audio system that is relevant to the current invention. Audio sinks for the output signals, i.e., the destinations of the various output signals, are not shown. The output signals may be transmitted to the various audio sinks through the interfaces 435 , 455 , 475 and 495 . For each of the sinks, any of the several versions of the microphone signal may be selected. Although three of the output signals are processed and configured for three particular uses, they can be used for any purposes. Thus the audio sinks for the output signals can be many things that can accept audio signals, e.g., a loudspeaker, a conference unit at a far end site, a tape recorder, a radio transmitter, or other broadcast transmitter, etc.
[0033] Referring back to the setting illustrated in FIG. 5 , the audio system 510 at the near site can employ the embodiment in FIG. 4 . Using the embodiment of the current invention, the goal for each application can be achieved. The microphone signal 532 generated by microphone 502 is processed by a process module 506 as shown in FIG. 4 , in three different paths for different applications. An ungated signal 538 is the output signal from the ungated path. It is recorded by recorder 582 for future use. In a court setting, the recorder 582 could be a court recorder.
[0034] The gated signal 536 is the output signal from the gated path. It is transmitted through a network 530 to the far site. This signal is substantially echo free.
[0035] The local sound reinforcement signal 534 is the output signal from the sound reinforcement path. It is combined with the loudspeaker signal 537 from the far site at a mixer 541 to form a local loudspeaker signal 539 . Local loudspeaker signal 539 is reproduced by loudspeaker 504 . So at the near site, both the local speech 532 and the far site speech 537 are amplified and can be heard by people at the near site of the conference.
[0036] The audio system 550 at the far site can be similar to the audio system 510 at the near site as discussed above, but it is not necessary. For example as shown in FIG. 5 , system 550 may be a prior art conference unit. System 550 has a microphone 562 , loudspeaker 564 and a process module 566 . Since the audio system is only need to function as a conference unit, a prior art unit is sufficient. It is neither used for sound recording, nor for sound reinforcement. But if an audio system according to the current invention is available at the far site, then people at the far site would have the flexibility to add the two other functions that are available at the near site. If the far site has a system similar to the near site, then it can be used as a sound reinforcement system to accommodate many listeners at the far site. Also, it may record the lecture using its own recording device, instead of waiting for the near site to send the recording.
[0037] Most of the data processes can be implemented in a single data processor, such as a DSP. FIG. 6 illustrates one embodiment that utilizes the capacity of a DSP to minimize the size and number of discrete components in an audio system. In this example, three input signals 612 , 614 and 616 are shown, with four possible output signals 632 , 634 , 636 and 638 . The input signals may come from various sources, such as microphones 602 , 604 or a telephone network interface 606 . The input signals are converted to digital signals from analog signals when necessary, for example by A/D converters 622 , 624 or 626 . Each signal can be processed by a DSP 620 , which may perform many different processes, such as those discussed in reference to FIG. 4 . Unlike many existing systems, each signal may be processed by the DSP 620 into different versions, such as discussed in reference to FIG. 4 , i.e., ungated, gated or sound reinforcement versions. These different versions may be output as independent signals. For each of the audio sinks, any of the several versions of each source may be selected. For example, output signal 632 may be the gated version of signal 612 ; output signal 634 may be the sound reinforcement version of signal 612 ; output signal 636 may be an ungated version of signal 614 ; and output signal 638 may be a gated version of signal 616 . Similarly, the output signals may be a combination of processed input signals. In another example, output signal 632 is a mixture of gated version of signal 612 and 614 . Signal 634 is a mixture of ungated version of signal 616 and the sound reinforcement versions of signal 602 and 604 . There are many other possible combinations. The system is very flexible to adapt to a particular need. One benefit of such a system is that most of the signal processing, such as signal routing and mixing, is performed in the digital domain within the DSP. No rewiring of electrical cables is necessary. The output signals can be sent via appropriate interfaces for desired applications.
[0038] In prior art systems that include an adequate DSP, the current invention can be practiced by changing the process module in an existing audio system or reprogramming the processor in such a system. Such an upgrade can expand the capabilities of audio systems at very small incremental cost.
[0039] The current invention may also be practiced using a prior art system with limited capabilities, such as a Peavey Media Matrix and a Polycom Vortex conference unit. One such application is shown in FIG. 7 . An audio system 720 has multiple inputs and multiple outputs. Each input may be independently processed and be sent out of the system. The system 720 includes some of the desired processes as discussed in FIG. 4 . Others functions may be in other systems such as 729 . When various systems are combined, then an equivalent system similar to that shown in FIG. 4 can be formed, where conflicting versions of a single signal may be created. In FIG. 7 , microphone 702 generates a signal 712 . Signal 712 is digitized when necessary by A/D converter 722 . Signal 712 is processed by processor 723 in system 720 , which performs parametric equalization and noise cancellation processes. The output signal 732 is sent out of interface 742 as signal 770 and fed back to the inputs of system 720 . Signal 770 is split into three paths to make three versions, similar to those shown in FIG. 4 . One path 774 is processed by processor 725 of system 720 , which generates an ungated signal 734 . The second signal 777 is processed by processor 727 , which generates a gated signal 737 . The third signal 778 is fed to another processor 729 , outside of system 720 . System 720 does not have a feedback elimination processor. So another system that has such capability is used. Process 729 generates a sound reinforcement signal 738 . This way, using two systems and some wiring back and forth, three conflicting versions of the same input signal 712 are generated. This embodiment of the current invention is more cumbersome. It may reduce the number of signals that can be processed because it may use several processors to process one signal. But it does have the advantage of using existing equipment.
[0040] According to the embodiments of the current invention, a microphone signal can go through several different processing paths. Each path is configured for a particular application. Different paths share the common processes to reduce computation loads. The individual processes may also be combined differently by a user to make a customized signal processing for a highly specialized application. The above discussion has focused on three common audio system applications that are distinct. Sometimes they have conflicting objectives or priorities. There are many other applications and processes not mentioned here. The current invention, where a signal can go through different processing paths and sharing common processes, is still applicable to them.
[0041] While illustrative embodiments of the invention have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
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A multiplexed microphone signal with multiple signal processing paths is disclosed. Each signal processing path has it own priority and other characteristics. A signal path is selected based on the application of the processed signal. Similar processes within different paths may be shared to reduce computation workload.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is the US National Stage of International Application No. PCT/EP2005/052293, filed May 18, 2005 and claims the benefit thereof. The International Application claims the benefits of German application No. 102004025416.8 DE filed May 24, 2004, both of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
The present invention relates to a computer-supported determination method for supplementary position set values for a position guided moving supplementary element of a machine, in particular a production machine, which also features a position guided moving base element.
with the computer determining, in accordance with a predetermined base track in space, a base position set value, so that when the base position set value is specified to the base element, the latter would be moved along the base track in a position-guided manner from a base start position to a base end position, with the computer also determining in each case a supplementary position set value for the supplementary element, so that when the supplementary position set value is specified to the supplementary element, the latter would be moved in a position-guided manner.
BACKGROUND OF INVENTION
These types of methods are generally known for machines with a number of position-guided elements, especially machine tools.
For machines other than machine tools, especially for production machines, other procedures are generally adopted. However numerous position-guided moving elements are present in these machines too. The movements of the individual elements are however only roughly synchronized with each other in these types of machine. This is explained in greater detail below using a plastic injection molding machine as an example.
Plastic injection molding machines have a multipart—as a rule two-part—tool form. One part of the tool is arranged statically on a chassis unit of the injection molding machine and the other part moves in relation to the chassis unit.
Once a plastic part has been injection molded, the tool mold is opened, meaning that the moving part of the tool is moved from the closed position to the open position. The injection-molded plastic part in this case is generally held in the moving part of the tool.
After the opening position is reached a handling device is moved from a rest position into a removal position, in which the handling device can remove the injection-molded plastic part from the moving tool part. Afterwards the handling device is moved back into its rest position. The moving tool part stays in its opening position in this case until the handling device has reached its rest position. Only then does the moving tool part move into its closed position again, so that the next injection molding process can begin.
The movement of the handling device and the movement of the moving tool part must obviously be coordinated with one another, so that no collisions can occur between the moving tool part and the handling device. In the prior art this is ensured by using end position switches to only enable the handling device to be moved from the rest position into the removal position once the moving tool part has reached its open position. Likewise the movement of the tool part back into its closed position is only enabled once the handling device has reached its rest position.
Although the prior art method securely guarantees that no collisions can occur, because of the movement-related delay time it often provides less than optimum dynamics and thereby an associated less than optimum machine productivity. It is thus desirable for the moving tool part and the handling device to determine the corresponding sequences of position set values, so that the moving tool part and the handling device can be moved simultaneously. In such cases, there must still be a guarantee that any collisions will be prevented.
It would be possible for a programmer to determine the supplementary position set values for the moving tool part and the handling device in such a way that the two elements are moved simultaneously and in this case the freedom from collisions is still guaranteed. However significant intellectual effort would be involved in such cases.
The object of the present invention is thus to achieve this type of simultaneous mobility of handling device and moving tool part—or in more general terms of a base element and a supplementary element—without having to make the effort of programming the two movements.
SUMMARY OF INVENTION
The object is achieved by the computer-supported determination method such that
the computer determines, on the basis of the base set value determined, a corresponding instantaneous supplementary end position in space, the computer, on the basis of a predetermined fixed supplementary start position in space and the instantaneous supplementary end position, determines a supplementary position set value in each case, so that on specification of the supplementary position set value to the supplementary element, the latter, starting from the supplementary start position, would be moved in a position-guided manner along an instantaneous supplementary track to the instantaneous supplementary end point.
Furthermore the object is achieved by a data medium with a determination program stored on the data medium for executing such a determination method.
Furthermore the object is also achieved by a computer which features a program memory, in which such a determination program is stored, so that the computer executes such a determination procedure when the determination program is called.
The computer-supported determination method can be executed either online or offline.
With off-line execution the object is achieved by a data medium with a stored sequence of base position set values and a corresponding sequence of supplementary position set values for the control device, with the sequence of supplementary position set values having been determined in accordance with such a determination method.
With online execution the object is also achieved by a method of operation for such a machine,
in which the control device includes a computer, which executes such a determination method online, and in which the control device specifies to the base element the base position set values determined and to the supplementary element the supplementary position set values determined, so that the base element is moved in accordance with the base position set values determined and the supplementary element is moved in accordance with the supplementary position set values determined in a position-guided manner.
Here too the object is further achieved by a data medium with an operating program stored on the data medium to execute such a method of operation, a corresponding programmed control device and a machine which features the correspondingly programmed control device.
The relevant supplementary position set values can for example be determined such that the computer initially determines the instantaneous supplementary track on the basis of the predetermined fixed supplementary start position and the instantaneous supplementary end position and then determines the supplementary position set value.
Preferably the supplementary end positions in the space lie on a predetermined supplementary end position track. Furthermore in this case the respective supplementary end position is located, relative to supplementary end position track, at least in a partial area of the supplementary end position track in a linear relationship to the relevant base position set value, relative to the base track. This is because this makes it particularly easy to determine the instantaneous supplementary end position.
Preferably the supplementary position set value, relative to the instantaneous supplementary track is further located at least in a partial area of the instantaneous supplementary track in a linear relationship to the relevant base position set value, relative to the base track. This is because this also makes the determination of the relevant supplementary position set value especially simple.
The determination of the instantaneous supplementary track in the space is arranged very simply if the instantaneous supplementary tracks in the space in each case form a straight line from the supplementary start position to the instantaneous supplementary end position.
If the supplementary position set value is kept the same as the supplementary start position until the base position set value has reached a first base intermediate position, which, relative to the base track, lies between the base start position and the base end position, this provides an especially simple way of avoiding collisions.
Depending on the embodiment of the inventive determination method, the supplementary position set value can reach the instantaneous supplementary end position before, with or after the base end position is reached by the base position set value. Preferably however the supplementary position set value still changes even after the base position has been reached by the base position set value. This does not represent a conflict with any reaching of the instantaneous supplementary end position before or with the reaching of the base end position by the base position set value, since the instantaneous supplementary end position can continue to change even then.
The danger of collisions can be reduced even further, if the instantaneous supplementary end position is kept the same as an initial supplementary end position until the base position set value has reached a second base intermediate position, which, relative to the base track, lies between the base start position and the base end position.
The use of the inventive determination method is especially of advantage if the supplementary end position track and the base track have a common track section.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages and details emerge from the subsequent description of an exemplary embodiment in conjunction with the drawings. The Figures show the following basic diagrams
FIG. 1 a schematic diagram of a production machine,
FIG. 2 a flowchart,
FIG. 3 the relationship of different positions to each other,
FIG. 4 a further flowchart,
FIG. 5 a further relationship of different positions to each other and
FIG. 6 a block diagram of a computer.
DETAILED DESCRIPTION OF INVENTION
The present invention is explained below based on a typical production machine, namely an injection molding machine. However the present invention is not basically restricted to use in production machines or injection molding machines. Instead it is generally applicable to all types of machine which feature a position-guided moving base element and a position-guided moving supplementary element, with the movements of the base element and the supplementary element having to be coordinated with one another in order to avoid collisions.
In accordance with FIG. 1 a plastic injection molding machine includes a tool mold 1 and a handling device 2 . The tool mold in this case features a stationary tool part 3 and a moving tool part 4 .
The moving tool part 4 is able to be moved between a closed position and an open position. In the closed position of the moving tool part 4 the tool mold 1 is closed so that an injection-molded part can be manufactured by the injection molding machine. In the open position of the moving tool part 4 a manufactured injection molded part can be removed from the moving tool part 4 by the handling device 2 . To this end the handling device is able to be moved in a position-guided manner between a rest position and a removal position.
In accordance with FIG. 1 the moving tool part 4 is in the closed position and the handling device 2 is in the rest position. Also shown by a dotted outlines however in FIG. 1 are the locations in which the moving tool part 4 is located in its open position and the handling device 2 in its removal position.
The overall injection molding machine is controlled by a control device 5 . To this end an operating program 7 is stored in a program memory 6 of the control device 5 . The operating program 7 has been supplied to the control device 5 beforehand in this case by means of a data medium 8 on which the operating program 7 is also stored. An example of such a data medium 8 is a CD-ROM 8 . In principal the operating program 7 could also have been supplied to the control device 5 in another way, e.g. over a computer-to-computer connection not shown in the diagram for reasons of clarity.
The control behavior of the control device 5 is determined by the operating program 7 stored in the program memory 6 . When the operating program 7 is called the control device 5 thus executes an operating method which is described below in conjunction with FIG. 2 . For better understanding of the present invention only the parts of the operating method which are of significance for the present invention are discussed in greater detail below. In particular more detailed descriptions of the injection molding process as such and procedures for removing the injection molded part from the moving tool part 4 are not dealt with.
In accordance with FIG. 2 , the control device 5 initially has a number of parameters specified to it—either within the framework of the application program 9 or directly by an operator 10 —in it a step 201 . These parameters in particular include the closed position and the open position of the moving tool part 4 , subsequently designated as L 41 and L 42 , as well as two intermediate positions lying between the two positions of the moving tool part 4 , designated below as L 43 and L 44 . Furthermore the parameters include the rest position and the removal position of the handling device 2 , designated below as L 21 and L 22 , as well as an initial fictitious removal position of the handling device 2 , designated below as L 23 . As can be seen in FIG. 3 , the positions L 21 to L 23 and L 41 to L 44 , with the exception of position L 21 lie on a straight line in this case.
In a step 202 the control device 5 then checks whether an injection molding process is completed. Step 202 is processed repeatedly in this case it necessary.
When the injection molding process is completed, the control device 5 defines in a step 203
the closing position L 41 as base start position G 1 , the opening position L 42 as base end position G 2 , the intermediate positions L 43 and L 44 as first and second base intermediate position G 3 and G 4 , the rest position L 21 as supplementary start position Z 1 , the final removal position L 22 as the final supplementary end position Z 2 and the position L 23 as the initial supplementary end position Z 3 .
This situation is also shown in FIG. 3 . Furthermore, in step 203 , it sets a runtime variable a to the value zero. The control device 5 then passes this data in a step 204 to a computer 11 , which is implemented within the control device 5 .
The computer 11 operates online. It initially determines—see FIG. 4 —in a step 401 a base track and a supplementary end position track. The base element is to be moved along the base track. The base track always leads in this case from the base start position G 1 to the base end position G 2 . Because of the corresponding specification in the present case, the moving tool part 4 is the base element 4 . The supplementary end position track is the track of the instantaneous supplementary end positions Z 4 to be determined later. It leads from the initial supplementary end position Z 3 to the final supplementary end position Z 2 .
In principle the base track can be determined in accordance with any given functionality. In the simplest case the base track in space however is a straight line from the base start position G 1 to the base end position G 2 . The same then applies to the supplementary end position track.
Because of the type of determination of the base track and supplementary end position track, these feature a common track section. The common track section is first passed through by the base position set values G* and then by the instantaneous supplementary end position Z 4 , and this occurs in the same direction.
Next the computer 11 increments in a step 402 the runtime variable a. In a step 403 the computer 11 then determines the base position set value G*, to which the base element, in this case the moving tool part 4 , is to be moved. The base position set value G* lies in this case on the base track.
In the selected example of the straight-line connection between the base start position G 1 and the base end position G 2 , the base position set value G* can be determined for example in accordance with the formula specified in step 403 . A in this case is a constant natural number, which is significantly greater than zero, e.g. lies between 100 and 10,000. It is however also possible to determine the set value in another way.
In a step 404 the computer 11 then checks whether the run time variable a is greater than the constant A. If it is, in a step 405 it limits the base position set value G* to the base end position G 2 .
Then the computer 11 determines in a step 406 the instantaneous supplementary end position Z 4 . In accordance with the example specified in conjunction with FIG. 4 , the computer 1 specifies in this case as the instantaneous supplementary end position Z 4 a point which lies on the supplementary end position track. b in this case is an offset. b is a natural number. B is again a constant which is of the same order of magnitude as the constant A. It does not have to be identical to this however. It should also be mentioned that here too another type of determination is possible.
Because the instantaneous supplementary end position Z 4 is dependent on the run time variable a, the computer 11 determines the instantaneous supplementary end position Z 4 implicitly on the basis of the base position set value G* determined in each case. Furthermore, because of this state of affairs, the instantaneous supplementary end positions Z 4 , relative to the supplementary end position track, at least in a partial area of the supplementary end position track, are in a linear relationship to the respective base position set value G*, relative to the base track.
In a step 407 the computer 11 checks whether the difference between the runtime variable a and the offset b is less then zero. If this is the case, the computer 11 , in a step 408 , sets the instantaneous intermediate end position Z 4 to the value of the initial intermediate end position Z 3 . The offset b is thus determined so that the instantaneous supplementary end position Z 4 is kept equal to the initial supplementary end position Z 3 until the base position set value G* has reached the second base intermediate position G 4 .
If not, the computer 11 checks, in a step 409 , whether the difference between runtime variable a and offset b is greater than the constant B. If this is the case, the computer 11 , in a step 410 sets the instantaneous supplementary end position Z 4 to the value of the final supplementary end position Z 2 .
Next the computer 11 determines, in a step 411 on the basis of the supplementary start position Z 1 and the instantaneous supplementary end position Z 4 , an instantaneous supplementary track in space. In the simplest case the supplementary track is a straight line, extending from the supplementary start position Z 1 to the instantaneous supplementary end position Z 4 . In principle however another supplementary track is also conceivable.
The computer 11 then determines, in a step 412 , a supplementary set value Z* lying on the instantaneous supplementary track. In the simplest case the computer 11 determines the supplementary position set value Z* in such a case in accordance with the formula specified in step 412 . c in this formula is again an offset which is a natural number. C is again a constant, lying in the same order of magnitude as the constants A and B, but not necessarily having the same value as one or both of these constants A, B.
As a result of the typically specified dependency of the supplementary position set value Z* on the runtime variable, the respective supplementary position set value Z* determined in this case, relative to the instantaneous supplementary track, lies at least in a partial area of instantaneous supplementary track in a linear relationship to the relevant base position set value G*, relative to the base track. Because of the offset c the supplementary position set value Z* continues to be kept equal to the supplementary start position Z 1 until the base position set value G* has reached the first base intermediate position G 3 .
Depending on the choice of offset c and constants A and C the supplementary position set value Z* reaches the instantaneous supplementary end position Z 4 before, with or after the base position set value G* has reached the base end position G 2 . Likewise, depending on the choice of offset b and constant A and B, the instantaneous supplementary end position Z 4 reaches the final supplementary end position Z 2 before, with or after the base position set value G* has reached the base end position G 2 . The offsets b and c and the constants B and C may however not be determined such that both the supplementary position set value Z* reaches the instantaneous supplementary end position Z 4 and the instantaneous supplementary end position Z 4 reaches the final supplementary end position Z 2 before the base end position G 2 is reached by the base position set value G*. The maximum permitted is that the value is reached simultaneously in both cases. Preferably the supplementary position set value Z* should even change after the base position set value G* has reached the base position set value G 2 .
The supplementary position set values G*, Z* determined are returned by the computer 11 to the control device 5 in a step 417 . This device accepts the transferred supplementary position set values G*, Z* in a step 205 . In a step 206 the control device 5 then outputs the base position set value G* to the moving tool part 4 , the supplementary position set value Z* determined to the handling device 2 . This causes the moving tool part 4 and the handling device 2 to be moved in a position-guided manner according to the required values G*, Z* determined. The moving tool part 4 is moved in this case along the base track from the base start position G 1 for the base end position G 2 . The handling device 2 is moved starting from the supplementary start position Z 1 to the instantaneous supplementary end position Z 4 .
In a step 207 the control device 5 then checks whether the base position set value G* is equal to the opening position of the moving tool part 4 . If this is not the case, the sequence returns to the step 205 . Else it checks, in a step 208 , whether the supplementary position set value Z* has also reached the removal position of the handling device 2 . If this is not the case, it returns to the step 205 again, else it continues the further processing of the operating program with a step 209 .
In the step 209 the control device 5 controls the handling device 2 such that the handling device 2 removes the injection-molded plastic part from the moving tool part 4 .
Next the handling device 2 must be moved back into its rest position, the moving tool part 4 into its closed position. To do this it is possible in principle to output the base and supplementary position set values G*, Z* in the reverse order again to the moving tool part 4 or the handling device 2 . However the procedure explained in greater detail below in connection with FIG. 2 is also possible.
In accordance with FIG. 2 , a number of initial parameters are namely again defined in a step 210 . This is shown in FIG. 5 . The positions L 24 and L 25 are in this case suitable specific positions of the handling device 2 on the supplementary track which leads from the removal position L 22 to the rest position L 21 . Another value, e.g. the closing position L 41 , could also be selected as the supplementary end position Z 3 . As a result the handling device 2 is now the base element, the moving tool part 4 the supplementary element. In steps 211 to 213 —in a similar way to steps 204 to 206 —the computer 11 is called, the base and the supplementary position set value G* and Z* are accepted and also the supplementary position set values G*, Z* output to the handling device 2 and the moving tool part 4 . By contrast with step 206 however, the base position set value G* is now specified to the handling device 2 , the supplementary position set value Z* to the moving tool part 4 .
In step 214 and 215 a check is performed as to whether the base position set value G* corresponds to the rest position of the handling device 2 and the supplementary position set value Z* to the closing position of the moving tool. Only when the two conditions are fulfilled is a transition to a step 216 undertaken, else the program returns to the step 212 .
In the step 216 the control device 5 checks whether the further execution of the method of operation is to be ended. If this is not the case, the next injection molding process is initiated in a step 217 and the program returns to step 202 . Else the method of operation is ended.
For the method explained above in connection with FIGS. 1 to 4 the control device 5 also specifies to the handling device 2 and the moving tool part 4 the base position set values G* determined and the supplementary position set values Z* determined. On the basis of these specifications the base element (e.g. the moving tool part 4 ) and the supplementary element (e.g. the handling device 2 ) is moved in a position-guided manner in accordance with the position set values G*, Z* determined and specified. The inventive determination method in this case is executed online by the computer 11 .
It is also possible however to determine the base and supplementary position set values G*, Z* in advance and offline. In this case the computer 11 itself features, in accordance with FIG. 6 , a program memory 12 in which a determination program 13 is stored. The determination program 13 is this case is supplied to the computer 11 by means of a data medium 14 on which the determination program is also stored. An example of such a data medium 14 is again a CD-ROM 14 . Supply via a computer-computer link would again also be possible.
When the determination program 13 is called, the computer 11 basically executes the same method as was described above in connection with FIG. 2 to 5 . The steps 202 , 209 , 216 and 217 are omitted however. Instead of steps 204 to 206 and 211 to 213 , steps 401 to 417 are executed.
Furthermore it must obviously be guaranteed that a correct assignment to the moving elements 2 , 4 of the base and supplementary position set values G*, Z* determined is undertaken. To do this, the computer 11 preferably creates a control file 15 , containing the sequence of base position set values G* and corresponding supplementary position set values Z*. The control file 15 can then again be stored on a suitable data medium 16 , for example a memory card 16 .
It is thus possible to guarantee in a simple manner, by means of the inventive determination or operation method, that the production machine can be operated on the one hand in a highly dynamic way but that collisions are still certain to be avoided.
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A control device for controlling the movement of a machine determines a base position set value according to a given base track in space. By limitation of a base element of a machine therewith, the above is hence positionally moved along a base track. The control device further determines a corresponding current supplementary end position in space using the base position set value. The control device also determines a supplementary position set value from a given fixed supplementary start position in space and the current supplementary end position. By limitation of a supplementary element of the machine thereto, the above is thus displaced along an current supplementary track from the supplementary start position, to the current supplementary end position.
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[0001] This application is a division of application Ser. No. 11/338,729 filed Jan. 25, 2006, which is a division of application Ser. No. 10/186,745 filed Jul. 2, 2002, which is a division of application Ser. No. 09/584,406, filed Jun. 1, 2000, the entire contents of each of which is hereby incorporated by reference in this application.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a wheel speed detector that is intended to detect the rotating speed of a wheel and used for the antilock brake or the like of an automobile.
[0004] 2. Discussion of Prior Art
[0005] Conventionally, as a wheel speed detector of this type, there has been provided a detector that is provided with a magnetic sensor fixed to the fixed side of an inner ring and an outer ring and a magnetic ring arranged on the rotating side so as to face this magnetic sensor and detects the rotating speed of the wheel by detecting a magnetic field varied in accordance with the rotation of this magnetic ring by means of the magnetic sensor.
[0006] The wheel speed detector of the above type has conventionally been arranged independently of a seal device for sealing a space between the inner ring and the outer ring with respect to the outside. This accordingly requires a special-purpose space and disadvantageously leads to a lack of compactness. The above arrangement also requires certain consideration for the dispositional relation of the detector relative to the other components that constitute the wheels and accordingly leads to the problem that the workability in the assembling stage is not good.
SUMMARY OF THE INVENTION
[0007] Accordingly, the object of the present invention is to provide a compact wheel speed detector capable of saving space around the wheels and improving the workability.
[0008] In order to achieve the object, there is provided a wheel speed detector for detecting a relative rotating speed between an outer ring and an inner ring by means of a magnetic sensor in association with an opposite magnetic ring, wherein one of the outer ring and the inner ring is rotatable while the other is stationary, the magnetic ring is fixed to the rotatable ring and the magnetic sensor is fixed to the stationary ring,
[0009] the magnetic ring and the magnetic sensor being integrated with a seal device for sealing a gap between the inner ring and the outer ring.
[0010] According to the present invention, the magnetic ring and the magnetic sensor are integrated with the seal device for sealing the gap between the inner ring and the outer ring. This arrangement can improve the compactness and the workability in the assembling stage.
[0011] In one embodiment of the present invention, the seal device has the magnetic ring and the magnetic sensor built-in.
[0012] According to the above construction, the seal device has the magnetic ring and the magnetic sensor built-in. This arrangement can enable the space saving around the wheels.
[0013] In one embodiment of the present invention, the magnetic ring is fixed to a rotatable member of the seal device for sealing the gap between the inner ring and the outer ring, and the magnetic sensor is fixed to a stationary member of the seal device.
[0014] According to the above construction, the magnetic ring and the magnetic sensor are integrated with the seal device by fixing the magnetic ring to the rotatable member of the seal device and fixing the magnetic sensor to the stationary member. This arrangement can enable the space saving around the wheels and improve the compactness and the workability in the assembling stage.
[0015] In one embodiment of the present invention, the magnetic ring and the magnetic sensor are arranged in a space where the rotatable member and the stationary member of the seal device face each other.
[0016] According to the above construction, the magnetic ring and the magnetic sensor are arranged in the space where the rotatable member and the stationary member of the seal device face each other. This arrangement can enable the space saving around the wheels and improve the compactness and the workability in the assembling stage.
[0017] In one embodiment of the present invention, a seal portion of the seal device is provided on both sides of the portion where the magnetic ring and the magnetic sensor face each other.
[0018] According to the above construction, the seal portion is provided on both sides of the oppositional portion where the magnetic ring and the magnetic sensor face each other. This can prevent water from intruding into the bearing inwardly of the magnetic sensor and prevent lubricant from leaking out of the bearing.
[0019] In one embodiment of the present invention, the magnetic ring and the magnetic sensor face each other obliquely with respect to the axis of rotation of the inner ring and the outer ring.
[0020] According to the above construction, the magnetic ring and the magnetic sensor, which face each other obliquely with respect to the axis of rotation of the inner ring and the outer ring, can be reduced in the radial dimension and compacted.
[0021] In one embodiment of the present invention, the stationary member of the seal device concurrently serves as a magnetic path of the magnetic sensor.
[0022] According to the above construction, the stationary member of the seal device concurrently serves as the magnetic path (yoke) of the magnetic sensor, and this can reduce the number of components for the achievement of compacting.
[0023] In one embodiment of the present invention, a seal portion constructed of a slinger and a seal lip to be brought in sliding contact with the slinger is provided axially outside the oppositional portion where the magnetic ring and the magnetic sensor face each other, and a main seal portion is provided between this seal portion and the oppositional portion.
[0024] According to the above construction, the additional seal portion constructed of the slinger and the axial seal lip is provided outside the main seal portion. This arrangement can improve the sealing performance and improve, in particular, the waterproof performance of the sensor portion.
[0025] In one embodiment of the present invention, the seal device is constructed of a rotatable member and a stationary member,
[0026] the magnetic sensor is fixed to the stationary member, the magnetic ring is fixed to the rotatable member, and the magnetic ring is covered with a nonmagnetic elastic member.
[0027] According to the above construction, the magnetic ring is covered with the nonmagnetic elastic member. This arrangement can prevent the magnetic foreign material such as iron powder from adhering to the magnetic ring and prevent the occurrence of noises.
[0028] In one embodiment of the present invention, the stationary member and the rotatable member constitute a labyrinth seal, and
[0029] the nonmagnetic elastic member is provided with an axial lip that extends in the axial direction and comes in sliding contact with the stationary member and a main lip that extends in the radial direction and comes in sliding contact with the stationary member.
[0030] According to the above construction, the labyrinth seal constructed of the stationary member and the rotatable member, the axial lip and the main lip can provide three-point sealing, and this can reliably prevent water from intruding into the bearing.
[0031] In one embodiment of the present invention, the nonmagnetic elastic member is provided with an auxiliary lip that comes in sliding contact with the stationary member inside the main lip.
[0032] According to the above construction, the auxiliary lip brought in sliding contact with the stationary member inside the main lip is provided, and this can further improve the waterproof performance.
[0033] In one embodiment of the present invention, the stationary member is made of austenite-based stainless steel, copper or aluminum.
[0034] According to the above construction, the stationary member for fixing the magnetic sensor is made magnetic with the material of austenite-based stainless steel, copper or aluminum. This arrangement can improve the magnetic detection accuracy of the magnetic sensor.
[0035] In one embodiment of the present invention, the seal device is constructed of a rotatable member and a stationary member,
[0036] an axial lip that extends axially outwardly of an axial outer surface of the rotatable member and comes in sliding contact with an axial inner surface of the stationary member is provided,
[0037] the magnetic ring is fixed to an axial inner surface of the rotatable member, and the magnetic sensor is fixed to an axial outer surface of the stationary member.
[0038] According to the above construction, the magnetic ring is fixed to the inner surface of the rotatable member, and the axial lip is fixed to the outer surface of the rotatable member. This arrangement can magnetize the magnetic ring from inside the rotatable member without being obstructed by the axial lip and facilitate the manufacturing.
[0039] In one embodiment of the present invention, the rotatable member is a magnetic body.
[0040] According to the above construction, the rotatable member to which the magnetic ring is fixed is magnetic, and this can increase the magnetic force of the magnetic ring.
[0041] In one embodiment of the present invention, the magnetic ring and the magnetic sensor face each other in the radial direction.
[0042] According to the above construction, the magnetic ring and the magnetic sensor face each other in the radial direction, and this can reduce the axial dimension and achieve compacting in the axial direction.
[0043] In one embodiment of the present invention, the seal device is constructed of a rotatable member and a stationary member,
[0044] the magnetic ring is fixed to the rotatable member, the magnetic sensor is fixed to the stationary member and there are provided
[0045] a main lip that is fixed to the rotatable member or the stationary member and seals a path between the rotatable member and the stationary member, a first auxiliary lip located inside the main lip, an axial lip located outside the main lip and a second auxiliary lip located outside the axial lip.
[0046] According to the above construction, the second auxiliary lip located outside the axial lip is provided in addition to the main lip, the first auxiliary lip and the axial lip, and this can improve the sealing performance. The second auxiliary lip prevents muddy water from directly splashing on the axial lip, and this can improve muddy water resistance.
[0047] In one embodiment of the present invention, the inner ring is rotatable, and
[0048] the second auxiliary lip is fixed to the rotatable member fixed to the inner ring and extends radially outwardly to seal a path between the rotatable member and the stationary member.
[0049] According to the above construction, the second auxiliary lip is fixed to the rotatable member fixed to the rotatable inner ring located, and therefore, a centrifugal force in the rotating stage presses the second auxiliary lip against the stationary member located radially outside. This arrangement can improve the sealing performance in the rotating stage.
[0050] In one embodiment of the present invention, a cover member for covering the magnetic sensor is provided,
[0051] the cover member has an inclined surface inclined relative to the axis of rotation of the outer ring and the inner ring and
[0052] a harness connected to the magnetic sensor is projecting from the inclined surface.
[0053] According to the above construction, the harness is made to project from the inclined surface of the cover member of the magnetic sensor, and this can widen the harness outlet width.
[0054] In one embodiment of the present invention, the seal device is constructed of a rotatable member and a stationary member,
[0055] a magnetic ring and a magnetic sensor are fixed to an axial oppositional portion where the rotatable member and the stationary member face each other, and
[0056] a cover member for covering the magnetic sensor has
[0057] one or more ring-shaped projections that form a labyrinth in a path that extends in the radial direction between the rotatable member and the stationary member.
[0058] According to the above construction, the cover member for covering the magnetic sensor fixed to the stationary member has the ring-shaped projection, and this ring-shaped projection forms the labyrinth in the path that extends in the radial direction between the stationary member and the rotatable member. This arrangement accordingly obviates the need for forming an axial lip for sealing the path in the radial direction on the rotatable member. Therefore, the axial lip does not become an obstacle in magnetizing the magnetic ring fixed to the radial portion of the rotatable member, allowing the manufacturing to be facilitated.
[0059] In one embodiment of the present invention, the seal device is constructed of a rotatable member and the stationary member,
[0060] the magnetic ring is fixed to the rotatable member, the magnetic sensor is fixed to the stationary member and
[0061] at least part of the magnetic sensor is arranged in a hole formed through the stationary member.
[0062] According to the above construction, at least part of the magnetic sensor is arranged in the hole formed in the stationary member. This arrangement can promote the space saving and provides excellent mountability in the case of a small space.
[0063] In one embodiment of the present invention, all seal lips are fixed to the stationary member to which the magnetic sensor is fixed.
[0064] According to the above construction, all the seal lips are fixed to the stationary member to which the magnetic sensor is fixed, and this simplifies the structure.
[0065] In one embodiment of the present invention, the stationary member has a removable cover metal fitting, and the magnetic sensor is mounted on the cover metal fitting.
[0066] According to the above construction, the magnetic sensor is mounted on the removable cover metal fitting, and this facilitates the replacement of the magnetic sensor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0067] The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
[0068] FIG. 1 is a sectional view of a wheel speed detector according to a first embodiment of the present invention;
[0069] FIG. 2 is a sectional view of a wheel speed detector according to a second embodiment of the present invention;
[0070] FIG. 3 is a sectional view of a modification example of the second embodiment;
[0071] FIG. 4 is a sectional view of a wheel speed detector according to a third embodiment of the present invention;
[0072] FIG. 5 is a sectional view of a wheel speed detector according to a fourth embodiment of the present invention;
[0073] FIG. 6 is a sectional view of a wheel speed detector according to a fifth embodiment of the present invention;
[0074] FIG. 7 is a sectional view showing the structure around the wheel speed detector of the fifth embodiment;
[0075] FIG. 8 is a sectional view of a wheel speed detector according to a sixth embodiment of the present invention;
[0076] FIG. 9 is a sectional view of a wheel speed detector according to a seventh embodiment of the present invention;
[0077] FIG. 10 is a sectional view of a wheel speed detector according to an eighth embodiment of the present invention;
[0078] FIG. 11 is a sectional view of a wheel speed detector according to a ninth embodiment of the present invention;
[0079] FIG. 12 is a sectional view of a wheel speed detector according to a tenth embodiment of the present invention;
[0080] FIG. 13 is a sectional view of a wheel speed detector according to an eleventh embodiment of the present invention;
[0081] FIG. 14 is a sectional view of a wheel speed detector according to a twelfth embodiment of the present invention;
[0082] FIG. 15 is a sectional view of a wheel speed detector according to a thirteenth embodiment of the present invention;
[0083] FIG. 16 is a sectional view of a wheel speed detector according to a fourteenth embodiment of the present invention;
[0084] FIG. 17 is a sectional view of a wheel speed detector according to a fifteenth embodiment of the present invention;
[0085] FIG. 18 is a sectional view of a wheel speed detector according to a sixteenth embodiment of the present invention; and
[0086] FIG. 19 is a sectional view of a modification example of the sixteenth embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0087] The present invention will be described in detail below on the basis of the embodiments thereof shown in the drawings.
First Embodiment
[0088] FIG. 1 shows the wheel speed detector of the first embodiment of the present invention. The wheel speed detector of the present first embodiment is integrated into a seal device 5 that seals a space between an inner ring 2 and an outer ring 3 of a ball bearing 1 .
[0089] The seal device 5 is provided with a core bar 6 fixed to an inner peripheral surface 3 A of the outer ring 3 located on the rotating side and a slinger 7 fixed to an outer peripheral surface 2 A of the inner ring 2 located on the stationary side. The core bar 6 has a cylindrical portion 6 A that is projecting in the axial direction from the outer ring 3 and a flange portion 6 B that extends from this cylindrical portion 6 A outwardly in the radial direction. The cylindrical portion 6 A is provided with a plurality of windows 8 at specified intervals in the circumferential direction, and a seal lip 10 made of a nonmagnetic elastic member is fixed to the flange portion 6 B. The cylindrical portion 6 A constitutes a magnetic ring 9 of the wheel speed detector. Further, the seal lip 10 has a main lip 10 A, an auxiliary lip 10 B and an axial lip 10 C. The seal lip 10 has a lid portion 10 D that closes the windows 8 of the cylindrical portion 6 A.
[0090] On the other hand, the slinger 7 is constructed of an inner cylindrical portion 7 A, an outer cylindrical portion 7 B and a disk portion 7 C that connects the inner cylindrical portion 7 A with the outer cylindrical portion 7 B. A magnetic sensor 11 is fixed to the inner peripheral surface of the inner cylindrical portion 7 A. This magnetic sensor 11 is constructed of a magnet 12 , a coil 13 and a yoke 15 . This magnetic sensor 11 faces from inside the cylindrical portion 6 A provided with the windows 8 that constitute the magnetic ring 9 . A signal line 16 is connected to this coil 13 . The signal line 16 is led outwardly in the axial direction through a cylindrical hole 17 formed in the disk portion 7 C of the slinger 7 . A cylindrical connector 18 is fit in the cylindrical hole 17 of the slinger 7 , and the signal line 16 passes through the approximate center of this connector 18 .
[0091] The disk portion 7 C of the slinger 7 faces the flange portion 6 B of the core bar 6 , and the main lip 10 A and the auxiliary lip 10 B fixed to this flange portion 6 B are brought in sliding contact with the disk portion 7 C. The axial lip 10 C is brought in sliding contact with the inner peripheral surface of the outer cylindrical portion 7 B of the slinger 7 .
[0092] The cylindrical portion 6 A of the core bar 6 that constitutes the magnetic ring 9 and the magnetic sensor 11 constitute the wheel speed detector of the present first embodiment. The magnetic sensor 11 is covered with a resin 14 .
[0093] In the wheel speed detector having the above construction, the core bar 6 that constitutes the magnetic ring 9 integrally with the outer ring 3 rotates when the outer ring 3 rotates relative to the inner ring 2 , and a change in magnetic field due to the rotation of this magnetic ring 9 is detected by the magnetic sensor 11 , and a signal that represents the rotating speed is taken out of the signal line 16 . On the other hand, the seal device 5 prevents water and dust from intruding into the bearing from the outside by means of the seal lip 10 fixed to the core bar 6 and prevents lubricant from leaking out of the bearing.
[0094] The wheel speed detector of the present first embodiment is integrated with the inside of the seal device 5 , and the magnetic ring 9 serves as part (core bar 6 ) of the seal device 5 . This arrangement can achieve the compacting and reduction in the number of components and improves the space saving and assembling workability.
Second Embodiment
[0095] Next, FIG. 2 shows the wheel speed detector of the second embodiment of the present invention. The present second embodiment is integrated with the inside of a seal device 23 for sealing a space between an inner ring 21 and an outer ring 22 of the bearing. This seal device 23 has a sectionally L-figured ring-shaped rotating side member 25 fixed to the outer peripheral surface of the inner ring 21 and a ring-shaped stationary side member 26 fixed to the inner peripheral surface of the outer ring 22 . This stationary side member 26 is constructed of an outer cylindrical portion 26 A, an inner cylindrical portion 26 B and a disk portion 26 C extending between both the cylindrical portions. Then, a sectionally H-figured seal lip 27 having a two-layer structure is fixed to the leading end of a flange portion 25 A of the rotating side member 25 , and this seal lip 27 is brought in sliding contact with the inner peripheral surface of the outer cylindrical portion 26 A of the stationary side member 26 . On the other hand, a seal lip 28 is fixed to the leading end of a cylindrical portion 25 B of the rotating side member 25 . This seal lip 28 is brought in sliding contact with the outer peripheral surface of the inner cylindrical portion 26 B of the stationary side member 26 .
[0096] On the other hand, a magnetized pulser ring 30 that serves as a magnetic ring is fixed to the axial outer surface of the flange portion 25 A of the rotating side member 25 . A magnetic sensor 31 is fixed to the inner surface of the disk portion 26 C of the stationary side member 26 and axially faces the magnetized pulser ring 30 . This magnetized pulser ring 30 is formed of a material obtained by mixing magnetic powder with a rubber or resin and is magnetized so that a north pole and a south pole are alternately arranged in the circumferential direction. On the other hand, the magnetic sensor 31 is constructed of a semiconductor circuit, and this magnetic sensor 31 is fit in a space between the outer cylindrical portion 26 A and the inner cylindrical portion 26 B of the stationary side member 26 and covered with a resin 32 . A signal line 33 from the magnetic sensor 31 is led axially outwardly through a hole 34 formed in the disk portion 26 C of the stationary side member 26 and arranged inside a cylindrical connector 37 mounted on an edge 35 of the hole 34 via an O-ring 36 .
[0097] The magnetized pulser ring 30 and the magnetic sensor 31 constitute the wheel speed detector of the present embodiment. Even in the present embodiment, the magnetized pulser ring 30 and the magnetic sensor 31 are integrated with the inside of the seal device 23 . This arrangement enables the compacting and space saving and improves the assembling workability. Furthermore, a seal portion is constructed of the seal lips 27 and 28 on both sides of a portion where the magnetized pulser ring 30 and the magnetic sensor 31 face each other. This arrangement can prevent water from entering inwardly of the magnetic sensor 31 and prevent the lubricant from leaking out of the bearing.
[0098] In the second embodiment, the magnetized pulser ring 30 and the magnetic sensor 31 are made to face each other in the axial direction. However, as shown in FIG. 3 , it is acceptable to fix a magnetic sensor 42 to the inner peripheral surface of a cylindrical portion 43 A elongated in the axial direction of a stationary side member 43 , fix a magnetized pulser ring 41 to the outer peripheral surface of a cylindrical portion 45 A elongated in the axial direction of a rotating side member 45 and make the magnetized pulser ring 41 and the magnetic sensor 42 face each other in the radial direction. Although the magnetized pulser ring is made to face the very front of the magnetic sensor in the second embodiment and the embodiments described below, the magnetized pulser ring and the magnetic sensor may be made to obliquely face each other. There may be an arrangement such that the magnetized pulser ring and the magnetic sensor are relatively displaced from the face-to-face positions to the mutually displaced positions along the plane of opposition. It was confirmed that the magnetic sensor was able to detect a magnetic change due to the rotation of the magnetized pulser ring even in the obliquely displaced positions or the mutually displaced positions as described above.
Third Embodiment
[0099] Next, FIG. 4 shows the wheel speed detector of the third embodiment of the present invention. The present third embodiment is integrated with the inside of a seal device 53 arranged between an inner ring 51 and an outer ring 52 . The inner ring 51 is mounted around an inner cylinder 50 . Then, balls 54 are arranged between the inner ring 51 and the outer ring 52 , while balls 59 are arranged between the inner cylinder 50 and the outer ring 52 .
[0100] The seal device 53 is provided with a rotating side annular member 55 fixed to the outer peripheral surface of the inner ring 51 located on the rotating side and a stationary side annular member 57 fixed to the inner peripheral surface of the outer ring 52 located on the stationary side. The rotating side annular member 55 has a sectionally roughly V-figured shape and includes an axial cylindrical portion 55 A and an inclined flange 55 B. The stationary side annular member 57 has an axial cylindrical portion 57 A and inner flanges 57 B and 57 C located on both ends of the axial cylindrical portion 57 A. A seal lip 58 is fixed to this inner flange 57 C, and this seal lip 58 has an axial lip 58 A brought in sliding contact with the inner peripheral surface of the inclined flange 55 B of the rotating side annular member 55 , a main lip 58 B brought in sliding contact with the axial cylindrical portion 55 A of the rotating side annular member 55 and an auxiliary lip 58 C.
[0101] A base portion 60 A of a wire harness 60 is fixed from the inner flange 57 B of the stationary side annular member 57 to the axial cylindrical portion 57 A. In this base portion 60 A is a resin-molded outer seal lip 61 whose main lip 61 A and auxiliary lip 61 B are brought in sliding contact with the outer peripheral surface of the inner ring 51 . This base portion 60 A has an inclined surface 62 that faces the inclined flange 55 B of the rotating side annular member 55 at a specified interval, and a magnetic sensor 63 is buried in this inclined surface 62 . This magnetic sensor 63 is constructed of a semiconductor circuit and is connected to a signal processing circuit 65 . A magnetized pulser ring 66 that faces this magnetic sensor 63 and serves as a magnetic ring is fixed to the inclined flange 55 B. This magnetized pulser ring 66 uses a material obtained by mixing magnetic powder with a rubber or resin and magnetized so that a north pole and a south pole are alternately arranged in the circumferential direction.
[0102] The wheel speed detector constructed of the magnetic sensor 63 and the magnetized pulser ring 66 is integrated with the inside of the seal device 53 , and therefore, the detector is compact and has good assembling workability. The magnetic sensor 63 and the magnetized pulser ring 66 face each other obliquely with respect to the relative axis of rotation of the inner ring 51 and the outer ring 52 , and therefore, the radial dimensions can be reduced, allowing the compacting to be promoted.
Fourth Embodiment
[0103] Next, FIG. 5 shows the wheel speed detector of the fourth embodiment of the present invention. This fourth embodiment is integrated with a seal device 73 arranged between an inner ring 71 and an outer ring 72 . It is to be noted that the inner ring 71 is mounted around a shaft 74 . Balls 79 are arranged in a space between this shaft 74 and the outer ring 72 , while balls 70 are arranged in a space between the inner ring 71 and the outer ring 72 .
[0104] This seal device 73 is constructed of a sectionally bracket-shaped rotating side annular member 76 fixed to the outer peripheral surface of the inner ring 71 and a sectionally bracket-shaped stationary side annular member 78 fixed to the inner peripheral surface of the outer ring 72 . This stationary side annular member 78 is put inside the rotating side annular member 76 with interposition of a specified gap. Seal lips 80 and 81 are fixed to the radial inner ends 78 A and 78 B of the stationary side annular member 78 , and the seal lips 80 and 81 are brought in sliding contact with the cylindrical peripheral surface and the disk-shaped peripheral surface, respectively, of the rotating side annular member 76 .
[0105] A plurality of windows 82 are formed at specified intervals in the circumferential direction in the cylindrical portion of the rotating side annular member 76 , forming a magnetic ring 83 . A magnet 85 and a coil 86 are fixed to the inside of the stationary side annular member 78 , forming a magnetic sensor 87 . This stationary side annular member 78 is made of a magnetic material and plays the role of a yoke (magnetic path) of the magnetic sensor 87 .
[0106] The wheel speed detector of the present fourth embodiment, in which the magnetic ring 83 is constructed of the rotating side annular member 76 of the seal device 73 and the stationary side annular member 78 of the seal device 73 concurrently serves as the yoke (magnetic path) of the magnetic sensor 87 , can be reduced in the number of components, allowing the compacting to be further promoted.
Fifth Embodiment
[0107] Next, FIG. 6 shows the wheel speed detector of the fifth embodiment of the present invention. The present fifth embodiment is integrated with a seal device 93 arranged between an inner ring 91 and an outer ring 92 . It is to be noted that the inner ring 91 is arranged adjacently in two lines in the axial direction as shown in FIG. 7 where balls 94 are arranged between the inner ring 91 and the outer ring 92 . A seal device 99 having a structure similar to that of the seal device 93 is arranged axially on the opposite side of the seal device 93 .
[0108] The seal device 93 is provided with a sectionally L-figured annular slinger 95 fixed to the outer peripheral surface of the inner ring 91 and another sectionally L-figured annular slinger 96 fixed to the axial inside portion 95 A of this slinger 95 . These two slingers 95 and 96 constitute a rotating side member 97 . The seal device 93 has an annular core bar 98 that serves as a stationary side member fixed to the inner peripheral surface of the outer ring 92 . This annular core bar 98 is constructed of a bent portion 100 that is projecting outwardly in the axial direction and a projecting portion 101 that is projecting inwardly in the radial direction. A resin portion 102 that fills the inside of this bent portion 100 and forms a resin portion 102 along the projecting portion 101 , and a magnetic sensor 103 is molded in this resin portion 102 . A signal line 104 is connected to this magnetic sensor 103 , and this signal line 104 is connected to a harness 109 fixed to the outer peripheral surface of the bent portion 100 of the core bar 98 .
[0109] Then, a magnetic ring 105 is fixed to a radial portion 96 A of the slinger 96 so as to face this magnetic sensor 103 . On the other hand, a seal lip 106 is fixed to the projecting portion 101 of the core bar 98 . This seal lip 106 has a main lip 106 A and an auxiliary lip 106 B located axially inside this main lip 106 A. This main lip 106 A and the auxiliary lip 106 B are brought in sliding contact with the axial portion 95 A of the slinger 95 .
[0110] Further, the seal lip 106 is provided with an axial lip 106 C that extends obliquely in the axial direction radially outwardly of the main lip 106 A. This axial lip 106 C obliquely extends outwardly in the axial direction and outwardly in the radial direction and is brought in sliding contact with a radial portion 95 B of the slinger 95 .
[0111] In the wheel speed detector of the present fifth embodiment, the magnetic ring 105 and the magnetic sensor 103 are integrated with the inside of the seal device 93 . This arrangement enables the compacting and space saving and improves the assembling workability. Furthermore, the waterproof performance can be improved since the slingers 95 and 96 and the core bar 98 constitute the labyrinth structure and the seal lip 106 extending from the core bar 98 is brought in sliding contact with the slinger 95 by the three lips of the main lip 106 A, the auxiliary lip 106 B and the axial lip 106 C.
Sixth Embodiment
[0112] Next, FIG. 8 shows the wheel speed detector of the sixth embodiment of the present invention. The present sixth embodiment is integrated with a seal device 113 arranged between an inner ring 111 and an outer ring 112 . This seal device 113 is provided with a sectionally roughly inverted L-figured core bar 115 fixed to the inner peripheral surface of the outer ring 112 located on the rotating side and a sectionally roughly L-figured slinger 116 fixed to the inner ring 111 located on the stationary side. The core bar 115 and the slinger 116 have oppositional portions 115 A and 116 A that face each other in the axial direction. A magnetized pulser ring 117 that serves as a magnetic ring is fixed to the oppositional portion 115 A of this core bar 115 . A seal lip 118 constructed of a nonmagnetic elastic member is fixed to the oppositional portion 115 A of this core bar 115 so as to cover the magnetized pulser ring 117 . This seal lip 118 is provided with an auxiliary lip 118 A, a main lip 118 B and an axial lip 118 C. The auxiliary lip 118 A and the main lip 118 B are brought in sliding contact with a cylindrical portion 116 B of the slinger 116 , and the axial lip 118 C is brought in sliding contact with the oppositional portion 116 A of the slinger 116 . This axial lip 118 C extends outwardly in the axial direction and outwardly in the radial direction from the root portion to the leading end portion.
[0113] On the other hand, a magnetic sensor 120 is fixed to the outer surface of the oppositional portion 116 A of the slinger 116 . This magnetic sensor 120 is covered with a resin mold that constitutes a mold portion 121 . This mold portion 121 forms a labyrinth 122 oppositional to an axial end surface 115 C of the core bar 115 and an axial end surface 112 A of the outer ring 112 . The mold portion 121 has an inclined surface 121 A that inclines relative to a plane perpendicular to the axis of the rotary shaft, and this inclined surface 121 A serves as a surface for leading a signal line 123 from the magnetic sensor 120 . This inclined surface 121 A is upslope from the outside toward the inside in the axial direction.
[0114] In the present sixth embodiment, the magnetized pulser ring 117 is covered with the seal lip 118 constructed of the nonmagnetic elastic member, and accordingly, there is formed no such bridge that might connect the south pole with the adjacent north pole due to the adhesion of iron powder or the like to the magnetized pulser ring 117 . Therefore, the magnetic noise can be reduced and the rotating speed detection accuracy can be improved. Further, in this sixth embodiment, a labyrinth 122 is formed of a mold portion 121 in addition to the three lips 118 A, 118 B and 118 C owned by the seal lip 118 , and therefore, the waterproof performance can be improved. Further, in the present sixth embodiment, the slinger 116 for fixing the magnetic sensor 120 is made nonmagnetic with a material of austenite-based stainless steel, and therefore, the magnetic detection accuracy of the magnetic sensor 120 can be improved. Further, in the present sixth embodiment, a signal line 123 can be led out of the inclined surface 121 A owned by the mold portion 121 .
Seventh Embodiment
[0115] Next, FIG. 9 shows the wheel speed detector of the seventh embodiment of the present invention. The present seventh embodiment differs from the sixth embodiment shown in FIG. 8 in that the magnetized pulser ring 117 is fixed to an inner surface 115 A- 1 of the oppositional portion 115 A of the core bar 115 . In the present sixth embodiment, the magnetized pulser ring 117 is fixed to the inner surface 115 A- 1 of the oppositional portion 115 A of the core bar 115 . With this arrangement, the pulser ring 117 that is made of a material obtained by mixing magnetic powder with a rubber or resin and put in a non-magnetized state can be magnetized axially from inside. Therefore, the axial lip 118 C does not become an obstacle during the magnetization.
[0116] In the present seventh embodiment, the core bar 115 is made of a magnetic material, and therefore, the magnetic force of the pulser ring 117 can be increased.
Eighth Embodiment
[0117] Next, FIG. 10 shows the wheel speed detector of the eighth embodiment of the present invention. The present eighth embodiment is integrated with a seal device 133 arranged between an inner ring 131 and an outer ring 132 . This seal device 133 is provided with a core bar 135 that serves as a stationary side member and is fixed to the inner peripheral surface of the outer ring 132 located on the stationary side and a slinger 136 that serves as a rotating side member and is fixed to the outer peripheral surface of the inner ring 131 located on the rotating side.
[0118] The core bar 135 is provided with a cylindrical portion 135 A, an outer flange 135 B and an inner flange 135 C that extend in the radial direction from both axial ends of this cylindrical portion 135 A. A seal lip 137 having a main lip 137 A and a first auxiliary lip 137 B is fixed to the leading end of this inner flange 135 C. On the other hand, the slinger 136 is constructed of a disk portion 136 A and an outer cylindrical portion 136 B and an inner cylindrical portion 136 C that extend axially inwardly from both radial ends of this disk portion 136 A. The main lip 137 A and the first auxiliary lip 137 B of the seal lip 137 are brought in sliding contact with the inner cylindrical portion 136 C of this slinger 136 . A seal lip 138 is fixed to the outer cylindrical portion 136 B of the slinger 136 . This seal lip 138 has an axial lip 140 brought in sliding contact with the inner flange 135 C of the core bar 135 and a fourth lip 141 located axially outside this axial lip 140 . This seal lip 138 covers a magnetized pulser ring 142 fixed to the inner surface of the outer cylindrical portion 136 B of the slinger 136 .
[0119] On the other hand, a magnetic sensor 143 is fixed to the cylindrical portion 135 A of the core bar 135 , and this magnetic sensor 143 is buried in a resin portion 145 that serves as a cover member. A fourth lip 141 of the seal lip 138 is brought in sliding contact with this resin portion 145 . The resin portion 145 has an axial end portion 145 A that closely fit to the outer flange 135 B of the core bar 135 , and this axial end portion 145 A has an inclined surface 146 that is inclined relative to the axis of rotation. This inclined surface 146 is upslope from the outside toward the inside in the axial direction, and a harness 147 is projecting from this inclined surface 146 . This harness 147 is connected to a signal line 148 extending from the magnetic sensor 143 .
[0120] In the wheel speed detector of the present eighth embodiment, a magnetized pulser ring 142 and a magnetic sensor 143 face each other in the radial direction, and therefore, the axial dimensions can be reduced to enable the compacting in the axial dimension. Further, the present eighth embodiment is provided with a second auxiliary lip 141 located outside the axial lip 140 in addition to the main lip 137 A, the auxiliary lip 137 B and the axial lip 140 , and therefore, the sealing performance can be improved. In particular, the second auxiliary lip 141 prevents muddy water from directly splashing on the axial lip 140 , and therefore, an improved muddy water resistance can be achieved. Further, in the present eighth embodiment, the second auxiliary lip 141 is fixed to the slinger 136 fixed to the inner ring 131 located on the rotating side, and therefore, a centrifugal force in the rotating stage presses the second auxiliary lip 141 against the core bar 135 (cylindrical inner peripheral surface 144 of the resin portion 145 ) located radially outside. Therefore, the sealing performance during rotation can be improved. In the present eighth embodiment, the harness 147 is projecting from the inclined surface 146 of the resin portion 145 that covers the magnetic sensor 143 , and therefore, the harness outlet width can be widened. In the present eighth embodiment, the magnetized pulser ring 142 is completely covered with the seal lip 138 and placed inside the seal portion constructed of the seal lip 137 and the seal lip 138 . This removes the concern about the adhesion of a magnetic foreign material to the magnetized pulser ring 142 and restrains the occurrence of noises, thereby allowing a correct speed detection to be achieved.
Ninth Embodiment
[0121] Next, FIG. 11 shows the wheel speed detector of the ninth embodiment of the present invention. The present ninth embodiment is integrated with a seal device 153 arranged between an inner ring 151 and an outer ring 152 . This seal device 153 is provided with a sectionally roughly inverted L-figured core bar 155 fixed to the inner peripheral surface of the outer ring 152 located on the rotating side and a sectionally reversed L-figured slinger 156 fixed to the inner ring 151 located on the stationary side. The core bar 155 and the slinger 156 have respective oppositional portions 155 A and 156 A that face each other in the axial direction. A magnetized pulser ring 157 that serves as a magnetic ring is fixed to the oppositional portion 155 A of this core bar 155 . A seal lip 158 constructed of a nonmagnetic elastic member is fixed to the oppositional portion 155 A of this core bar 115 so as to cover the magnetized pulser ring 157 . This seal lip 158 has a main lip 158 A and an auxiliary lip 158 B that are brought in sliding contact with a cylindrical portion 156 B of the slinger 156 .
[0122] On the other hand, a magnetic sensor 160 is fixed to the inner surface of the oppositional portion 156 A of the slinger 156 , and this magnetic sensor 160 is completely covered with a resin portion 161 in which the slinger 156 is molded. This resin portion 161 has an annular inner diameter side projection 162 and an annular outer diameter side projection 163 that are projecting axially inwardly from the front surface of the magnetic sensor 160 toward the magnetized pulser ring 157 . The projection 162 and the projection 163 constitute a labyrinth 165 between the projections and a thin portion 158 C of the seal lip 158 that covers the magnetized pulser ring 157 .
[0123] According to the present ninth embodiment, the resin portion 161 that covers the magnetic sensor 160 fixed to the slinger 156 has ring-shaped projections 162 and 163 , and these ring-shaped projections 162 and 163 form the labyrinth 165 in a path that extends in the radial direction between the core bar 155 and the slinger 156 . This obviates the need for forming the axial lip for radially sealing the path on the core bar 155 . Therefore, the axial lip does not become an obstacle in magnetizing the magnetic pulser ring 157 to be fixed to the oppositional portion (radial portion) 155 A of the core bar 155 , allowing the manufacturing to be facilitated.
[0124] The point that this resin portion 161 can widen the harness outlet width by virtue of the inclined surface 161 A located at the axial end is similar to those of the aforementioned sixth and seventh embodiments shown in FIG. 8 and FIG. 9 .
[0125] In the aforementioned embodiment, the magnetized pulser ring 157 is fixed to the axial outer surface of the oppositional portion 155 A of the core bar 155 . However, as indicated by the one-dot chain lines, the magnetized pulser ring 157 may be fixed to the axial inner surface of the oppositional portion 155 A.
Tenth Embodiment
[0126] Next, FIG. 12 shows the wheel speed detector of the tenth embodiment of the present invention. The present tenth embodiment is integrated with a seal device 173 arranged between an inner ring 171 and an outer ring 172 . This seal device 173 is provided with a sectionally inverted L-figured slinger 175 that serves as a rotating side member fixed to the inner peripheral surface of the outer ring 172 located on the rotating side and a sectionally L-figured core bar 176 that serves as a stationary side member fixed to the outer peripheral surface of the inner ring 171 located on the stationary side.
[0127] The sectionally L-figured core bar 176 is provided with a cylindrical portion 176 A and a flange portion 176 B that radially extends from the axial outer end of this cylindrical portion 176 A. This flange portion 176 B has an axial through hole 177 , and a magnetic sensor 178 is fit in this axial through hole 177 . Then, a seal lip 180 is fixed to the core bar 176 so as to cover this magnetic sensor 178 . This seal lip 180 is provided with a main lip 180 A, an auxiliary lip 180 B and an axial lip 180 C. This axial lip 180 C obliquely extends inwardly in the axial direction and outwardly in the radial direction from the root portion toward the leading end. The main lip 180 A and the auxiliary lip 180 B are brought in sliding contact with a cylindrical portion 175 A of the sectionally inverted L-figured slinger 175 , while the axial lip 180 C is brought in sliding contact with a flange portion 175 B of the sectionally inverted L-figured slinger 175 .
[0128] A magnetized pulser ring 181 that serves as a magnetic ring is fixed to the axial outer surface of the flange portion 175 B of the sectionally inverted L-figured slinger 175 so as to face the magnetic sensor 178 .
[0129] The magnetized pulser ring 181 and the magnetic sensor 178 constitute the wheel speed detector of the present tenth embodiment. A signal line 182 is connected to the radial inner end surface of this magnetic sensor 178 , and this signal line 182 is buried in a resin portion 183 fixed to the end surface of the core bar 176 and extends outwardly in the axial direction and outwardly in the radial direction.
[0130] In the present tenth embodiment, part of the magnetic sensor 178 is arranged inside the axial through hole 177 formed through the core bar 176 . This arrangement can promote the space saving and provides excellent mountability in the case of a small space. In the present tenth embodiment, all the seal lips (main lip 180 A, auxiliary lip 180 B and axial lip 180 C) are fixed to the core bar 176 to which the magnetic sensor 178 is fixed, and therefore, the structure becomes simple.
Eleventh Embodiment
[0131] Next, FIG. 13 shows the wheel speed detector of the eleventh embodiment of the present invention. The present eleventh embodiment is constructed of a magnetic sensor 193 and a magnetized pulser ring 203 and integrated with the inside of a seal device 187 arranged between an inner ring 185 and an outer ring 186 . This seal device 187 is provided with a sectionally inverted L-figured core bar 188 fixed to the inner peripheral surface of the outer ring 186 located on the stationary side and a sectionally reversed L-figured slinger 191 fixed to the outer peripheral surface of the inner ring 185 located on the rotating side. The seal device 187 is further provided with an inverted L-figured metal fitting 192 fixed in an overlapping manner to a cylindrical portion 188 A of the core bar 188 . A magnetic sensor 193 is fixed to the inner surface of an axial end radial portion 192 A of this inverted L-figured metal fitting 192 , and this magnetic sensor 193 is covered with a resin 194 . A signal line 195 extending from this magnetic sensor 193 extends obliquely outwardly inside a resin portion 197 through a hole 196 formed through a cylindrical portion 192 B of the inverted L-figured metal fitting 192 . This resin portion 197 is fixed to the L-figured metal fitting 192 and extends obliquely outwardly.
[0132] A second auxiliary lip 200 is fixed to an inner end 198 bent inwardly of the radial portion 192 A of this inverted L-figured metal fitting 192 . This second auxiliary lip 200 is externally brought in sliding contact with a flange portion 191 A of the slinger 191 .
[0133] On the other hand, a main lip 201 and a first auxiliary lip 202 are fixed to the inner end of an inner flange 188 b of the core bar 188 , and this main lip 201 and the first auxiliary lip 202 are brought in sliding contact with a cylindrical portion 191 B of the slinger 191 . A leading end portion 191 A- 1 of the flange portion 191 A of this slinger 191 is bent inward, and a magnetized pulser ring 203 that serves as a magnetic ring is fixed to the inner surface of this leading end portion 191 A- 1 . An axial lip 205 constructed of a nonmagnetic elastic member is fixed to the magnetized pulser ring 203 so as to cover the magnetized pulser ring 203 , and this axial lip 205 is brought in sliding contact with the inner flange 188 B of the core bar 188 .
[0134] The wheel speed detector of the present eleventh embodiment is protected from an external impact such as a kicked stone by the inverted L-figured metal fitting 192 . Both the magnetic sensor 193 and the magnetized pulser ring 203 are covered with the resin 194 constructed of a nonmagnetic member and the axial lip 205 so as to be protected from moisture and dust. The inverted L-figured metal fitting 192 and the slinger 191 constitute a labyrinth 206 , and a sealing performance is improved by the existence of the added second auxiliary lip 200 provided for the inverted L-figured metal fitting 192 .
Twelfth Embodiment
[0135] Next, FIG. 14 shows the wheel speed detector of the twelfth embodiment of the present invention. The present twelfth embodiment is constructed of a magnetic sensor 211 fixed to a sectionally step-shaped stationary side member 215 and a magnetized pulser ring 212 fixed to a sectionally step-shaped rotating side member 216 .
[0136] The stationary side member 215 is fixed to the outer peripheral surface of an outer ring 217 , bent inward along the end surface and then extended in the axial direction. The rotating side member 216 is fixed to the outer peripheral surface of an inner ring 218 , bent radially outwardly and extended in the axial direction so as to face the stationary side member 215 with interposition of a specified gap. The stationary side member 215 and the rotating side member 216 face each other in the respective oppositional portions 215 A and 216 A. A magnetic sensor 211 is fixed to the outer peripheral surface of this oppositional portion 215 A, and a magnetized pulser ring 212 is fixed to the inner peripheral surface of the oppositional portion 216 A.
[0137] The magnetic sensor 211 is completely covered with a resin portion 223 fixed to the stationary side member 215 . This resin portion 223 has a connecting portion 223 A that is projecting obliquely in the axial direction.
[0138] The magnetized pulser ring 212 is covered with a cover 220 constructed of a nonmagnetic elastic member, and this cover 220 has a seal lip 220 A brought in sliding contact with the oppositional portion 215 A of the stationary side member 215 . A core bar 221 is fixed to the inner peripheral surface of the outer ring 217 , and a seal lip 222 is fixed to a flange 221 A of this core bar 221 . This seal lip 222 has a main lip 222 A, a first auxiliary lip 222 B and an axial lip 222 C. The main lip 222 A and the first auxiliary lip 222 B are brought in sliding contact with a cylindrical portion 216 B of the rotating side member 216 . The axial lip 222 C is brought in sliding contact with a flange portion 216 C of the rotating side member 216 .
[0139] The wheel speed detector of the present twelfth embodiment is constructed of the magnetic sensor 211 and the pulser ring 212 and is integrated with a seal device constructed of the stationary side member 215 , rotating side member 216 , core bar 221 and seal lips 222 and 220 A. This arrangement can simplify the overall structure and reduce the number of components. The magnetic sensor 211 and the pulser ring 212 are completely covered with the resin portion 223 and the cover 220 , and therefore, the external influence of a foreign material can be avoided. The mixture of a foreign material into the sensor portion can be prevented by the second auxiliary lip 220 A.
Thirteenth Embodiment
[0140] Next, FIG. 15 shows the wheel speed detector of the thirteenth embodiment of the present invention. The present thirteenth embodiment is constructed of a magnetized pulser ring 231 and a magnetic sensor 232 that face each other in the axial direction. The magnetized pulser ring 231 is fixed to a core bar 233 and covered with a thin film 235 constructed of a nonmagnetic elastic member continued from a seal lip 234 . The magnetic sensor 232 is fixed to a slinger 236 and is covered with a nonmagnetic thin film 238 continued from a resin portion 237 .
[0141] The core bar 233 has a disk portion 233 A that extends radially inwardly at the axial inner end, and a seal lip 234 is fixed to this disk portion 233 A. This seal lip 234 has the three lips of a main lip 234 A, an auxiliary lip 234 B and an axial lip 234 C. The main lip 234 A and the auxiliary lip 234 B are brought in sliding contact with a cylindrical portion 236 A of the slinger 236 , while the axial lip 234 C is brought in sliding contact with a flange portion 236 B of the slinger 236 .
[0142] On the other hand, a resin portion 237 fixed to the slinger 236 has an annular projection 237 A that faces the inner peripheral surface of an outer peripheral wall 233 B of the core bar 233 , and this annular projection 237 A forms a labyrinth between the annular projection 237 A and the outer peripheral wall 233 B. Further, a harness 240 is projecting from an axial end surface 237 B of the resin portion 237 .
[0143] Then, a cylindrical portion 236 A of the slinger 236 is fixed to an inner ring 241 , and a cylindrical portion 233 C of the core bar 233 is fixed to an outer ring 242 .
[0144] The core bar 233 , the slinger 236 , the seal lip 234 and the annular projection 237 A of the resin portion 237 constitute a seal device.
[0145] In the wheel speed detector of the present thirteenth embodiment, the magnetized pulser ring 231 and the magnetic sensor 232 are integrated with the inside of the seal device. This enables the compacting and space saving and improves the assembling workability.
[0146] Further, the annular projection 237 A fixed to the slinger 236 and the outer peripheral wall 233 B of the core bar 233 constitute the labyrinth structure. This arrangement can prevent the external foreign material from entering the portion where the magnetic sensor 232 and the pulser ring 231 face each other and avoid the influence of the foreign material on the signal. The pulser ring 231 is covered with the thin film 235 made of a nonmagnetic elastic member, and the magnetic sensor 232 is covered with the nonmagnetic thin film 238 connected to the resin portion 237 . Therefore, the waterproof performance can be improved.
Fourteenth Embodiment
[0147] Next, FIG. 16 shows the wheel speed detector of the fourteenth embodiment of the present invention. The present fourteenth embodiment is integrated with the inside of a seal device 247 for sealing a gap between a rotating side inner ring 245 and a stationary side outer ring 246 .
[0148] This seal device 247 is provided with a core bar 248 fixed to the outer ring 246 and a slinger 250 fixed to the inner ring 245 . A seal lip 251 is fixed to an inner diameter portion 248 A of a core bar 248 . This seal lip 251 is provided with a main lip 251 A and a first auxiliary lip 251 B brought in sliding contact with a cylindrical portion 250 A of the slinger 250 and an axial lip 251 C brought in sliding contact with a disk portion 250 B of the slinger 250 .
[0149] The core bar 248 is provided with a bent portion 248 B that is bent along a corner 246 A of the outer ring 246 and an outer peripheral portion 248 C that extends axially outwardly from a radial end of this bent portion 248 B. A removable cover metal fitting 252 is mounted on the inside of the outer peripheral portion 248 C of this core bar 248 . A magnetic sensor 256 is fixed to a resin 254 filled inside this cover metal fitting 252 . This cover metal fitting 252 is provided with a radial portion 252 A bent radially inwardly from the outer peripheral portion 248 C, and a second auxiliary lip 253 is fixed to an end of this radial portion 252 A. This second auxiliary lip 253 is brought in sliding contact with an axial portion 250 C of the slinger 250 . This cover metal fitting 252 is fixed to the core bar 248 by a calking portion 255 formed in the outer peripheral portion 248 C of the core bar 248 . By releasing the calking of this calking portion 255 , the cover metal fitting 252 can be removed from the core bar 248 by being slid in the axial direction. A hole 258 through which a signal line 257 extending from the magnetic sensor 256 extends is formed through this cover metal fitting 252 . This signal line 257 is led obliquely outwardly in the axial direction and is buried in a resin portion 259 fixed to the radial portion 252 A of the cover metal fitting 252 .
[0150] A magnetized pulser ring 260 of the present fourteenth embodiment is fixed to an axial portion 250 C of the slinger 250 and made to face the magnetic sensor 256 . The wheel speed detector of the present fourteenth embodiment, in which the magnetic sensor 256 and the pulser ring 260 are integrated with the inside of the seal device 247 , can be compacted, allowing the mounting work to be simplified. The magnetic sensor 256 is mounted on the removable cover metal fitting 252 according to this wheel speed detector, and therefore, the magnetic sensor 256 can be easily replaced. The second auxiliary lip 253 can prevent the foreign material from entering a portion where the pulser ring 260 and the magnetic sensor 256 face each other.
Fifteenth Embodiment
[0151] Next, FIG. 17 shows the wheel speed detector of the fifteenth embodiment of the present invention. The present fifteenth embodiment is integrated with the inside of a seal device 263 for sealing a gap between a rotating side outer ring 261 and a stationary side inner ring 262 .
[0152] This seal device 263 is provided with a core bar 265 fixed to a corner 261 A located on the inner diameter side of the outer ring 261 and a slinger 266 fixed to the inner peripheral surface of the inner ring 262 . A seal lip 267 is fixed to the inner end of an inner diameter portion 265 A of the core bar 265 . This seal lip 267 is provided with a main lip 267 A, an auxiliary lip 267 B and an axial lip 267 C. The main lip 267 A and the first auxiliary lip 267 B are brought in sliding contact with an inside axial portion 266 A of a slinger 266 , while an axial lip 267 C is brought in sliding contact with a disk portion 266 B of the slinger 266 .
[0153] The core bar 265 has an outside axial portion 265 B, and a cover metal fitting 268 is fixed to the inner side of the outside axial portion 265 B by a calking portion 270 of this outside axial portion 265 B. This cover metal fitting 268 is constructed of an axial portion 268 A and a radial portion 268 B that is bent inward in the radial direction. A magnetized pulser ring 271 is fixed to the inside of this axial portion 268 A, and a second auxiliary lip 272 is fixed to an end of the radial portion 268 B. This second auxiliary lip 272 is brought in sliding contact with an axial end of an outer axial portion 266 C of the slinger 266 .
[0154] A magnetic sensor 273 is fixed to the outer axial portion 266 C of this slinger 266 so as to face the magnetized pulser ring 271 . This magnetic sensor 273 is covered with a resin layer 275 , and a signal line 276 extending from the magnetic sensor 273 is led radially inwardly through a hole 277 formed through the outer axial portion 266 C. This signal line 276 is connected to a harness 278 that extends in the circumferential direction, and this harness 278 is buried in a resin portion 280 fixed to the disk portion 266 B and the outer axial portion 266 C of the slinger 266 .
[0155] The wheel speed detector of the present fifteenth embodiment, in which the harness 278 connected to the signal line 276 extending from the magnetic sensor 273 is buried in the resin portion 280 fixed to the disk portion 266 B and the axial portion 266 C of the slinger 266 and led in the circumferential direction, can assure the strength of the root portion of the harness 278 . The cover metal fitting 268 is removably fixed to the core bar 265 by the calking portion 270 of the core bar 265 . This arrangement can simplify the replacement of the magnetized pulser ring 271 fixed to the cover metal fitting 268 . The second auxiliary lip 272 mounted on the cover metal fitting 268 can prevent the foreign material from entering the sensor portion.
Sixteenth Embodiment
[0156] Next, FIG. 18 shows the wheel speed detector of the sixteenth embodiment of the present invention. The present sixteenth embodiment is integrated with the inside of a seal device 283 for sealing a gap between a rotating side outer ring 281 and a stationary side inner ring 282 .
[0157] This seal device 283 is provided with a core bar 285 fixed to the inner peripheral surface of the outer ring 281 as well as a first slinger 286 and a second slinger 287 that are fixed to the outer peripheral surface of the inner ring 282 . The core bar 285 is provided with a radial portion 285 A, and a seal lip 288 is fixed to the radial portion 285 A. This seal lip 288 has a main lip 288 A and an auxiliary lip 288 B that are brought in sliding contact with a cylindrical portion 286 A of the first slinger 286 and an axial lip 288 C brought in sliding contact with a radial portion 286 B of the first slinger 286 .
[0158] On the other hand, the second slinger 287 is fixed to the axial end of the outer peripheral surface of the inner ring 282 and is provided with a radial portion 287 A that extends radially outwardly and an axial portion 287 B that extends axially inwardly. A magnetic sensor 290 is fixed to the inner surface of this radial portion 287 A, and this magnetic sensor 290 is covered with a resin portion 291 . A signal line 292 extending from this magnetic sensor 290 is led obliquely outwardly in the axial direction through a hole 293 formed through the axial portion 287 B and buried in the resin portion 291 that is projecting obliquely outwardly in the axial direction. An annular projection 296 that faces the outer peripheral surface of the outer ring 281 with interposition of a slight gap in the circumferential direction is fixed to the inner surface of the axial portion 287 B of the second slinger 287 .
[0159] A magnetized pulser ring 297 is fixed to an axial end surface 281 A of the outer ring 281 so as to face the magnetic sensor 290 .
[0160] The present sixteenth embodiment, in which the magnetized pulser ring 297 is made to directly adhere to the outer ring 281 located on the rotating side, has a simple structure and a reduced number of components. The annular projection 296 formed on the second slinger 287 forms the labyrinth structure and is able to prevent water and dust from entering the magnetized pulser ring 297 .
[0161] In the present sixteenth embodiment, the magnetic sensor 290 is fixed to the inner surface of the radial portion 287 A of the second slinger 287 . However, as shown in FIG. 19 , the magnetic sensor 290 may be fixed to the outer surface of the radial portion 287 A. In this case, the second slinger 287 can be put close to the outer ring 281 , allowing the compacting to be achieved.
[0162] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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A wheel speed detector for detecting a relative rotating speed between an outer ring and an inner ring by means of a magnetic sensor in association with a magnetic ring. A stationary seal member is fixed to the stationary ring and a rotatable seal member is fixed to the rotatable ring. The seal members engage to seal a gap between the inner ring and the outer ring. The magnetic sensor is fixed to a radial inner surface of the stationary seal member and the magnetic ring is fixed to a radial outer or a radial inner surface of the rotatable seal member and surfaces of the magnetic ring other than that fixed to the radial inner surface of the rotatable seal member are covered with a seal lip.
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This application is a continuation of and claims priority to U.S. application Ser. No. 10/298,844, filed Nov. 19, 2002, now U.S. Pat. No. 7,428,233, issued Sep. 23, 2008, which is a continuation of and claims priority to U.S. Pat. No. 6,563,797, filed Aug. 18, 1999, and issued May 13, 2003, the contents of both of which are incorporated herein by reference in their entirety.
FIELD OF TECHNOLOGY
The present disclosure relates to surveillance of telephone calls over a public communications link and is particularly concerned with providing assistance for such surveillance to law enforcement agencies. It particularly concerns surveillance of voice over IP (i.e., cable) networks.
BACKGROUND
Requirements for enabling surveillance of electronic communications have been enacted into public law (e.g., Public Law 103-414 enacted Oct. 25, 1994; CALEA Communications Assistance for Law Enforcement Act) reciting requirements for assuring law enforcement access to electronic communications. Such access is required to be in real time, have full time monitoring capabilities, simultaneous intercepts, and feature service descriptions. The requirements specifically include capacity requirements and function capability. It is incumbent upon communication carriers to provide such capability and capacity.
While initially limited in scope, at present, to certain communications technology it is almost assured that it will be extended to new forms of communication. New technologies require extension of CALEA to the new phone system technologies. With the advent of IP telephony it is desirable to provide surveillance capabilities for application to IP telephony.
One of the impediments to surveillance is the necessity of having dedicated equipment to perform the monitoring function. It would be useful to perform such surveillance of a targeted phone with non-dedicated telephone equipment. With use of such non-dedicated equipment it is desirable to distinguish normal calls from surveillance calls.
BRIEF SUMMARY
Surveillance of IP telephony may be performed through the use of conventional telephone equipment, according to principles of the invention while preventing giving indication to the monitored phone of the monitoring activity. The user of the monitoring phone is alerted to such surveillance use prior to pick up, by an agent for engagement of the monitoring phone, in response to the alert. Such alerts may assume many forms such as ringing, visual indicators, data readouts, activating ancillary equipment, various flags, etc. This alert prior to surveillance is distinct from alerts used for normal non-surveillance calls, which the monitoring phone is capable of receiving.
In an IP telephone environment, a cable modem bank (CMB) or an IP Phone intercept List (IP-PIL) lists the IP phones to be monitored and responds when one of those listed phones to be monitored becomes active. In response to notification by an IP Address Mapping Check Point with the IP-PIL, a distinctive alert is delivered to the monitoring phone, which indicates the call's existence and the monitoring purpose to be performed. The IP Address Mapping Check Point and associated WatchDog program alerts the monitoring phone when the monitored phone is in the process of receiving a call. In both instances the monitoring phone is controlled not to be active until both parties of the monitored call are connected and active.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present disclosure and the advantages thereof may be acquired by referring to the following description in consideration of the accompanying drawings, in which like reference numbers indicate like features and wherein:
FIG. 1 is a block schematic of a surveillance system incorporating the principles of the invention; and
FIG. 2 is a flow chart of the process by which the invention is performed in the system of FIG. 1 .
DETAILED DESCRIPTION
In the following description of the various embodiments, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration various embodiments in which aspects of the disclosure may be practiced. It is to be understood that other embodiments may be utilized and structural and functional modifications may be made without departing from the scope of the present disclosure.
A monitoring station/location 101 is shown, in the FIG. 1 , as connected, via a broadband gateway 121 , to a backbone Internet Protocol (IP) network 103 via the connection provided by an Hybrid Fiber Coax (HFC) distribution plant 105 . HFC distribution plant 105 is a distribution cabling arrangement employing both optical fiber and coaxial cable. Optical fiber is connected to the backbone and coaxial cable is connected to the terminating devices. The optical fiber and coaxial cable are joined by an electro-optical connection. The objective is to provide higher bandwidth to the terminating devices at a lower cost then by using optical fiber alone.
The target telephone/DN 111 to be monitored is also connected, via a broadband gateway 131 , to the backbone IP network 103 via the same HFC distribution plant 105 . Included with the backbone IP network is an IP address mapping Check Point (IP-AMCP) 125 , which provides numbers for various devices, connected to the backbone network 103 . The IP-AMCP 125 may be embodied in a server within or connected to the network. It has the capability, through programming, of examining packet contents and authenticating users of the network. With specific WatchDog software 127 the IP-AMCP identifies specific activity from certain designated telephone stations 112 and/or 113 at a specified DN or IP address and can replicate/duplicate the packets of that phone and the IP target telephone 111 which replicated/duplicated packets are forwarded to the monitoring station 101 .
The designated telephone stations 112 and 113 may be connected to the IP network 103 or to the Public Switched Telephone Network (PSTN) 115 , as shown, and be connected to the target DN 111 . The monitoring station 101 may not be dedicated to the surveillance function and hence some indication of its use is provided. The IP-AMCP 125 through its WatchDog 127 determines when an incoming call to the monitoring station is a surveillance call of the target DN 111 . It uses this determination to provide an alerting signal to the monitoring station 101 so that the answerer is knowledgeable that the incoming call is a monitoring of a target IP telephone. In one aspect the gateway coupling the monitoring IP telephone to the IP network is a source of distinctive ringing signals or in the alternative provides an audio announcement.
The procedure in providing such an indicating alert is shown in the flow chart of FIG. 2 . It starts, as indicted in block 203 , with the initiation of a call to an IP telephone having a known DN. A WatchDog program associated with the IP-AMCP notes that the call is being initiated as per block 205 . In decision block 207 an inquiry asks if the called DN is one of a list of IP telephone under surveillance. If it is not the flow proceeds per the instructions of block 209 to handle the call as a non-monitored call and the process ends at terminal 219 .
If the DN called is on the surveillance list the process as per block 211 locates the addresses of the calling and called DNs in the IP-AMCP. According to the instructions of block 213 the IP-AMCP sends a distinctive alert message to a gateway terminal connecting the target IP telephone to the IP network and also to the gateway serving the monitoring IP telephone. In the instance of the gateway of the monitoring IP telephone the gateway in one embodiment rings the monitoring IP telephone with a distinctive ring, as per block 215 , to indicate to the party answering the phone that this is a call connection for the purpose of eavesdropping in on the target IP telephone. In an alternative arrangement the gateway may have a facility to provide this information by means of an audio output. The monitoring process then proceeds, as per block 217 , until termination of the call where upon the process ends at terminal 219 .
The following applications are being filed concurrently with the present application and are incorporated herein by reference. All applications have the same inventors (e.g., Kung, Russell, Sankalia and Wang):
U.S. Pat. No. 6,381,220, entitled, Monitoring Selected IP Voice Calls Through Activity of a WatchDog Program at an IP-Addressing Mapping Checking Point, filed Aug. 18, 1999, and issued Apr. 30, 2002; U.S. patent application Ser. No. 09/375,750, entitled, Monitoring IP Voice Calls Under Command of a PSTN Phone, filed Aug. 18, 1999; U.S. Pat. No. 6,501,752, entitled, Flexible Packet Technique for Monitoring Calls Spanning Different Backbone Networks, filed Aug. 18, 1999, and issued Dec. 31, 2002; U.S. Pat. No. 6,553,025, entitled, Multiple Routing and Automatic Network Detection of a Monitored Call from an Intercepted Targeted IP Phone to Multiple Monitoring Locations, filed Aug. 18, 1999, and issued Aug. 22, 2003; U.S. Pat. No. 6,496,483, entitled, Secure Detection of an Intercepted Targeted IP Phone from Multiple Monitoring Locations, filed Aug. 18, 1999, and issued Dec. 17, 2002; and U.S. Pat. No. 6,560,224, entitled, Automatic IP Directory Number Masking and Dynamic Packet Routing for IP Phone Surveillance, filed Aug. 18, 1999, and issued May 6, 2003.
While exemplary systems and methods embodying the present inventions are shown by way of example, it will be understood, of course, that the invention is not limited to these embodiments. Modifications may be made by those skilled in the art which differ from the specific details disclosed here, but which are still within the scope of the invention. Further elements of one invention may be readily included as elements of one of the other inventions. Those skilled in the art may combine or distribute the elements in many different ways without departing from the spirit and scope of the invention.
As can be appreciated by one skilled in the art, a computer system with an associated computer-readable medium containing instructions for controlling the computer system can be utilized to implement the exemplary embodiments that are disclosed herein. The computer system may include at least one computer such as a microprocessor, digital signal processor, and associated peripheral electronic circuitry.
While the disclosure has been described with respect to specific examples including presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described systems and techniques that fall within the spirit and scope of the invention as set forth in the appended claims.
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Surveillance of IP telephony may be performed through the use of conventional telephone equipment, according to principles of the invention while preventing giving indication to the monitored phone by alerting the user of the monitoring phone to such surveillance use prior to pick up by an agent for engagement of the monitoring phone in response to the alert. Such alerts may assume many forms such as ringing, visual indicators, data readouts, activating ancillary equipment, various flags, etc. This alert prior to surveillance is distinct from alerts used for normal non-surveillance calls, which the monitoring phone is capable of receiving.
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RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 62/204,668, filed Aug. 13, 2015.
FIELD OF THE INVENTION
The present invention relates to adjustors for maintaining a tailgate, automobile hatchback or door in a desired position fixed in at least one direction, i.e., opposing a force having a vector in a substantially constant direction. Thus, the invention relates to the automotive and trucking industries, the building and moving industries and other fields in which maintaining a structure rotatable about an axis in a fixed position against at least one directional force vector (such as gravity and/or wind) is desired.
BACKGROUND OF THE INVENTION
A common feature of most trucks, such as pickup trucks, and some cars is a tailgate. The term “tailgate” generally refers to a door or gate comprising a hinged gate at the back of the cargo bed of a truck or car (such as a station wagon) that can be lowered or otherwise moved to facilitate loading or unloading the vehicle. Generally, a tailgate has two fixed positions: it may be locked and fastened e.g., to the side panels of the truck bed, or may be unlocked and permitted to freely move about the axis defined by a hinge—this may be, for example, generally in an “up and down” direction or less commonly from side to side.
Originally, tailgates, such as pickup truck tailgates, were designed without support in the “open” position; this when opened, the tailgate was simply permitted to fall down to an angle of about 180° to its closed position (unless hindered by the bumper or other vehicle features). Most modern trucks, station wagons, and the like are built to support the tailgate when it is the “open” position, in which the gate is generally horizontal and substantially parallel to the axis of the front-to-back aspect of the car and at about a 90° angle to its closed position. Support is generally provided by one or more cable or by one or more pneumatic cylinder. These support means may have one end anchored to the truck (for example, to the side panel(s) of the truck) and the other end may be mounted on the back or side of the tailgate itself.
Similarly, some vehicles, such as some trucks, hatchback cars and station wagons, have rear gates, windows, or doors that open by being raised rather than lowered. Some of the gates, windows or doors have springs and/or pneumatic cylinders that automatically cause the door to raise to the fullest extend when they are opened.
In one illustration, occasionally the bed or cargo area of a vehicle may be used to transport an item (such as e.g., a motorcycle, lumber, surfboards) that is larger than, or extends beyond the rear tailgate or window thereof. In such cases it is difficult to assure that the cargo remains firmly secured within the bed when the vehicle is in motion. It is therefore common practice in such situations to use twine, rope or cords to maintain the gate, door, or window in a partially closed position, and/or to otherwise to tie the cargo down within the bed or cargo area. This practice can be inconvenient, time consuming and potentially dangerous.
Tailgates that are supported only in a horizontal position, or which are supported only by cables, make the loading and unloading of cargo, particularly wheeled cargo such as motorcycles, ATV's tractors and the like more difficult, as the tailgate cannot be used as a ramp. It would be helpful in some instances to securely support the tailgate at an angle greater than about 90° to its closed position so as to permit the tailgate to be used as a ramp.
Furthermore, many owners put a load on their tailgate without knowing the integrity of the installed cables or pneumatic cylinders.
Zelinsky (U.S. Pat. Nos. 8,075,038, 8,070,207, 8,070,208 and 8,087,710) discloses systems for installation on pickup trucks employing a cable element, in certain cases having a rigid portion comprising an adjustor or lever to lengthen or shorten the cable between 2 positions, or wherein the cable has a long and a short end than can be hooked to the tailgate or truck body, or where the cable fits into a slider built into the tailgate to permit the tailgate to rest in more than two positions, or have a cable section and a rigid section to hook the cable onto. In each case, the systems are somewhat complex to adjust, provide for adjustment of the tailgate between a limited set of positions, and/or require significant alternation of the tailgate and/or truck panels to function.
Cauley, U.S. Patent Publication 2014/0028046 discloses a tailgate system using two straps (one on each side of the tailgate) and provides for continuous adjustment of the length of the straps and thus the tailgate position. However, each strap must be adjusted and then matched to the length of the opposing strap in order to attain full support of the tailgate.
Kuzmich, U.S. Pat. No. 6,267,429 discloses a cable-based system in which a hinge provides first and second (primary and secondary) open positions.
These cable or strap systems may have the disadvantage of lacking rigidity resisting forces in the “upward” direction. That is, they may permit the tailgate to bounce up and down on a bumpy road, or of a quick braking was applied.
Lisk, U.S. Pat. No. 6,857,678, which uses a threaded rod and a roller to provide continuous adjustment of the tailgate height. This system may be time-consuming and difficult to use to balance the support of each side of the tailgate when in place.
Casey, U.S. Pat. No. 6,206,444 shows a tailgate spoiler apparatus which involves a rigid rod that can be extended or retracted into a pivoted housing constructed on the inside of the truck bed; this can be adjusting using a hydraulic cylinder or a motor to optimize the passage of air over the tailgate to create a spoiler effect. This system is complex and may take up valuable bed space.
Sauri, U.S. Pat. No. 5,630,637 discloses a somewhat complicated tailgate adjustment apparatus having shafts and a pair of chains traveling around sprockets. This invention would seem to require a major and expensive rebuilding of the truck bed.
Vars, U.S. Pat. No. 2,561,081 discloses the use of two rigid metal straps that a permanently affixed to the truck. Each is hinged to a swivel the side panel of the truck. These straps have keyhole apertures placed along their length to engage studs fixed at the outer edges of the tailgate; in this way the tailgate can be adjusted to a particular angle, and held in place using the corresponding keyhole apertures.
Thus, there is a need in the art for a simple and easily installed apparatus capable of rigidly holding a gate, door or window in a fixed position with respect to the direction of a force. There is also a need for a simple and easily installed apparatus for permitting the tailgate or be rigidly and adjustably supported in a variety of positions, which may include a position of greater than about 90° relative to the locked, closed position of the tailgate to facilitate the use of the tailgate as a ramp for the loading and unloading of cargo into the truck or car bed.
SUMMARY OF THE INVENTION
The present invention is directed to apparatus and methods for maintaining and supporting structures movable around at least one axis, such as hinged doors, gates and windows, rigidly in a desired and fixed position. In particularly useful examples, the apparatus and methods pertain to vehicle tailgates and hatchbacks (collectively “tailgates” unless indicated otherwise) that rotate around a substantially horizontal axis positioned proximate an edge (for example, a lower edge) of the tailgate. Furthermore, in some examples, the apparatus and methods of the present invention may be used to secure a window, such as a horizontally opening window of a camper shell, sports utility vehicle, or a recreational vehicle, in a partially open position.
In addition to helping secure a payload to the vehicle, and preventing it from falling or being ejected from the vehicle during transit, the apparatus and methods of the present invention may be used to provide a securely positionable, adjustable tailgate and/or window locking device to provide less drag and thereby increase gasoline, diesel and electrical mileage. As used herein, the word “payload” shall mean goods or other objects being transported or arranged for transport.
In other examples, the apparatus and method of the present invention may be useful for purposes other than, or in addition to, those related to motor vehicles, such as to provide a way to adjustably maintain a door wholly or partially open (for example, for ventilation purposes) in strong winds or another resisting force.
It therefore will be understood that as used in the present specification the term “tailgate adjustor(s)” shall refer to the apparatus of the invention without specific regard to where or how the apparatus is used, unless specifically indicated otherwise.
In certain examples, tailgate adjustors are provided which comprise a sprocketed support apparatus (e.g., a rotatable bracket) preferably comprised of a rigid metal, a metal alloy, a polymer, or a mixture of a polymer and a strengthener such as carbon fiber, and having a first end structured to be rotatably fixed to a vehicle panel located proximal to the rear gate or hatch opening of the vehicle, and a second end structured to be rotatably fixed to a tailgate, for example to a lateral side of a tailgate. The apparatus comprises a plurality of rigid approximately rectangular shanks (preferably, but not invariably, two shanks), pairs of shanks being joined and rotatable with respect to each other around a common axis thereby permitting the apparatus to be folded around the at least one common axis to shorten its reach, or unfolded around the at least one common axis to extend its reach. By “shank” is meant a generally rectangular rigid material (such as a stainless steel, a carbon fiber polymer, or a similarly strong material) having dimensions of length greater than their width, and dimensions of width greater than their thickness; shanks may have rounded ends. Preferably, the shanks are made from cold rolled steel or a similarly hard material. On one example, at least two shanks may be of unequal length and/or width to each other. Those of ordinary skill in the art will recognize that in certain embodiments of the invention three more shanks may be serially linked in a similar manner.
In a particular example two shanks may be used, with a first shank preferably being shorter than the second shank. The first shank may have exact or approximate dimensions of ¼×1×7¼ inches, while the second shank may have exact or approximate dimensions of 3/16×1×9⅝ inches; those of ordinary skill in the art will be aware that these dimensions may be varied considerably depending upon the application, such as the dimensions of the vehicle, the dimensions and spacing of the attachment points for the shanks, the dimensions of the space between the window, door or gate and the side or frame panels, etc., without departing from the spirit or scope of the present invention.
The first end of the apparatus is located distally along the length of a first shank from the point of connection between the first shank and another shank; while the second end of the apparatus is located distally along the length of a second shank from the point of connection between the second shank and another shank. In a preferred example, the first and second shanks are rotatably connected to each other, for example, by a hinge, rod, bolt, screw, or rivet. In some examples, the first and second shanks are of equal length; in currently preferred examples the first and second shanks are of unequal length.
Preferably, the first end, the second end, or both ends of the apparatus are structured to be rotatably fixed to a vehicle panel and/or tailgate, respectively, by means of a hole or channel in the shank proximal to each said end. The hole or channel permits a shank to be rotatably fixed to the vehicle by bolting or screwing the shank, for example, by using a machine screw, to affix the shank to the truck side panel or tailgate, preferably using washers, such as a spacer washer and a shoulder washer. For tailgates, preferably, the existing cable systems may be removed from both the truck side panel and the tailgate, and the shanks of the present support apparatus joined thereto using the same tap holes (e.g., 10 mm×1.25 mm) as were used to join the cable system to these parts. For example, in certain cases a 10 mm×1.25 mm×30 mm machine screw may be used. The machine screws may be placed within polymer bushings having an opening slightly larger than the screw such that the screws can be tightened without inhibiting the ability of the support apparatus to swivel around them during use. It will be recognized that specialized systems may also be devised or used to facilitate the swiveling of the shanks when attached to the vehicle side panel and/or tailgate.
One of the shanks (preferably, but not necessarily, the long shank) has a sprocket firmly (i.e., non-rotatably) attached thereto, such as by gluing, screwing, bolting, riveting or welding. Preferably, the sprocket comprises a plurality of teeth, circumferentially or semi-circumferentially arranged around the sprocket body, biased and oriented towards the opposing end of the shank on which the sprocket is mounted; that is toward the second end of the apparatus if the sprocket is mounted on the shank joined to the tailgate, or toward the first end of the apparatus if the sprocket is mounted on the shank joined to the truck panel. The number of the sprocket teeth may be between about 6 and about 10 or more, such as about 8. The sprocket teeth may be spaced apart so as to orient the rotatably connected shanks in conveniently chosen increments with respect to each other; for example, in about 11.25 degree increments, or about 22.5 degree increments. It will be understood that for any given spacing of sprocket teeth, the addition of a greater number of teeth will permit the tailgate adjuster to be locked at an increased number of angles relative to the closed position of the tailgate.
The sprocket teeth are used to lock the tailgate adjuster in place (i.e., with the shanks locked at a specific angle) by a trigger component rotatably mounted on the shank that does not bear the sprocket, at a location proximal to the sprocket when the support apparatus is assembled and mounted. When the shanks are moved about the rotatable connection with respect to each other, the sprocket teeth are rotated with respect to the trigger component. The trigger has a hook-shaped sprocket-engaging tooth that is shaped and oriented to catch and securely hold a chosen sprocket tooth, thereby causing the shanks to be locked at a chosen angle with respect to each other in at least one dimension when the trigger is engaged. When the shanks are mounted on the tailgate and truck side panel, moving the tailgate up or down without the trigger component in an engaged position causes the shanks to rotate about the rotatable connection with respect to each other.
In preferred examples, the other shank (preferably the short shank) is rotatably joined to the sprocket-containing shank; the means of joining may be any suitable means, such as a rivet or a screw; preferably the shanks are joined by a rivet made of the same material as the shank. The sprocket (firmly joined to, and sufficiently braced against rotational movement due to torque forces on, the longer shank) may also be sandwiched between the shanks at this point. Preferably, the sprocket has a hole through which the rivet or machine screw joining the shanks can be inserted.
The trigger component may be biased in one position (e.g., the “closed” position), for example, with a spring. In preferred embodiments, a clip may be joined (e.g., screwed or bolted) to the shank carrying the trigger component; the trigger component may comprise an arm component for closing (e.g., engaging) and opening (e.g., disengaging) the trigger. The clip may be structured to capture and hold the arm of the trigger component (e.g., in an open position) with enough holding force to counteract the spring or other biasing means. The clip may comprise a flexible element, such as a channel, to engage and hold the trigger handle; this flexible element may, without limitation, comprise a rubber, a plastic such as PVC, or an elastomer. Alternatively, the clip and/or flexible element may comprise a metal such as a spring steel clip element.
The apparatus may be mounted in a pickup truck as follows: first the factory installed cable system is removed from one side of the truck side panel and the tailgate by removing the screws attaching the cables to the panel and tailgate. The short shank bearing the trigger component may be connected to the truck side panel with the original screw, and the long shank bearing the sprocket may be connected to the tailgate with the original screw. In both cases, preferably a spacer washer is placed between the shank and the truck panel or tailgate, then the shank, followed by a shoulder washer and finally the screw. The same thing is then done with the truck side panel and the tailgate on the other side of the car. A person of ordinary skill will recognize that the adjustor apparatus on each side of the tailgate are mirror images of each other. In presently preferred embodiments the maximum weight to be placed on the tailgate when the apparatus of the invention is mounted and engaged is about 200 pounds, or about 250 pounds or about 300 pounds or more.
The adjustor apparatus of the present invention thus permits the tailgate to, for example, be locked in an open position in which the tailgate is at a greater than 90° angle with respect to the fully closed position. This position conveniently permits the loading and unloading of items such as wheeled vehicles into the cargo bed.
The adjustor apparatus may also be used to lock the tailgate in a slightly open position (for example, approximately 20 to 30 degrees) to act as a spoiler and to direct airflow over the rear of the truck more efficiently while the truck is in motion; this can result in reduced gasoline, diesel and/or electricity usage, thereby increasing mileage and fuel efficiency.
The adjustors of the present invention may be adapted for use in adjusting the hatchback of a car or the window of a camper shell (both of which, unlike the tailgate, open in an “up” position) so as to lock the window or hatch in a stable, partially closed position when an oversized load is placed in the cargo area, thereby securing the load within the cargo area.
When made of a metal or alloy, preferably the shanks of the apparatus are electrocoated, galvanized, or otherwise covered with an anticorrosion material. Such a material may, without limitation, be a zinc-containing material, a nickel-containing material, a polymeric material, and mixture of such materials. Exemplary anti-corrosion materials are well known to those of skill in the art.
In some uses, the support apparatus of the present invention may be used in conjunction with one or preferably two reinforcing sheaths, which may be installed on each lateral end of a truck tailgate. Modern truck and SUV tailgates are made using relatively thin metal sheeting, which can lack sufficient strength or rigidity to support heavier objects (such as motorcycles loaded using the tailgate, held at a desired angle by the support apparatus, as a ramp) without the tailgate bending or becoming distorted.
The sheaths may be made from similar material as the support apparatus, such as stainless steel (e.g., 440C and/or 304 stainless steel) or a similar hard metal, or a polymer or carbon fiber material. The sheathes are generally shaped and sized to fit the lateral end profiles of the tailgate, and are preferably bout 3 to about 9 inches wide, surrounding the top and bottom sides of the tailgate and preferably covering the ends thereof as well. If the reinforcing sheaths include end coverings, the ends may have a hole, for example a tapped hole, for rotatable connection of the support apparatus to the tailgate, as described above.
Although the foregoing invention has been exemplified and otherwise described in detail for purposes of clarity of understanding, it will be clear that modifications, substitutions, and rearrangements to the explicit descriptions may be practiced within the scope of the appended claims. To the extent that a plurality of inventions are disclosed herein, any such invention shall be understood to have disclosed herein alone, in combination with other features or inventions disclosed herein, or lacking any feature or features not explicitly disclosed as essential for that invention. For example, the inventions described in this specification can be practiced within elements of, or in combination with, other any features, elements, methods or structures described herein. Additionally, features illustrated herein as being present in a particular example are intended, in other aspects of the present invention, to be explicitly lacking from the invention, or combinable with features described elsewhere in this patent application, in a manner not otherwise illustrated in this patent application or present in that particular example. Solely the language of the claims shall define the invention. All publications, patents and patent documents cited herein are each hereby incorporated by reference in its entirety for all purposes to the same extent as if each were so individually denoted.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a side view of the tailgate adjuster of the present invention installed on a truck having an oversized flat payload.
FIG. 1B is a side view of the tailgate adjuster of the present invention installed on a truck having a motorcycle as payload.
FIG. 2 is an exploded view showing the components of an adjustably locking rotatable bracket (tailgate adjustor) of the present invention.
FIG. 3A is a side view of an assembled example of the adjustably locking rotatable bracket shown in FIG. 2 , in a locked, angled position.
FIG. 3B is a side view of the adjustably locking rotatable bracket locked in a fully extended position.
FIG. 3C is a side view of the adjustably locking rotatable bracket in a fully extended position with the trigger component unengaged.
FIG. 3D is a partial cutaway top view of the adjustably locking rotatable bracket in a fully extended position with the trigger component unengaged.
FIG. 4 is a close-up of the rotatable joint between shanks of an example of the support apparatus of the present invention.
FIG. 5A is a top view of a tailgate reinforcing sheath of the present invention.
FIG. 5B shows a[[q]] side view of the tailgate reinforcing sheath shown in FIG. 5A .
DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed to methods and compositions for adjustably maintaining a structure at least partially rotatable about a hinge. Preferably the structure to be maintained in a given position has a substantially flat, planar shape, such as a door, a window or a truck tailgate. As used in the present application, a shape that is “substantially flat and/or planar” is not limited to a two dimensional surface, but may include three dimensional shapes as well. For example, a cuboid shape having a relatively thin depth (such as a window or door) is within this definition, as is the shape of a truck tailgate, which may have a curve in an interior or exterior surface thereof, but nevertheless has the general essential shape and interchangeable function of a flat gate.
Thus, FIG. 1A is a side view of a pickup truck 101 having a cargo bed 103 . The cargo bed in this figure contains a flat payload 107 . As shown in the figure, the payload 107 is longer than the length of the cargo bed 103 ; such a payload may comprise, for example, planks of lumber or sheets of drywall. Such loads of substantially flat, substantially planar payloads are notoriously difficult to secure for transit, since they generally do not have any easily securable “hold down” features, such as holes, hooks, or protrusions, to which a rope or length of line can be conveniently made fast. If the truck tailgate 105 is left open, the payload can easily slide out of the truck bed, for example, during turns or acceleration of the vehicle. Contrarily, if the tailgate is maintained in a completely raised position the driver's rear view visibility may be compromised.
As shown, this problem is solved by the present invention wherein one end of an adjustably locking rotatable bracket (tailgate adjuster) 109 is rotatably connected to an outside surface of one side of the tailgate, and the other end of adjustably locking rotatable bracket 109 is rotatably connected to a vehicle panel 111 located proximal and opposing the same side of the tailgate, and the tailgate is raised to about 45° from the horizontal. Preferably, the tailgate is equipped with adjustably locking rotatable brackets 109 on each side of the tailgate, with each such bracket rotatably connected to the vehicle panel 111 located proximal and opposing the side of the tailgate to which the other end of the bracket is connected. The use of two adjustably locking rotatable brackets 109 aids in firmly and securely retaining the tailgate locked at the desired angle, and increases the possible mass of the load that can be placed on the tailgate during use.
FIG. 1B is a side view of a pickup truck 101 having a cargo bed 103 , wherein the figure is identical to FIG. 1A except the payload comprises a motorcycle 109 . Those of ordinary skill will immediately envision other possible payloads, for example other oversized payloads, for which the present invention will prove useful.
Turning now to FIG. 2 , there is shown an exploded side view of an example of the adjustably locking rotatable bracket of the present invention. The adjustably locking rotatable bracket apparatus as shown comprises two rigid shanks, a longer shank 203 and a shorter shank 205 . The shanks are preferably approximately cuboid—as shown in FIG. 2 the ends of the shanks 221 are rounded, but the top and bottom surfaces and the side surfaces are flat and parallel, and such shapes are within the definition of “approximately cuboid” as used herein. The shanks may be comprised of, without limitation, a metal, a metal alloy, a carbon fiber composition, or a strong, durable polymer. In preferred example, the shanks are made of stainless steel, but may be made of any suitable metal, such as a hardened bronze or a titanium alloy. Each of the shanks comprise a hole, preferably an elongated circular or stadium shaped hole 217 , proximate to one end thereof.
The longer shank 203 comprises a sprocket 213 fitted proximate to the end of the shank that does not contain hole 217 . The sprocket may be affixed to the longer shank by any suitable means, such as by welding, cementing, gluing, bolting, or riveting. As shown in FIG. 2 , the longer shank comprises a circular larger diameter hole 215 and three small pins 223 arranged in an equidistant arrangement from each other, with each small pin also equidistant from hole 215 , thereby defining an equilateral triangle around hole 215 .
The sprocket 213 likewise comprises a hole 225 , preferably of the same diameter as that of the longer shank, as well as small holes 227 slightly larger than the smaller holes 223 of the longer shank. Hole 225 and smaller holes 227 of the sprocket are arranged to exactly overlay those of the longer shank, such that bolts, screws, and or rivets may be used to join the sprocket 213 to the longer shank 203 . In some examples, holes 215 and 225 may be tapped to permit machine screws to connect the longer shank 203 , the sprocket 231 , and the shorter shank 205 . Those of ordinary skill in the art will be aware that this is simply one description of how the sprocket may be fastened to and supported on the shank, and other methods, and variations of these methods, will be easily apparent based upon this disclosure and may be used instead.
The sprocket 213 comprises a plurality of teeth 229 arranged biased and oriented towards the opposing end (in this case, the end having the elongated circular or stadium shaped hole 217 ) of the shank on which the sprocket is mounted. Preferably, although not necessarily to the functioning of the invention, the sprocket teeth 229 are arranged and oriented substantially around one side or “hemisphere” of the body of the sprocket, while the remainder of the circumference of the sprocket 231 remains rounded, i.e., without teeth. It will be understood that in other examples, the sprocket teeth may extend further or even entirely around the sprocket body. The sprocket is affixed to the longer shank 203 in an orientation that places the teeth of the sprocket along one edge of the shank. In other example of the invention the sprocket may comprise curved plates on each side of the sprocket teeth to prevent the sprocket-engaging trigger tooth 237 from becoming disengaged or slipping from the sprocket teeth during use.
The shorter shank 205 comprises hole 233 having the same or similar diameter as hole 215 . Additionally, shank 205 comprises hole 235 , located in this example, about ⅝ inches along the length of the shank from hole 233 ; holes 233 and 235 may have the same or similar diameter as holes 215 and 225 , or may have different diameters, In preferred examples the shanks 203 and 205 , and/or the trigger component 207 and shank 205 , may be joined using rivets.
Trigger component 207 comprises handle 235 , the main body 241 of the trigger, comprising sprocket-engaging tooth 237 , and spring component 239 . In some examples, the majority of the trigger may, for example, be cut out from one sheet of metal, except for the spring component 239 ; in other examples the handle 235 may be welded, bolted or otherwise affixed to the main body of the trigger. The trigger component 207 is rotatably joined to the shorter shank 205 , for example, by means of a rivet or machine screw of suitable length, size and diameter to fit hole 233 . The spring component may be of any suitable design to bias the trigger to apply torque to the trigger towards an “engaged” position (i.e., in the direction of the sprocket engaging tooth; counter-clockwise in FIG. 2 ).
In one preferred example, the spring component 239 comprises a length of spring wire or a narrow ribbon of bent spring steel affixed and anchored at one end thereof to the shorter shank 205 by way of, without limitation a shallow protrusion and or a hole or slit located on the shorter shank, proximal to the hole 233 . The other end of the spring component is affixed to, or made to engage with a protrusion, shelf, hole or slit on the trigger component in a manner that applies torque to the trigger towards an “engaged” position.
FIG. 3A is a side view of an assembled example of the adjustably locking rotatable bracket shown in FIG. 2 wherein the longer shank 203 has been joined to the shorter shank 205 with sprocket 213 placed in between, using a rivet through holes 215 , 235 and 225 (see FIG. 2 ), respectively, to grip and join shanks 203 and 205 , and sprocket 213 . The sprocket 213 is non-rotatably joined to longer shank 203 , for example, by welding. The rivet permits the longer shank and the shorter shank to articulate with respect to each other about the axis of the machine screw projecting through and aligning holes 215 , 235 and 225 . In other examples, the rivet may be replaced by, for example, a machine screw.
In the view shown in FIG. 3A the adjustably locking rotatable bracket 301 is shown in a locked position with the angle between the two shanks 203 and 205 being about 115°. The trigger component 207 is held in the counterclockwise direction by torque forces generated by spring component 239 so that sprocket-engaging tooth 237 fits between selected sprocket teeth 229 . The engagement of the trigger sprocket-engaging tooth with the teeth of the sprocket effectively prevents further articulation of shanks 203 and 205 with respect to each other to increase the angle between them, thereby locking the articulated joint in one direction. However, due to the shape of the sprocket teeth and the trigger tooth, this angle can still be readily reduced (and the reach of the bracket shortened) when the trigger is engaged by articulating the joint in the other direction; that is by moving the shorter shank 205 in a counter clockwise direction (or the longer shank 203 in a clockwise direction).
Those of skill in the art will quickly recognize that in some cases it may be useful for the adjustably locking rotatable bracket to be structured to be capable of locking in both directions. This can be accomplished by various methods, such as (without limitation) by making the teeth of the sprocket and the sprocket-engaging tooth of the trigger substantially triangular and extending generally radially outward from the sprocket rather than in the counterclockwise-biased arrangement shown in FIGS. 2, and 3A-3C .
FIG. 3B shows the adjustably locking rotatable bracket 301 locked in a fully extended position, in which the angle about the machine screw joining holes 215 , 235 and 225 and rotatably linking the shorter shank 205 and the longer shank 203 is about 180°.
FIG. 3C shows the adjustably locking rotatable bracket 301 in a fully extended position (in which the angle about the rivet joining holes 215 , 235 and 225 and rotatably linking the shorter shank 205 and the longer shank 203 is about 180°), but wherein the trigger component 213 is not engaged, and the bracket is thus in an “unlocked” position. As can be seen, the handle 235 of the trigger component 207 has been pulled down and inserted into trigger clip 331 , thus raising the sprocket-engaging trigger tooth 237 away from the sprocket, and permitting the longer shank and shorter shank to freely rotate with respect to each other (thus initially shortening the bracket as a whole).
Also shown in FIG. 3C is trigger clip 331 , which is affixed to the shorter shank 205 . The trigger clip may be screwed, cemented, glued, or otherwise fastened to a base or side of the shank. As shown, the trigger clip is screwed to the underside of the shank. The trigger clip contains or consists of a flexible material, which may comprise, for example, a plastic such as polyvinyl chloride (“PVC”), a natural or synthetic rubber, or another elastomeric material. A narrow horizontal channel (not shown) extends along an outside side of the clip; the channel is preferably slightly narrower than the width of trigger handle 235 such that, when the trigger handle is inserted into the channel, it is retained there against, and to counter, the force of compressed spring component 239 . In some examples, the channel, or trigger clip as a whole, may comprise a flexible metal clip such as one made of spring steel.
FIG. 3D is a partial cutaway top view of the adjustably locking rotatable bracket 301 in a fully extended position, as also shown in side view in FIG. 3C . As shown the longer shank 203 is connected by a rivet 327 through holes 215 , 235 and 225 (see FIG. 2 ) to shorter shank 205 , with sprocket 213 affixed in between. A shorter rivet 329 connects trigger component to the shorter shank 205 . Screws 321 are inserted through shoulder washer 323 , then through hole 217 and spacer washer 325 before being inserted in a tapped hole in either the side of the tailgate (preferably, longer shank), or a side panel of the truck or truck cargo bed (preferably, shorter shank). Usually, the preexisting standard issue flexible wire cables are fastened by screws and tapped holes to the same locations of the tailgate and cargo bed, and the same tapped holes can be reused to connect the adjustably locking rotatable bracket 301 of the present invention to the vehicle truck and tailgate, although if necessary, suitable holes can be drilled and tapped de novo. As will be apparent to a person of ordinary skill in the art, it is very preferable that an adjustably locking rotatable bracket of the present invention be connected to each side of the tailgate to provide stability and structural strength to the tailgate when locked in a position intermediate between fully open and fully closed.
FIG. 4 shows another example of the support apparatus of the present invention, and comprises a close-up of the sprocket 213 and trigger component assembly 207 . In this example, longer shank 203 is joined to sprocket 213 by welding at three locations 401 . Rivet 403 rotatably joins the longer shank 203 with sprocket 213 attached and the shorter shank 205 through hole 215 (and holes 225 and 233 ; not shown). Pins 227 secure the sprocket 213 to the longer shank 203 to prevent torque displacement of the sprocket during use.
Trigger component 207 is shown in both engaged and disengaged configurations. When the trigger component is in the disengaged position, the handle 235 is inserted into clip 331 . As described above, the trigger component is biased in an engaged position by torsion spring 239 , which is anchored to the trigger component by protrusion 405 and protrusion 407 (in this example, the spring is bent around the protrusions.) In this example, sprocket component 213 comprises two curved sheets of metal ( 409 ; only one curved sheet is shown in this side view) formed on each side of the sprocket teeth 229 . The trigger component is rotatably joined to the shorter shank 205 by a rivet 411 through hole 235 .
FIG. 5A is a top view of another example of the present invention comprising a tailgate-reinforcing sheath 501 . The sheath is very preferably made from a strong metal or metal alloy such as steel, and is effective to prevent bending of the tailgate when the support apparatus of the invention is employed in concert with a large load, such as a one or more motorcycle or all terrain vehicle (ATV). As shown in this figure, the sheath has a rear surface 509 , side surfaces 505 , front surface 507 , and top surface 513 . Optional U-shaped brackets 511 may be welded to top surface 509 ; these are also preferably made of a strong metal or metal alloy.
The tailgate-reinforcing sheath also has a plurality of holes on facing surface 513 for fastening to the underlying tailgate surface near the end of the tailgate, preferably using blind rivets.
FIG. 5B shows a side view of the same exemplary tailgate-reinforcing sheath. Thus, Surfaces 513 , 509 and 507 are shown, as is optional U-shaped bracket 511 with a removable hook 515 . Dotted line 521 shows the underlying end portion of the vehicle tailgate. Holes 519 are available on side surface 505 for the insertion of screws to join the sheath to the side of the tailgate. As can be seen in this figure, the tailgate-reinforcing sheath comprises a hollow void within shaped to receive and closely fit and cover the end portion of the tailgate 521 .
The various descriptions of the invention provided herein illustrate presently preferred examples of the invention; however, it will be understood that the invention is not limited to the examples provided, or to the specific configurations, shapes, and relation of elements unless the claims specifically indicate otherwise. Based upon the present disclosure a person of ordinary skill in the art will immediately conceive of other alternatives to the specific examples given, such that the present disclosure will be understood to provide a full written description of each of such alternatives as if each had been specifically described.
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A tailgate adjuster in a preferred example comprises an adjustably locking rotatable bracket comprising a plurality of rotatably linked shank components, with at least one shank component joined to a sprocket component having a plurality of sprocket teeth, and at least one other shank component joined to a rotatable trigger component having a sprocket-engaging trigger tooth. The trigger component is preferably spring biased to maintain the trigger tooth in an engaged position with the sprocket teeth, and can be adjusted to disengage the trigger component from the sprocket teeth. The sprocket teeth are spaced to permit the locking of shank components at a desired angle to each other. Holes at each end of the tailgate adjuster permit the rotatable mounting of one such end to a vehicle tailgate or hatchback and the other end to a fixed location of the vehicle. In other examples the invention concerns a tailgate-reinforcing sheath and methods for maintaining a vehicle tailgate or other hinged door, gate or window in a one of a plurality of partly open positions.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the construction industry and, more specifically, to an improved trench lining system.
2. Description of the Prior Art
The general concept of trench drainage has long been used. Trenches are used where liquid run-offs occur, such as chemical plants, food processing operations, pulp and paper mills, pharmaceutical manufacturing, bottling plants, in parking garages and parking areas of shopping centers. The fluid from a trench generally goes into a catch basin or sewer large enough to release the material from the trench as it arrives. The top of the trench is normally covered with a slotted grate to allow entrance of the fluids, catching of debris, load carrying capacity for whatever may pass over it and, in some applications, they are solidly covered, such as crossing sidewalks or where conduits are carried within the trench and fluid entry is minimal and not necessarily desirable.
The liquid run-off in a trench may overflow. There exists trench systems made of rigid materials. In these systems, the rigid liners are held together with an annular space between them. A piece of thermoplastic, such as polypropylene or polyetheylene or other material, is used to seal the opening between the primary and secondary liners thus preventing overflowing trenches from getting behind a liner or liners. Such systems are the ACROLINE systems manufactured and sold by Agru of Austria, A-4540 Bad Hall, Ing.-Pesendorfer Street 19-23, Austria and BEKAPLAST systems manufactured and sold by Steuler of Germany, Georg-Steuler Strasse 175, D-56203, Hohr-Grenzhausen, Germany. For trench systems which are constructed from flexible liners where the liners are allowed to expand and contract independently of each other, there does not exist a system for preventing the liquid run-off to escape behind the flexible liners. Such a system is needed to prevent any possible overflow from leaking behind the liners onto the trench walls and bottom and between the primary and secondary liners. Thus, there exists a world-wide need for an economical means and method to line a trench into a single or double containment trench and prevent the escape of liquid run-off during overflows.
SUMMARY OF THE INVENTION
The disadvantages of the prior art are overcome by the present invention, which relates to overflowing trenches and prevents the liquid run-off migrating behind and between the liners and possibly leaking onto the trench walls and bottom surface.
The present invention is a trench liner system for forming a single or dual containment trench and for relining an existing trench having at least two walls, a bottom surface, and a bearing surface adjacent each of the tops of the side walls. One embodiment for a single containment trench comprises a primary liner means, with an interior surface and an exterior surface, extending along the length of the trench and disposed within the trench. This embodiment may include a means disposed between the primary liner means and the trench walls for separating the exterior surface of the primary liner means from the trench walls. Migration of the liquid run-off to the exterior surface of the liner means is prevented by the upper portion of the liner means which overlies a portion of each of the bearing surfaces.
For a dual containment trench, the embodiments comprise of a secondary liner means, with an interior surface and an exterior surface, extending along the length of the trench; and a primary liner means, having an interior surface and an exterior surface, disposed within the trench within the secondary liner means and extending along the length of the trench. This embodiment may also include a means disposed between the secondary liner means and the primary liner means for separating the interior surface of the secondary liner means from the exterior surface of the primary liner means.
Migration of the liquid run-off behind the liners is prevented by the liner means having upper portions that overlap portions of each of the bearing surfaces. One embodiment includes an upper portion on the primary liner means alone, another embodiment includes an upper portion on the secondary liner means alone, and a further embodiment includes upper portions on both the primary liner means and the secondary liner means.
All these embodiments, for both single containment and dual containment, include a means for holding the primary liner means and the separating means or the primary liner means, the separating means, and the secondary liner means against the trench walls and bearing surface so as to allow each upper portion of either the primary liner means or the secondary liner means or both to overlap at least a portion of the bearing surface. The separating means and holding means are basically the same as those disclosed in my copending applications Ser. No. 08/287,654 filed on Aug. 9, 1994; Ser. No. 08/349,901 filed on Dec. 6, 1994; Ser. No. 08/404,586 filed on Mar. 15, 1995; and Ser. No. 08/584,170 filed on Jan. 11, 1996.
The present invention also comprises a method of lining an existing trench, having a bottom, at least two walls and a bearing surface adjacent each of the tops of the side walls. To line a single containment trench, a primary liner means is placed along the length of the trench or a separator means and a primary liner means are placed along the length of the trench. The upper portion of the primary liner means overlies at least a portion of each of the bearing surfaces of the trench. A holding means is then installed to hold the liner means against the trench walls with the upper portion of the liner means overlapping at least a portion of each of the bearing surfaces.
For a dual containment trench, a secondary liner is first placed in the trench. A separating means may be then be disposed within the secondary liner means and the primary liner means is disposed within the separating means, if used, or within the secondary liner means. The upper portions of either or both liner means is/are placed so that it/they overlie at least a portion of each of the bearing surfaces of the trench. A holding means is then installed to hold the liner means against the trench walls with the upper portion(s) of the liner means overlapping at least a portion of each of the bearing surfaces of the trench.
The trench containment unit is extremely flexible along its length, allowing continuous walls with no joints for two hundred feet or more. The trench containment unit should be an unbroken unit as long as possible to minimize the number of joints which might leak. The primary and secondary liners can have a neutral grade or be sloping as needed.
Therefore, it is an object of the present invention to provide an improved lining system and method for lining a containment trench.
It is also an object of the present invention to prevent liquid run-off during trench overflows to migrate outside and between the liners.
These and other objects will become apparent from the following description of the preferred embodiment taken in conjunction with the following drawings, although variations and modifications may be effected without departing from the spirit and scope of the novel concepts of the disclosure.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS
FIG. 1 is a cross-sectional side view of a single containment trench with the primary liner means overlapping at least a portion of the bearing surface.
FIG. 2 is a cross-sectional side view of a double containment trench with the secondary liner means overlapping at least a portion of the bearing surface.
FIG. 3 is a cross-sectional side view of a double containment trench with the primary liner means overlapping at least a portion of the bearing surface.
FIG. 4 is a cross-sectional side view of a double containment trench with the primary liner means and the secondary liner means joined to, and overlapping, at least a portion of the bearing surface.
FIG. 5 is a cross-sectional side view of a double containment trench with both the primary liner means and the secondary liner means overlapping at least a portion of the bearing surface.
FIG. 6 is a perspective view of a double containment trench according to one form of the present invention, depicted in situ.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the invention is now described in detail. Referring to the drawings, like numbers indicate like parts throughout the views.
The present invention is basically the trench liner systems described in my copending applications Ser. No. 08/287,654 filed on Aug. 9, 1994; Ser. No. 08/349,901 filed on Dec. 6, 1994; Ser. No. 08/404,586 filed on Mar. 15, 1995; and Ser. No. 08/584,170 filed on Jan. 11, 1996, with the addition of a means for preventing liquid run-off from migrating behind and between the flexible liners. The invention relates to both a single and a double containment trench. For single containment, the liner means is extended to overlie at least a portion of each of the bearing surfaces of the trench. For double containment, either the primary liner means, the secondary liner means, or both are extended to overlie at least a portion of each of the bearing surfaces. An overall view of one embodiment of the trench liner system of the present invention is shown, in situ, by FIG. 6.
FIG. 1 shows a preferred embodiment of the present invention 10 for a single containment trench which comprises a separating means 13 disposed within an existing trench having at least two walls, a bottom and a bearing surface 28 adjacent each of the walls (the separating means 13 is the same as described in my copending applications Ser. No. 08/287,654 filed on Aug. 9, 1994; Ser. No. 08/349,901 filed on Dec. 6, 1994; Ser. No. 08/404,586 filed on Mar. 15, 1995; Ser. No. 08/584,170 filed on Jan. 11, 1996; and Ser. No. 08/680,966 filed on Jul. 16, 1996. Within the trench, a primary liner means 14 rests within the separating means 13 and has an upper portion 163, an interior surface 160 and an exterior surface 162, disposed along the length of the trench. The primary liner means 14 comprises a flexible material (i.e., plastic, metal, or any other flexible material) that is resistant to the fluids which the trench is designed to hold. The upper portion 163 of the primary liner means 14 overlies a portion of each of the bearing surfaces 28 for preventing an overflow of liquid run-off within the trench to migrate to the exterior surface of the primary liner means 14.
This embodiment may include a holding means 312 adapted to hold the primary liner means 14 and the separating means 13 against the trench walls so as to allow the primary liner means 14 to expand and contract along its length. Embodiments of the holding means 312 are described in my copending applications Ser. No. 08/287,654 filed on Aug. 9, 1994; Ser. No. 08/349,901 filed on Dec. 6, 1994; Ser. No. 08/404,586 filed on Mar. 15, 1995; Ser. No. 08/584,170 filed on Jan. 11, 1996; and Ser. No. 08/680,966 filed on Jul. 16, 1996.
A holding means 312 may be used to hold the primary liner means 14 against the trench walls and the bearing surface 28 so as to allow the primary liner means 14 to expand and contract along its length. Embodiments of the holding means 312 are described in my copending applications Ser. No. 08/287,654 filed on Aug. 9, 1994; Ser. No. 08/349,901 filed on Dec. 6, 1994; Ser. No. 08/404,586 filed on Mar. 15, 1995; Ser. No. 08/584,170 filed on Jan. 11, 1996; and Ser. No. 08/680,966 filed on Jul. 16, 1996.
A sealant 400 may be placed between the bearing surface and the primary liner means and between the primary liner means 14 and the holding means 312 to better hold in place the upper portion 163 of the primary liner means 14 and to further protect against any liquid run-off from seeping through or migrating to the exterior surface 162 of the primary liner means 14. A coating 401 may also be placed on top of the holding means 312 to further prevent any liquid run-off from seeping through or migrating to the exterior surface 162 of the primary liner means 14.
FIG. 2 shows another embodiment of the present invention for a double containment trench with a secondary liner means 12. In this embodiment, the secondary liner means 12 is disposed within and along the length of the trench, with the separating means 13 disposed within the secondary liner means 12 and the primary liner means 14 being disposed within the separating means 13 within the secondary liner means 12. The secondary liner means 12 is flexible and also comprises a material that is resistant to the fluids which the trench is designed to hold. The secondary liner means 12 has an upper portion 164, an interior surface 158 and an exterior surface 156, disposed along the length of the trench. The upper portion 164 of the secondary liner means 12 overlies at least a portion of each of the bearing surfaces 28 for preventing an overflow to migrate to the exterior surface 156 of the secondary liner means 12.
A holding means 312 and an anchor stand 90 may be used to hold the secondary liner means 12, the separating means 13, and the primary liner means 14 against the trench walls. Embodiments of the holding means 312 and anchor stand 90 are described in my copending applications Ser. No. 08/287,654 filed on Aug. 9, 1994; Ser. No. 08/349,901 filed on Dec. 6, 1994; Ser. No. 08/404,586 filed on Mar. 15, 1995; Ser. No. 08/584,170 filed on Jan. 11, 1996, and Ser. No. 08/680,966 filed on Jul. 16, 1996.
A sealant 400 may be placed between the bearing surface and the upper portion 164 of the secondary liner means 12 and between the secondary liner means 12 and the holding means 312 to better hold in place the upper portion 164 of the secondary liner means 12 and to further protect against any liquid run-off from seeping through or migrating to the exterior surface 156 of the secondary liner means 12. A coating 401 may also be placed on top of the holding means 312 to further prevent any liquid run-off from seeping through or migrating to the exterior surface 156 of the secondary liner means 12.
FIG. 3 shows another embodiment for a double containment trench. In this embodiment, the upper portion 163 of the primary liner means 14 overlies at least a portion of each of the bearing surface 23 to prevent an overflow within the trench to migrate to the exterior surface 156 of the secondary liner means 12.
FIG. 4 shows yet another embodiment for a double containment trench in which the upper portion 164 of the secondary liner means 12 and the upper portion 163 of the primary liner means 14 are joined 15 to form one liner section 16. Joining together of the means 12 14 may be accomplished by welding, using sealants, or mechanical means on the upper portions 163, 164 of the liner means 12, 14. Liner section 16 has an upper section 165 that overlies at least a portion of each the bearing surfaces 23 to prevent an overflow to migrate to the exterior surface 156 of the secondary liner means 12.
FIG. 5 shows another embodiment for a double containment trench. In this embodiment, the upper portion 164 of the secondary liner means 12 overlies at least a portion of each of the bearing surfaces 23. The upper portion 163 of the primary liner means 14 overlies the upper portion 164 of the secondary liner means 12.
The present invention also comprises a method of lining an existing trench, having a bottom, at least two walls and a bearing surface adjacent each of the tops of the side walls. As shown in FIG. 1, to line a single containment trench, a separator means 13 and a primary liner means 14 are placed along the length of the trench. The upper portion 163 of the primary liner means 14 overlies at least a portion of each of the bearing surfaces 28 of the trench. A holding means 312 is then installed to hold the liner means against the trench walls with the upper portion of the primary liner means 14 overlapping at least a portion of each of the bearing surfaces 28.
For a dual containment trench, as shown in FIG. 2, a secondary liner means 12 is placed along the length of the trench. A separating means 13 may then be disposed within the secondary liner means 12 and the primary liner means 14 is disposed within the separating means 13. As shown in FIGS. 2, 3 and 5, the upper portions 164, 163 of either or both liner means is/are placed so that it/they overlie at least a portion of each of the bearing surfaces of the trench 28. A holding means 312 is then installed to hold the liner means against the trench walls with the upper portion(s) 164, 163 of the liner means overlapping at least a portion of each of the bearing surfaces of the trench 28. In FIG. 4, the upper portions 163, 164 of the primary liner means 14 and the secondary liner means 12 are joined 15 to form a liner section 16 having an upper section 165. The upper section 165 is placed so that it overlies at least a portion of each of the bearing surfaces 28.
The above embodiments are given as illustrative examples and are not intended to impose any limitations on the invention. It will be readily appreciated that many deviations may be made from the specific embodiments disclosed in this specification without departing from the invention. Accordingly it is intended to cover all such modifications as within the scope of this invention.
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A flexible trench liner system used for forming a single or a dual containment trench where during a trench overflow, the liquid run-off is prevented from migrating behind the primary flexible liner or behind the secondary flexible liner and possibly leaking onto the trench walls and bottom. The system includes an upper portion on the flexible liner means that overlaps at least a portion of the bearing surface of the trench. The overlapping upper portion of the flexible liner can be part of the primary liner and/or the secondary liner. The flexible liner means are held against the trench walls and the bearing surface by a holding means.
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BACKGROUND OF THE INVENTION
Price display devices employing precoiled indicia strips and holders or guideways for such strips are known in the prior art. Examples of such prior art teachings are contained in U.S. Pat. Nos. 3,939,584; 4,095,359; and 4,258,490 issued to Trame. An objective of the present invention is to provide a display device of this general character which has improved utility in a number of respects and which eliminates certain recognized drawbacks of the prior art structures.
More particularly, in the prior art, one of the problems frequently encountered is the inadvertent separation and/or breakage of components by personnel not adequately qualified to adjust or repair the display device. Another common problem in the prior art is frequent misalignment or shifting of pricing modules on their support structures or accidental removal of the module from the support structure while changing prices. In the prior art, buckling and/or bulging of the precoiled pricing tapes frequently occurs. Additionally, some of the prior art devices are restricted to one type of menu system.
The present invention eliminates the above and other deficiencies of the known prior art through the provision of a menu and price display device having uniquely formed pricing modules of either two-piece or one-piece construction, each possessing a simplified finger operated spring locking element which can engage any of a series of locator notches provided along the mounting trackway for the pricing modules, preferably in the vertical wall thereof. The locations of pricing modules can be quickly changed with precision and without removing the module from the mounting trackway assembly.
The improved pricing modules provided in the present invention enable total control of pricing tape placement, that is, each tape is locked on four sides. The pricing module provides an illuminated decimal point. Its precoiled numeric indicia tape can be conveniently operated from the rear of the assembly without removing the display structure from a provided frame or cabinet.
In addition to these specific improvements, the present invention is characterized by simplicity and economy of construction, durability, versatility and convenience of use.
Other features and advantages of the invention will become apparent to those skilled in the art during the course of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a menu and price display device according to the present invention.
FIG. 2 is an enlarged fragmentary transverse vertical section taken through the assembled device.
FIG. 3 is a fragmentary perspective view showing components of a mounting trackway assembly.
FIG. 4 is a fragmentary perspective view of a two-piece pricing module according to one embodiment.
FIG. 5 is an exploded perspective view of the components of the two-piece pricing module prior to assembling.
FIG. 6 is a horizontal section taken through the assembled two-piece module.
FIG. 7 is a front elevation of the two-piece pricing module.
FIG. 8 is an end elevation thereof including the precoiled numeric indicia tape.
FIG. 9 is an exploded perspective view showing a onepiece pricing module and an associated opaque mask in accordance with a second embodiment.
FIG. 10 is a horizontal section taken through the onepiece module in FIG. 9.
FIG. 11 is a front elevation thereof.
FIG. 12 is a transverse vertical section taken through the one-piece pricing module.
DETAILED DESCRIPTION
Referring to the drawings in detail wherein like numerals designate like parts, a menu and price display device typically used in a fast food restaurant or the like comprises a mounting trackway assembly 20, FIGS. 1 and 3, consisting of three identical mounting trackway sections 21, it being understood that one or more of the sections 21 can be employed in the display device, depending upon requirements. Preferably, the mounting trackway sections 21 are metal extrusions.
Each mounting trackway section 21 includes a relatively thin vertical wall 22 having a pair of unobstructed longitudinal slots or window openings 23 formed therethrough. At its top and bottom and at an intermediate point, each mounting trackway section 21 includes a continuous longitudinal extruded portion 24, 25 and 26, as shown. Each portion 24 is provided with an upper continuous longitudinal dovetail groove 27 and two lower continuous longitudinal grooves 28 and 29 of unequal widths. Each lower extruded portion 25 is provided with a bottom continuous longitudinal dovetail tongue 30 and a pair of upper continuous longitudinal grooves 31 and 32 of unequal widths and being disposed in vertical alignment with the grooves 28 and 29.
The intermediate extruded portion 26 of each mounting trackway section 21 is similarly provided in its top and bottom with continuous longitudinal grooves 33 and 34 of unequal widths which are vertically aligned with the grooves 28 and 29 and 31 and 32, as clearly shown in FIG. 2. Each intermediate extruded portion 26 is further provided on its rear side with a continuous longitudinal circularly curved channel element 35, for a purpose to be described.
As best shown in FIG. 3, plural mounting trackway sections 21, such as the three shown in FIG. 1, are assembled to form a unit by sliding engagement of the described dovetail tongues 30 in the dovetail grooves 27.
The display device further comprises a required number of pricing modules 36 of two-piece construction in accordance with one preferred embodiment of the invention. Each two-piece pricing module 36 includes a molded clear plastics lens 37 and a molded opaque bezel 38. The opaque bezel contains plural side-by-side rectangular window openings 39.
Each transparent lens 37 in its curved front wall, FIG. 5, has a pair of spaced parallel vertical grooves 40 formed therein for the reception of vertical bars 41 on the bezel 38 separating its window openings 39. When the bars 41 are fully seated in the grooves 40, the bezel 38 is vertically disposed and its two vertical end bars 42 will straddle the end faces of the lens 37, as best shown in FIG. 6. The lens 37 and bezel 38 are permanently joined in assembled relationship by cementing.
The pricing module 36 further includes a conventional manually adjustable precoiled pricing tape 43 adjacent to each window opening 39 of the opaque bezel 38. Each precoiled tape carries pricing indicia, such as a series of numerals 44, 1 through 9 and 0. The tapes 43 may be opaque with their numerals 44 being clear or translucent.
Each pricing module 36 at one end thereof close to the adjacent bar 42 includes a spring lock arm 45 having a tapered locking head 46 at its upper end. The vertical wall 22 of each mounting trackway section 21, adjacent to the top of each slot 23, is provided with a series of spaced locator notches 47, any one of which may receive the tapered locking head 46 to position the pricing module 36 at the desired location along the mounting trackway assembly 20.
The bezel 38 of each pricing module 36 is received slidably within the grooves 28 and 33 or 33 and 31 of each mounting trackway section 21, FIG. 2, whereby the pricing module can be moved longitudinally of the trackway section and locked therein at a desired location caused by interengagement of the locking head 46 with one of the locator notches 47 along the top of the adjacent window opening 23. The frontal curved wall of the clear lens 37 is now adjacent to the opening or slot 23 and also adjacent to the window openings 39 of the bezel 38. Upper and lower feed slots 48 for the precoiled pricing tapes 43 are provided by the assembling of the lenses 37 with their bezels 38 in the described manner. It can be seen that the precoiled tapes are locked and guided on four sides by the feed slots and the adjacent faces of vertical bars 41 and 42, thereby providing easy control of the precoiled tapes from the rear of the modules 36.
Customized opaque elongated copy strips 49 are received slidably within the frontal longitudinal grooves 29-34 and 34-32 of each mounting trackway section 21. The strips 49 extend for the full length of the trackway section 21 and have clear window portions 50 or window openings provided therein in proper spaced relationship to register with the window openings 39 and the pricing indicia 44 of pricing modules 36. The strips 49 near their other ends contain food or beverage item displays 51 in the form of transparent lettering or letter openings in the opaque strips 49. Intermediate portions of the strips 49 may carry additional viewable indicia 52 to indicate portion size of foods and beverages, such as "small", "medium" or "large". A suitable light source 53, FIG. 8, is provided behind the display device, such as a fluorescent tube adjacent to each pricing module. Various conventional lighting arrangements may be used.
In accordance with a modification of the invention shown in FIGS. 9 through 12, an essentially one-piece pricing module 54 may be utilized in lieu of the described two-piece pricing module 36. The one-piece module 54 comprises a united or integral lens 55 and bezel 56, both formed of clear plastics. The one-piece module 54 serves the identical purpose as the two-piece module 35 and functions with the mounting trackway 20 in the exact manner described for the module 36. The one-piece module 54 receives three precoiled pricing tapes 57 which may be identical in construction and operation to the previous described tapes 43. The one-piece module is formed to provide frontal window recesses 58 and vertical bars 59 separating the window recesses. Each module 54 carries a spring arm 60 at one end thereof having tapered locking head 61 at its upper end for interlocking engagement within a selected notch 47 of the mounting trackway assembly 20. The upper and lower longitudinal edge portions of the bezel 56 are received adjustably in the grooves 28-33 and 33-31 in the same manner shown and described for the two-piece module 36 relative to FIG. 2.
The entire frontal surface of the bezel 56 is covered by an opaque mask 62, such as a decal. This mask includes a clear decimal point 63 or decimal point aperture so that a decimal point will be displayed for a three digit or two digit price being displayed by the one-piece pricing module 54. Similarly, the opaque bezel 38 of the two-piece module 36 contains a decimal point aperture 64 for the same purpose, FIGS. 5 and 7.
A feature of the invention realized by use of the opaque copy strips 49 is the elimination of frontal light leaks in the display device, such leaks tending to occur at the narrow slits 65, FIGS. 4 and 9, between the spring arms 45 and 60 and the adjacent bars of bezels 38 and 56. Since the opaque strips 49 extend for the lengths of mounting trackway sections 21, they will cover the slits 65 or any other openings through which light could leak from the system. The spacings of the window openings 50 in strips 49 can be varied as can the other indicia on these strips to enable proper registration with the pricing modules.
When the mounting trackway assembly 20 is completed, its sections 21 are connected at their opposite ends by vertical frame members 66 which are apertured to receive screws 67, having self-threading engagement within the extruded circular channel elements 35. The members 66 can be part of a complete framework for the display device, or part of a cabinet structure containing the device.
It may be seen that the stated objectives of the invention which overcome certain deficiencies of the prior art are achieved in a simple and economical manner. A modular display device is created whose mounting trackway assembly can be expanded to meet all needs. Pricing modules in two-piece or one-piece configurations which are self-contained and easy to operate are provided. By virtue of a very simple finger-operated spring lock, the modules 36 and 54 are readily located with precision along the mounting trackway assembly through interlocking of the elements 46 and 47.
The terms and expressions which have been employed herein are used as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding any equivalents of the features shown and described or portions thereof but it is recognized that various modifications are possible within the scope of the invention claimed.
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Pricing modules of the type having precoiled numeric indicia tapes are slidably held in guide channels of a mounting trackway assembly. Additional guide channels in the trackway assembly receive customized alpha indicia strips forwardly of the pricing modules. Pricing module locator notches are provided in wall portions of the trackway assembly to interlock with spring locking elements on each pricing module to properly position each module along the mounting trackway assembly. Multiple sections of the mounting trackway assembly can be provided in interlocking engagement.
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RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/004,451, filed Nov. 26, 2007, the contents herein incorporated into this application by reference.
BACKGROUND
[0002] The present inventive subject matter relates to stunning and/or euthanization of laboratory fish using electric currents and the monitoring of the laboratory fish to prevent injury thereof.
[0003] The effect of electric currents on fish are well known in the prior art and especially in the general techniques of electrofishing. Electrofishing involves the use of electric currents to attract and/or repel fish with the intent of creating aquatic barriers, sample fish barriers, and/or to increase collection yields.
[0004] It has been established that relatively small potentials that are impressed across the body of a fish invoke a flight reaction. Larger potentials result in the alignment of the fish with the electric current, or electrotaxis. Still larger potentials may result in unconciousness or complete euthanasia of the fish. (See Introduction to Electrofishing, pages 24-26, Smith-Root, Inc. which is incorporated herein by reference).
[0005] Electrofishing has traditionally been used in freshwater lakes and streams and is the subject of U.S. Pat. Nos. 5,445,111; 5,327,854; 4,750,451; 4,672,967 4,713,315; 5,111,379; 5,233,782; 5,270,912; 5,305,711; 5,311,694; 5,327,668; 5,341,764; 5,551,377; and 6,978,734 which are incorporated herein by reference. Also, electrofishing has been the used to stimulate yields of fishing in conjunction with the use of trawl nets as described in U.S. Pat. Nos. 3,110,978 and 4,417,301 which are also incorporated herein by reference.
[0006] Systems for controlling electricity in aquatic environments have been described in U.S. Pat. No. 5,460,123 which is incorporated herein by reference.
[0007] There are also electrofishing systems that attempt to reduce the leaching of metal ions into water due to the electrolytic action of passing current through the solution. Also systems for monitoring small laboratory fish using cameras are described in U.S. Patent Publication 2006/0018833 which is incorporated herein by reference.
[0008] Therefore in the prior art, a considerable body of work is associated with the electrification of large bodies of water to impress electric fields across larger fish, such as salmon or trout, as compared to smaller fish, that would be typically be used for the purpose of laboratory experimentation.
[0009] The use of small fish, in particular zebrafish, are popular as biological models for scientific studies. The studies involve placing fish in laboratory desktop tanks, then subjecting the fish to physical, chemical, or biological stress. This is followed by an examination of the subject fish to determine the various effects on the fish as a result of the stresses. For the purpose of this application the term “fish” will refer to any suitable aquatic laboratory fish, including, but not limited to zebrafish.
[0010] A recurring problem with the examination of laboratory fish is that they tend to be very active. Also laboratory fish are dimensionally very small. The small size of the fish combined with their activity can impair the researcher from making precise scientific measurements unless the fish is caught and inspected.
[0011] Therefore there is a need for the laboratory researcher to euthanize laboratory fish in a relatively quick and painless manner. Ideally the state of euthanasia can be controlled for a period of time in which the measurement of the fish is needed. To induce euthanasia an electric field is applied to the water in the tank. This, in turn, induces induces an electric field across the body of the fish. This amount of electricity that is passed through the fish varies based on the orientation of the fish and the magnitude of the electric field.
[0012] Low electric fields evoke a deterrent response in the fish causing the fish to be repelled from the electric field. Greater electric fields may evoke an involuntary response that results in the fish being attracted and swimming towards the anode and away from the cathode. Still larger electric fields may result in a state of narcosis being induced in the fish. Higher electric fields may result in euthanasia (i.e. death) of the fish.
[0013] Prior art solutions and techniques that induce euthanasia in fish involve the addition of chemicals to the tank. Chemicals used for euthanasia are expensive to acquire, pose a storage and maintenance problem, and are at risk of degradation. These chemicals, which are toxic to fish, may have the unfortunate consequence of skewing laboratory results during any post-euthanasia pathology. Furthermore, the researcher runs the risk of exposure to the chemicals that are used to euthanize the fish. Also, the use of chemicals to euthanize fish may be unnecessarily complex and expensive, which would result in the added cost of training specialized personnel.
[0014] Furthermore, there is also a view that the chemical euthanasia of fish may induce unnecessary pain. In response, the American Veterinary Medical Association (AVMA) Panel on Euthanasia has lets lists three acceptable methods of euthanasia for fish, and two conditionally acceptable methods. These methods include the use as acceptable of such chemicals as tricaine methanesulfonate (MS-222), benzocaine (related to MS-222 but less soluble in water) and barbiturates.
[0015] In view of the high cost and risk of certain chemical agents that induce euthanasia in fish, there is a need to have a unit that will induce unconsciousness and euthanasia in laboratory fish without chemicals. There is also a need for a portable unit that can euthanize fish without the use of chemical agents. There is also a need for a unit that will shield the researcher from contact with potentially hazardous chemical agents. There is also a need for unit that can euthanize fish using electrical currents. There is also a need for a unit that can euthanize fish using rechargeable batteries.
[0016] There is also a need to have a monitoring system to insure that a laboratory fish does not come into contact with an anode or a cathode to reduce the risk of injurious shock to the fish.
[0017] There is also a need to reduce the leaching of anions into the solution (e.g. fish water) during fish euthanasia. In certain cases, a laboratory fish may be euthanized first by transferring to a euthanasia tank, then followed by actual euthanasia, then disposal. During operation, anions will leach from the electrodes via electrolytic action resulting in the further contamination of the water. It is therefore desirable to have a unit that minimizes the leaching of anions from an electrode during euthanasia.
[0018] Therefore, what is desired is an apparatus to immobilize fish and place the fish in the state of euthanasia. It is also desired that this apparatus operate at relatively low voltage levels. It is also desired is an apparatus that is portable. It is also desired that the apparatus prevent the leaching of anions from electrodes into the water electrodes during operation.
SUMMARY
[0019] The present inventive subject matter overcomes problems in the prior art by providing a fish anesthetizing apparatus that induces a potential field across the body of a laboratory fish with a programmable power supply, the programmable power supply having a first output terminal and a second output terminal, a pair of electrodes, the first electrode connected to the first output terminal and the second electrode connected to the second output terminal; whereby when the pair of electrodes are inserted in the enclosed body of water, a potential field is created by the programmable power supply so that two electrodes inducing an altered stated in a laboratory fish. The fish anesthetizing system also includes a programmable power supply where the potential difference between the first electrode and the second electrode is an impulse signal. The fish anesthetizing system also has a programmable power supply where the potential difference between the first electrode and the second electrode creates a field that induces electronarcosis in a laboratory fish. There is also a need for a fish euthanasia system where programmable power supply creates a potential difference between the first electrode and the second electrode thereby creates a field that induces electrotaxis in a laboratory fish. The fish anesthetizing system apparatus also induces an electric field across a fish with a programmable power supply, an anode and a cathode, the anode and cathode capable of immersion water and ; so that when the anode and cathode are immersed in water, a potential difference is generated across a laboratory fish, such that the fish experiences a physiological change. The fish anesthetizing apparatus wherein the potential difference is a periodic waveform for fish anesthetizing. The fish anesthetizing apparatus also having a cyclic waveform that is a square wave. The fish anesthetizing apparatus also having the amount of the power generated in the positive and negative phases that are approximately equal. The fish anesthetizing apparatus that having a waveform that is an impulse wave. The fish anesthetizing apparatus also having a maximum potential difference ranges from 0.2 V/cm to 10.0 V/cm such that electronarcosis is induced in a fish. The fish anesthesizing apparatus where in the maximum potential difference ranges from 0.1 V/cm to 10 V/cm such that electrotaxis or euthanasia is induced in a fish.
[0020] Also described is a method for inducing an electrical potential across a laboratory fish, the method consisting of obtaining a programmable power supply, connecting an anode and a cathode to the programmable power supply, inserting the anode and the cathode into a fish tank, increasing the potential difference between the anode and the cathode so that there is a potential difference of up to 10 V/cm across the body of the fish, decreasing the potential difference between the anode and the cathode to approximately 0 V/cm across the body of the fish; so that when the potential difference first increases and then decreases across the body of the fish, the fish experiences a physiological change. Furthermore, the method also includes inducing a potential difference between the anode and cathode such that an electric field is increased and decreased across the fish in a cyclic manner.
[0021] Also described is a system for impressing a voltage across a laboratory fish, the system which comprises a means for generating a voltage, a means for introducing the voltage into a laboratory tank, so that when the voltage is generated a potential difference is created across the laboratory fish that ranges from 0.0 to 10.0 V/cm.
[0022] Also described is a portable fish anesthetizing system having a tank cover, an electrode pair, the electrode pair configurable attached to the tank cover; a control system for creating a potential difference, the control system electrically connected to the electrode pair, so that when the tank cover is placed on a laboratory tank and the control system is activated, current flows from the control system through the electrodes. Also shown is a portable fish anesthetizing system with a tank cover further incorporating a top part and a bottom part, the bottom part being configured to fit on the top rim of the laboratory tank and the bottom part is adjustable in the either the lengthwise or widthwise dimension so that it may conform to the top of the laboratory tank.
[0023] The portable fish anesthetizing system also has a tank cover further control system further comprises a camera, where the camera is connected to the control system, a series of fish images are recorded from fish in the tank, the control system then identifies a class of fish, and in response to the class of fish detected, adjusts the current flow; so that the fish experiences electronarcosis, electrotaxis, and/or euthanasia. The portable fish anesthetizing camera system also is integrated with the tank cover.
[0024] These and other embodiments are described in more detail in the following detailed descriptions and the figures.
[0025] The foregoing is not intended to be an exhaustive list of embodiments and features of the present inventive subject matter. Persons skilled in the art are capable of appreciating other embodiments and features from the following detailed description in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a system diagram of the laboratory fish anesthetizing system.
[0027] FIG. 2 is a waveform diagram of a single pulse with a continuous positive and negative opposite polarity lobes.
[0028] FIG. 3 is a waveform diagram of plural positive and negative lobes.
[0029] FIG. 4 is a modified waveform diagram with a zero-field dwell portion interposed between the positive and negative field lobes.
[0030] FIG. 5 is a system diagram of the laboratory fish anesthetizing system incorporating a proximity detector.
[0031] FIG. 6 is a system diagram of the laboratory fish anesthetizing system which incorporates a programmable database of voltage waveforms that are species and/or subject specific.
[0032] FIG. 7 is a flowchart of the laboratory fish anesthetizing system which incorporates a programmable database of voltage waveforms that are species and/or subject specific.
[0033] FIG. 8 is one physical configuration of the laboratory fish anesthetizing system.
LIST OF REFERENCE CHARACTERS
[0000]
110 —Tank
120 ′, 120 ″—Electrodes
130 ′, 130 ″—Wires
140 —Programmable Voltage Source
160 —Fish
180 —Water Level
250 —Impulse Voltage Vmax
260 —Impulse Voltage Vmin
230 —Impulse Voltage “t”
350 —Periodic Voltage Vmax
360 —Periodic Voltage Vmin
330 —Periodic Voltage “t”
450 —Dwell Voltage Vmax
460 —Dwell Voltage Vmin
470 —Dwell Voltage “t”
510 —Proximity Detector
610 —Voltage Mapper
620 —Product to Waveform database
630 —Waveform Input
720 —Species Selection Step
730 —Subject Selection Step
740 —Load the Waveform from the Database Step
750 —Download the Waveform to the Voltage Source Step
810 —Laboratory Fish Anesthetizer
820 —Storage Unit
830 —Electrode Support
840 —Width Support
845 —Width Expansion
850 —Length Support
855 —Length Expansion
860 —Top Protector
DETAILED DESCRIPTION
[0065] Representative embodiments according to the inventive subject matter are shown in FIGS. 1-8 , wherein similar features share common reference numerals.
[0066] The term “fish” refers to experimental fish used in a laboratory setting, which include, but are not limited to zebrafish. These fish typically belong to, but are not limited to, the taxa group Telostei or Teleostomi. The teleost fish include such fish as zebrafish ( Danio rerio ), medaka ( Oryzias, sp.), fathead minnow ( Pinephales promelas ), or goldfish ( Carassius auratus ). It is well established that fish have a typical response to electrical fields applied in the water, although each individual fish and each type of species may have a varying response.
[0067] The term “tank” is generally known to those in the arts as a water tank, the preferred embodiment being a 10-40 gallon tank used by researchers that customarily sets on a laboratory top. Tank can also include larger tanks including outdoor tanks and naturally occurring ponds and streams. Also, the characteristics of the water should not be limited to freshwater, but, may also include water of differing salinities including sea water.
[0068] The term “electrical stimulation” refers to an electrical field impressed on the tissue of a fish in water. This electrical field will have a range in values that is dependent on the age and species of the fish.
[0069] The term “programmable voltage supply” shall mean a device that can output a range of voltages and currents in a waveform that is programmed either by hardwire switch (e.g., a pulse generator) or by software (e.g. a computer controlled voltage generator).
[0070] Now referring to FIG. 1 , a system 100 is shown for the anesthetizing fish. The system 100 has a water tank 110 , two electrodes 120 ′, 120 ″ immersed in the water tank 110 , two wires 130 ′, 130 ″ connected to the programmable voltage source 140 . The water in the water tank 110 is filled to the water level 180 . The electrodes 120 ′, 120 ″ are typically immersed below the water level 180 . When voltage is applied across the two electrodes 120 ′, 120 ″ a voltage gradient is impressed across the fish 160 . Depending on the size of the voltage gradient induced in the fish will determine the effect on the fish.
[0071] To anesthetize the fish 160 , (electronarcosis), a voltage gradient of 150-250 V/m (1.5 to 2.5 V/cm) should be induced across the fish 160 . To induce paralysis in the fish (electrotaxis) a greater voltage gradient than needed for electronarcosis should be induced across the body of the fish. To euthanize the fish 160 , a voltage gradient of 1.5 to 5.0 V/cm or greater should be induced across the body of the fish 160 . The voltage gradients needed for electronarcosis, electrotaxis, and euthanasia vary from fish species to fish species, and of course, differ based on the individual physiology of each fish.
[0072] In the laboratory setting, the water tank 110 will usually have dimensions of 2 feet in width, 4 feet in length, and 2 feet in height, holding the total water volume of 8 cubic feet or approximately 60 gallons. Freshwater conductivity in a laboratory tank ranges from 100 to 5000 S.
[0073] As previously mentioned, a fish typically used in laboratory biological studies is the zebrafish. Mature zebrafish grow to a size of approximately 6.4 cm. Juvenile zebrafish, which are more commonly used in research, range in size from approximately 0.9 to 1.5 cm.
[0074] The voltage potential varies as a matter of time and may be positive or negative on either electrode. The voltage potential may alternate in a manner such there is an equal balance of energy of time between the electrodes.
[0075] Now referring to an exemplary waveform as shown in FIG. 2 . FIG. 2 shows an impulse waveform at the electrodes 120 ′, 120 ″ (as shown in FIG. 1 ) such that the impulse voltage Vmax 250 and the impulse voltage Vmin 260 are during the time period “t” 230 . This impulse voltage Vmax 250 and impulse Vmin 260 should be of sufficient strength and duration to induce the physiological effects (e.g. electrotaxis and/or electronarcosis) on the laboratory fish.
[0076] Now referring to another exemplary waveform as shown in FIG. 3 . FIG. 3 shows a periodic waveforms at the electrodes 120 ′, 120 ″ (as shown in FIG. 1 ) such that the periodic voltage Vmax 350 and the periodic voltage Vmin 360 are during the period time “t” 330 . The periodic voltage Vmax 350 and the period voltage Vmin 360 should be of sufficient strength and duration to induce the preferred physiological effect (e.g. electrotaxis, electronarcosis, or euthanasia) on the laboratory fish.
[0077] Now referring to another exemplary waveform as shown in FIG. 4 . FIG. 4 shows a periodic with dwell waveforms at the electrodes 120 ′, 120 ″ (as shown in FIG. 1 ) such that the dwell voltage Vmax 450 is separated by a dwell voltage Vdwell 470 and then followed by the periodic with dwell voltage Vmin 460 during the time period “t” 430 . The periodic voltage with dwell should be of sufficient strength and duration to induce the physiological effects (e.g. electrotaxis and/or electronarcosis) on a laboratory fish.
[0078] Now referring to the system as shown in FIG. 5 . FIG. 5 depicts a programmable voltage supply 140 connected to electrodes 120 ′, 120 ″ which are immersed in the tank 110 . The programmable voltage supply 140 is connected to a proximity detector processor 520 and a proximity detector 510 . The proximity detector 510 is used to determine if the fish 160 is too close to the electrodes 120 ′, 120 ″. If the fish is in close proximity to the electrodes, then the output waveform (see FIGS. 2 , 3 , 4 ) is modified to prevent injury to the fish 160 either by diminishing or eliminating the range of voltage from the programmable voltage supply 140 .
[0079] Now referring to the fish anesthetizing system which is shown in FIG. 6 . FIG. 6 depicts a programmable power supply 140 connected to electrodes 120 ′, 120 ″ which create an electric field in the tank 110 and across the fish 160 . Connected to the programmable voltage supply 140 is a species to voltage mapping device 610 . The species to voltage mapping device 610 stores a database of species electrical waveforms in a database 620 . This database is updated by the input device 630 .
[0080] The operation of the fish anesthetizing system of FIG. 6 is shown in the flowchart of FIG. 7 . A species 720 or subject 730 waveform is selected and is loaded from a database 740 . This waveform will have a voltage range and characteristics induces either electrotaxsis or electronarcosis in the fish depending on the desired effect on the target species. Likewise the voltage range and characteristics depending on the subject profile, for example, if it is known that the target fish is a minnow that is 2 cm in length, this characteristic can be preselected from a database. Once the database voltage is selected it is transferred (i.e. downloaded) 750 from the species to voltage mapper to the programmable voltage source.
[0081] Now referring to FIG. 8 that illustrates one configuration of the physical implementation of the laboratory fish anesthetizer 810 . The system has a storage unit 820 that contains the electronics and associated power supply. The storage unit is connected to the electrode supports 830 which are integrated with the length supports 850 . Interconnecting the two length supports are two width supports 840 . The length support 850 can be expanded lengthwise 855 to accommodate tanks of varying lengths. The width support 840 can be expanded widthwise 845 so that tanks of varying widths can be accommodated. Optionally present is a top protector 860 so that access to the top of the laboratory water is blocked.
[0082] The system in FIG. 8 may be configured to prevent access to the water in the tank while the apparatus is operating. Those skilled in the arts will recognize that interlocking switches may be employed so that the electrodes 120 ′, 120 ″ of the laboratory fish anesthetizer 810 are not energized if power is applied.
[0083] Persons skilled in the art will recognize that there are a wide variety of databases that can used to store signal patterns, including, but not limited to SQL databases, text databases, or object oriented databases. Persons skilled in the art will recognize that there are a wide variety of programmable voltage supplies, including, but not limited to products manufactured by Lamda (Neptune, N.J., USA). It is also understood by those skilled in the art that the database and/or the programmable power supply may be implemented in firmware in a manner to reduce and/or minimize costs.
[0084] Persons skilled in the art will recognize that many modifications and variations are possible in the details, materials, and arrangements of the parts and actions which have been described and illustrated in order to explain the nature of this inventive concept and that such modifications and variations do not depart from the spirit and scope of the teachings and claims contained therein.
[0085] All patent and non-patent literature cited herein is hereby incorporated by references in its entirety for all purposes.
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A system and method to induce fish anesthetizing or narcosis is described that induces a potential field across the body of a laboratory fish having a pair of electrodes, the waveform generated by this potential field is approximately balanced to reduce the introduction of anions into the solution, and a camera is mounted to observe the activity of the fish, so that the potential difference may be adjusted based on the state of the fish.
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This is a divisional of application Ser. No. 08/376,258, filed on Jan. 23, 1995, now U.S. Pat. No. 5,518,775, which is a divisional of Ser. No. 08/175,807, filed on Dec. 30, 1993, now U.S. Pat. No. 5,409,620.
BACKGROUND OF THE INVENTION
The present invention relates to a fiber treatment compositions and to a method of making fiber treatment compositions. More particularly, the present invention relates to organofunctional silicone emulsions and their ability to impart beneficial characteristics such as slickness, softness, compression resistance and water repellency to substrates such as fibers and fabrics that is not possible without the use of the compositions and method of the instant invention.
It is generally known to treat textile fibers with organopolysiloxanes to impart a variety of valuable properties to the fibers, such as water repellency, softness, lubricity, anti-pilling, good laundry and dry cleaning durability, and the like. The use of organopolysiloxanes to achieve such properties is now well established but there continues to be a need to improve these and other desirable properties of the fibers, especially the anti-pilling properties of the fabrics made from treated fibers. In particular, there has existed a desire to improve the properties of the fibers while improving the processes by which the organopolysiloxane compositions are applied to the fibers, and in this regard, the need to speed up the processing of the fibers is the most urgently needed.
Typical of prior art compositions and processes used for achieving the desirable processing and end use properties are those curable compositions disclosed in U.S. Pat. No. 3,876,459, issued Apr. 8, 1975 to Burrill in which there is set forth compositions obtained by mixing polydiorganosiloxanes having terminal silicon-bonded hydroxyl radicals with an organosilane (or partial hydrolysates thereof) of the formula RSiR'n(X)3-n, in which R is a monovalent radical containing at least two amine groups, R' is an alkyl or aryl group, X is an alkoxy radical and n is 0 or 1.
The polydiorganosiloxanes are linear or substantially linear siloxane polymers having terminal silicon-bonded hydroxyl radicals and an average degree of substitution on silicon of 1.9 to 2.0 wherein the substituents are generally methyl radicals. The siloxane polymers have an average molecular weight of at least 750 with the preferred molecular weight being in the range of 20,000 to 90,000. The cure mechanism appears to arise through the reaction of the hydrolyzable groups on the silane with the silanol groups of the siloxane polymer, usually under the influence of a catalyst, and at elevated temperatures.
Burrill discloses in U.S. Pat. No. 4,177,176, issued Dec. 4, 1979, an additional composition for use in treating fibrous materials. The composition is disclosed as containing a polydiorganosiloxane having a molecular weight of at least 2500 and terminal --OX groups in which X is hydrogen, lower alkyl or alkoxyalkyl groups with the proviso that there also be present at least two substituents in the polydiorganosiloxanes which are amine groups. There is also present an organosiloxane having at least three silicon-bonded hydrogen atoms, the curing mechanism being based on the reaction of the silicon-bonded hydrogen atoms with the silanol end blocks of the polydiorganosiloxane polymers under the influence of a catalyst.
Also included in the prior art is the disclosure of Burrill,. et al. in U.S. Pat. No. 4,098,701, issued Jul. 4, 1978 in which the inventors set forth yet another curable polysiloxane composition which has been found useful for treating fibers which comprises a polydiorganosiloxane in which at least two silicon-bonded substituents contain at least two amino groups, a siloxane having silicon-bonded hydrogen atoms, and a siloxane curing catalyst. A study of the '701 patent shows that "siloxane curing catalyst" is used in the sense that non-siloxane containing organofunctional compounds are used to cure siloxane curable materials, and that siloxane compositions that function as catalysts is not intended.
Also, there is disclosed in the prior art the curable system described by Spyropolous et al, in European patent application publication 0 358 329 wherein microemulsions are described in which the oil phase comprises a reaction product of an organosilicon compound having amino groups and an organosilicon compound having epoxy groups, wherein the reaction product has at least one amino group and two silicon-bonded --OR groups, and a method for making the microemulsions. The organosilicon compound having at least one silicon-bonded substituent of the general formula --R'NHR", wherein R' is a divalent hydrocarbon group having up to 8 carbon atoms, and R" denotes hydrogen, an alkyl group or a group of the general formula --RBH2, and (B) an organosilicon compound having at least one substituent of the general formula --R'--Y, wherein R' is as defined for those above, and Y denotes an epoxy group containing moiety, whereby the molar ratio of amino groups in (A) to epoxy groups (B) is greater than 1/1, there being present in the reaction product at least two silicon-bonded --OR groups, wherein R denotes an alkyl, aryl, alkoxyalkyl, alkoxyaryl or aryloxyalkyl groups having up to 8 carbon atoms.
Chen et al., in U.S. Pat. No. 5,063,260 discloses curable silicone compositions which impart beneficial characteristics to fibers, the compositions comprising an amino organofunctional substantially linear polydiorganosiloxane polymer, a blend of an epoxy organofunctional substantially linear polydiorganosiloxane polymer and a carboxylic acid organofunctional substantially linear polydiorganosiloxane polymer, and an aminoorganosilane. Chen et al. also discloses a process for the treatment of animal, cellulosic, and synthetic fibers by applying the composition described above the fiber and thereafter curing the composition on the fiber to obtain a treated fiber.
Yang in European Pat. No. Application No. 0415254 discloses stable aqueous emulsion compositions containing an aminofunctional polyorganosiloxane containing at least two amino functionalized groups per molecule, one or more silanes and optionally a hydroxy terminated polydiorganosiloxane, textiles treated with the emulsion compositions, and processes for the preparation of the emulsion compositions. Revis in U.S. Pat. Nos. 4,954,401, 4,954,597, and 5,082,735 discloses a coating for a paper substrate produced by contacting and forming a mixture of an allyl ester with at least one methylhydrogensiloxane in the presence of a Group VIII metal catalyst, coating the mixture on the substrate, and heating the mixture of the allyl ester, the methylhydrogensiloxane, the substrate, and the Group VIII metal catalyst in the presence of ambient moisture until the methylhydrogensiloxane becomes cured and cross-linked.
Bunge in U.S. Pat. No. 4,954,554 discloses aqueous emulsions compositions consisting essentially of a curable silicone composition comprising organopolysiloxane having silicon-bonded hydroxyl radicals or silicon-bonded olefinic radicals, an organohydrogenpolysiloxane and a curing catalyst, a polyvinylalcohol emulsifying agent having a degree of hydrolysis of 90 mole percent or more, and water. These compositions are disclosed as having improved gloss and/or water-repellency and/or adhesive release.
Other silicone emulsions containing olefinic siloxanes have been disclosed. For example, Hara et al. in U.S. Pat. Nos. 5,095,067 and 5,104,927 teaches a release silicone emulsion composition comprising 100 parts by weight of a specific organovinylpolysiloxane, from 1 to 50 parts by weight of a specific organohydrogensiloxane, from 0.5 to 5 parts of a platinum catalyst having a viscosity of 10 centistokes or less at 25° C., from 1.5 to 15 parts by weight of a nonionic emulsifying agent having an average HLB of from 10 to 20, and a Ph of 6.5 or less, and water. These compositions are disclosed as having good pot life, curability and that the cured film has good release properties and residual adhesive properties of adhesives.
However, none of the references hereinabove disclose a one component fiber treating emulsion comprising an unsaturated acetate, at least one organohydrogensiloxane, a metal catalyst, an organosilicon compound, and one or more surfactants or solvents which imparts beneficial characteristics to textile fibers.
SUMMARY OF THE INVENTION
The instant invention relates to compositions and to improved methods for their use to treat substrates such as fibers and fabrics to enhance the characteristics of the substrates. More specifically, the present invention relates to a fiber treatment composition comprising: (A) an unsaturated acetate; (B) an organohydrogensiloxane; (C) a metal catalyst; and (D) an organosilicon compound.
It has been discovered that a heat activated crosslinking composition consisting of a blend of an unsaturated acetate, an organohydrogensiloxane, a metal catalyst, and an organosilicon compound can be used for the treatments of fibers and fabrics to impart slickness, softness, compression resistance and water repellency to the substrates. The composition remains a fluid until an activation temperature is reached which point crosslinking occurs.
The present invention further relates to a method of treating a substrate, the method comprising the steps of (I) mixing: (A) an unsaturated acetate, (B) at least one organohydrogensiloxane, (C) a metal catalyst, and (D) an organosilicon compound, and (E) a dispersant selected from the group consisting one or more surfactants and one or more solvents to the mixture of (I), (II) applying the mixture from (I) to a substrate, and (III) heating the substrate.
The present invention also relates to a method of making a fiber treatment composition comprising (I) mixing (i) an organosilicon compound and (ii) a dispersant selected from the group consisting one or more surfactants and one or more solvents, (II) adding to the mixture of (I) a mixture of: (iii) an unsaturated acetate, (iv) at least one organohydrogensiloxane, and (v) a metal catalyst.
It is an object of this invention to provide a fiber treatment composition which imparts slickness, softness, compression resistance, and water repellency to fibers and fabrics.
It is also an object of this invention to provide a fiber treatment composition as a one component stable emulsion composition. It is an additional object of this invention to provide a fiber treatment composition which is non-toxic.
It is an additional object of this invention to provide a fiber treatment composition which has a low cure temperature.
These and other features, objects and advantages of the present invention will be apparent upon consideration of the following detailed description of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a fiber treatment composition comprising: (A) an unsaturated acetate; (B) an organohydrogensiloxane; (C) a metal catalyst; and (D) an organosilicon compound.
Component (A) in the fiber treatment compositions of the instant invention is an unsaturated acetate. The unsaturated acetate can be an allyl ester or vinyl ester such as allyl butyrate, allyl acetate, linallyl acetate, allyl methacrylate, vinyl acetate, allyl acrylate, vinyl butyrate, isopropenyl acetate, vinyl trifluoroacetate, 2-methyl-l-butenyl acetate, vinyl 2-ethyl hexanoate, vinyl 3,5,5-trimethylhexanoate, allyl 3-butenoate, bis-(2-methylallyl) carbonate, diallyl succinate, ethyl diallylcarbamate, and other known allyl esters. It is preferred for the compositions of the instant invention that the unsaturated acetate is selected from the group consisting of allyl acetate, linallyl acetate, and isopropenyl acetate.
The amount of Component (A) employed in the compositions of the present invention varies depending on the amount of organohydrogensiloxane, metal catalyst, and organosilicon compound that is employed. It is preferred for purposes of this invention that from 0.1 to 50 weight percent of (A), the unsaturated acetate, be used, and it is highly preferred that from 2 to 10 weight percent of unsaturated acetate be employed, said weight percent being based on the total weight of the composition.
Component (B) in the compositions of the present invention is at least one organohydrogensilicon compound which is free of aliphatic unsaturation and contains two or more silicon atoms linked by divalent radicals, an average of from one to two silicon-bonded monovalent radicals per silicon atom and an average of at least one, and preferably two, three or more silicon-bonded hydrogen atoms per molecule thereof. Preferably the organohydrogensiloxane in the compositions of the present invention contains an average of three or more silicon-bonded hydrogen atoms such as, for example, 5, 10, 20, 40, 70, 100, and more.
The organohydrogenpolysiloxane is preferably a compound having the average unit formula R a 1 H b SiO.sub.(4-a-b)/2 wherein R 1 denotes said monovalent radical free of aliphatic unsaturation, the subscript b has a value of from greater than 0 to 1, such as 0.001, 0.01, 0.1 and 1.0, and the sum of the subscripts a plus b has a value of from 1 to 3, such as 1.2, 1.9 and 2.5. Siloxane units in the organohydrogenpolysiloxanes having the average unit formula immediately above have the formulae R 3 3 SiO 1/2 , S 2 3 HSiO 1/2 , R 2 3 SiO 2/2 , R 3 HSiO 2/2 , R 3 SiO 3/2 , HSiO 3/2 , HSiO 3/2 and SiO 4/2 . Said siloxane units can be combined in any molecular arrangement such as linear, branched, cyclic and combinations thereof, to provide organohydrogenpolysiloxanes that are useful as component (B) in the compositions of the present invention.
A preferred organohydrogenpolysiloxane for the compositions of this invention is a substantially linear organohydrogenpolysiloxane having the formula XR 2 SiO(XRSiO) c SiR 2 X wherein each R denotes a monovalent hydrocarbon or halohydrocarbon radical free of aliphatic unsaturation and having from 1 to 20 carbon atoms. Monovalent hydrocarbon radicals include alkyl radicals, such as methyl, ethyl, propyl, butyl, hexyl, and octyl; cycloaliphatic radicals, such as cyclohexyl; aryl radicals, such as phenyl, tolyl, and xylyl; aralkyl radicals, such as benzyl and phenylethyl. Highly preferred monovalent hydrocarbon radical for the silicon-containing components of this invention are methyl and phenyl. Monovalent halohydrocarbon radicals free of aliphatic unsaturation include any monovalent hydrocarbon radical noted above which is free of aliphatic unsaturation and has at least one of its hydrogen atoms replaced with a halogen, such as fluorine, chlorine, or bromine. Preferred monovalent halohydrocarbon radicals have the formula C n F 2n+1 CH 2 CH 2 -- wherein the subscript n has a value of from 1 to 10, such as, for example, CF 3 CH 2 CH 2 -- and C4F9CH 2 CH 2 . The several R radicals can be identical or different, as desired. Additionally, each X denotes a hydrogen atom or an R radical. Of course, at least two X radicals must be hydrogen atoms. The exact value of y depends upon the number and identity of the R radicals; however, for organohydrogenpolysiloxanes containing only methyl radicals as R radicals c will have a value of from about 0 to about 1000.
In terms of preferred monovalent hydrocarbon radicals, examples of organopolysiloxanes of the above formulae which are suitable as the organohydrogensiloxane for the compositions of this invention include HMe 2 SiO(Me 2 SiO) c SiMe 2 H, (HMe 2 SiO) 4 Si, cyclo(MeHSiO) c , (CF 3 CH 2 CH 2 )MeHSiO{Me(CF 3 CH 2 CH 2 )SiO} c SiHMe(CH 2 CH 2 CF 3 ), Me 3 SiO(MeHSiO) c SiMe 3 , HMe 2 SiO(Me 2 SiO) 0 .5c (MeHSiO) 0 .5c SiMe 2 H, HMe 2 SiO(Me 2 SiO) 0 .5c (MePhSiO) 0 .1c (MeHSiO) 0 .4c SiMe 2 H, Me 3 SiO(Me 2 SiO) 0 .3c (MeHSiO) 0 .7c SiMe 3 and MeSi(OSiMe 2 H) 3 organohydrogenpolysiloxanes that are useful as Component (B).
Highly preferred linear organohydrogenpolysiloxanes for the compositions of this invention have the formula YMe 2 SiO(Me 2 SiO) p (MeYSiO) q SiMe 2 Y wherein Y denotes a hydrogen atom or a methyl radical. An average of at least two Y radicals per molecule must be hydrogen atoms. The subscripts p and q can have average values of zero or more and the sum of p plus q has a value equal to c, noted above. The disclosure of U.S. Pat. No. 4,154,714 shows highly-preferred organohydrogenpolysiloxanes.
Especially preferred as Component (B) are methylhydrogensiloxanes selected from the group consisting of bis(trimethylsiloxy)dimethyldihydrogendisiloxane, diphenyldimethyldisiloxane, diphenyltetrakis(dimethylsiloxy)disiloxane, heptamethylhydrogentrisiloxane, hexamethyldihydrogentrisiloxane, methylhydrogencyclosiloxanes, methyltris(dimethylhydrogensiloxy)silane, pentamethylpentahydrogencyclopentasiloxane, pentamethylhydrogendisiloxane, phenyltris(dimethylhydrogensiloxy)silane, polymethylhydrogensiloxane, tetrakis(dimethylhydrogensiloxy)silane, tetramethyltetrahydrogencyclotetrasiloxane, tetramethyldihydrogendisiloxane, and methylhydrogendimethylsiloxane copolymers.
The amount of Component (B) employed in the compositions of the present invention varies depending on the amount of unsaturated acetate, metal catalyst, and organosilicon compound that is employed. It is preferred for purposes of this invention that from 40 to 99.9 weight percent of Component (B) be used, and it is highly preferred that from 70 to 90 weight percent of Component (B) be employed, said weight percent being based on the total weight of the composition.
Component (C) in the compositions of the present invention is a metal catalyst. Preferred metal catalysts for the present invention are the Group VIII metal catalysts and complexes thereof. By Group VIII metal catalyst it is meant herein iron, cobalt, nickel, ruthenium, rhodium, palladium, osmium, iridium and platinum. The metal catalyst of Component (C) can be a platinum containing catalyst component since they are the most widely used and available. Platinum-containing catalysts can be platinum metal, optionally deposited on a carrier, such as silica gel or powdered charcoal; or a compound or complex of a platinum group metal. A preferred platinum-containing catalyst component in the compositions of this invention is a form of chloroplatinic acid, either as the commonly available hexahydrate form or as the anhydrous form, as taught by Speier, U.S. Pat. No. 2,823,218, incorporated herein by reference. A particularly useful form of chloroplatinic acid is that composition obtained when it is reacted with an aliphatically unsaturated organosilicon compound such as divinyltetramethyldisiloxane, as disclosed by Willing, U.S. Pat. No. No. 3,419,593, incorporated herein by reference, because of its easy dispersibility in organosilicon systems. Other platinum catalysts which are useful in the present invention include those disclosed in U.S. Pat. Nos. 3,159,601; 3,159,602; 3,220,972; 3,296,291; 3,516,946; 3,814,730 and 3,928,629, incorporated herein by reference. The preferred Group VIII metal catalyst as Component (C) for the compositions of the present invention is RhCl 3 , RhBr 3 , RhI 3 , and complexes thereof, although as described hereinabove other appropriate catalyst systems may be employed such as ClRh(PPh 3 ) 3 and complexes thereof; H 2 PtCl 16 ; a complex of 1,3-divinyl tetramethyl disiloxane and H 2 PtCl 6 ; and alkyne complexes of H 2 PtCl 6 . A more exhaustive list of appropriate catalyst systems which can be employed as Component (C) in the present invention is set forth in U.S. Pat. No. 4,746,750, which is considered incorporated herein by reference. The Group VII metal catalyst may be complexed with a solvent such as THF (tetrahydrofuran).
Also suitable as a catalyst for Component (C) in the compositions of the instant invention are the novel rhodium catalyst complexes disclosed in copending U.S. application for patent, Ser. No. 08/176,168, filing date Dec. 30, 1993, and assigned to the same assignee as this present application, incorporated herein by reference. These novel rhodium catalyst complexes are generally compositions comprising a rhodium catalyst, an unsaturated acetate such as linallyl acetate, and alcohols having having 3 or more carbon atoms including diols, furans having at least one OH group per molecule, and pyrans having at least one OH group per molecule.
The amount of Group VIII metal catalyst, Component (C), that are used in the compositions of this invention is not narrowly limited and can be readily determined by one skilled in the art by routine experimentation. However, the most effective concentration of the Group VIII metal catalyst has been found to be from about one part per million to about two thousand parts per million on a weight basis relative to the unsaturated acetate of Component (A).
Also suitable for use as the metal catalyst Component (C) in the compositions of the instant invention are encapsulated metal catalysts. The encapsulated metal catalyst can be a microencapsulated liquid or solubilized curing catalyst which are prepared by the photoinitiated polymerization of at least one solubilized hydroxyl-containing ethylenically unsaturated organic compound in the presence of a photoinitiator for the polymerization of said compound, an optional surfactant, and a liquid or solubilized curing catalyst for organosiloxane compositions such as the catalysts described by Lee et al. in U.S. Pat. Nos. 5,066,699 and 5,077,249 which are considered incorporated herein by reference. It is preferred for purposes of the present invention that the encapsulated metal catalyst is a microencapsulated curing catalyst prepared by irradiating with UV light in the wavelength range of from 300 to 400 nanometers a solution containing (1) at least one of a specified group of photocrosslinkable organosiloxane compounds derived from propargyl esters of carboxylic acids containing a terminal aromatic hydrocarbon radical and at least two ethylenically unsaturated carbon atoms and (2) a liquid or solubilized hydrosilylation catalyst, such as the catalysts described by Evans et al. in U.S. Pat. No. 5,194,460 and in copending U.S. application for patent, Ser. No. 08/001,607, filing date Jan. 7, 1993, and assigned to the same assignee as this present application, now U.S. Pat. No. 5,279,898, which are considered incorporated herein by reference.
The amount of microencapsulated curing catalyst in the fiber treatment compositions of this invention are typically not restricted as long as there is a sufficient amount to accelerate a curing reaction between components (A) and (B). Because of the small particle size of microencapsulated curing catalysts it is possible to use curing catalyst concentrations equivalent to as little as 1 weight percent or less to as much as 10 weight percent of microencapsulated curing catalyst as Component (C) in the compositions of the present invention, said weight percent being based on the total weight of the composition.
Component (D) in the compositions of this invention is an organosilicon compound having an average of at least one group per molecule selected from the group consisting of hydroxy groups, carboxy groups, ester groups, amino groups, acetoxy groups, sulfo groups, alkoxy groups, acrylate groups, epoxy groups, fluoro groups, ether groups, olefinic hydrocarbon or halohydrocarbon radicals having from 2 to 20 carbon atoms, and mixtures thereof. It is preferred for purposes of the present invention that Component (D) is a compound having its formula selected from the group consisting of (i) R 1 3 SiO(R 2 SiO) x (R 1 RSiO) y SiR 1 3 , (ii) R 2 R 1 SiO(R 2 SiO) x (R 1 RSiO) y SiR 2 R 1 , (iii) RR 1 2 SiO(R 2 SiO) x (R 1 RSiO) y SiRR 1 2 , wherein R is a monovalent hydrocarbon or halohydrocarbon radical having from 1 to 20 carbon atoms, R 1 is a group selected from the group consisting of hydroxy groups, carboxy groups, ester groups, amino groups, acetoxy groups, sulfo groups, alkoxy groups, acrylate groups, epoxy groups, fluoro groups, ether groups, olefinic hydrocarbon or halohydrocarbon radicals having from 2 to 20 carbon atoms, and mixtures thereof, x has a value of 0 to 3000, and y has a value of 1 to 100.
The monovalent radicals of R in Component (D) can contain up to 20 carbon atoms and include halohydrocarbon radicals free of aliphatic unsaturation and hydrocarbon radicals. Monovalent hydrocarbon radicals include alkyl radicals, such as methyl, ethyl, propyl, butyl, hexyl, and octyl; cycloaliphatic radicals, such as cyclohexyl; aryl radicals, such as phenyl, tolyl, and xylyl; aralkyl radicals, such as benzyl and phenylethyl. Highly preferred monovalent hydrocarbon radical for the silicon- containing components of this invention are methyl and phenyl. Monovalent halohydrocarbon radicals include any monovalent hydrocarbon radical noted above which has at least one of its hydrogen atoms replaced with a halogen, such as fluorine, chlorine, or bromine. Preferred monovalent halohydrocarbon radicals have the formula C n F 2n+1 CH 2 CH 2 -- wherein the subscript n has a value of from 1 to 10, such as, for example, CF 3 CH 2 CH 2 -- and C 4 F 9 CH 2 CH 2 --. The several R radicals can be identical or different, as desired and preferably at least 50 percent of all R radicals are methyl.
The functional groups of R 1 are selected from the group consisting of hydroxy groups, carboxy groups, ester groups, amino groups, acetoxy groups, sulfo groups, alkoxy groups, acrylate groups, epoxy groups, fluoro groups, ether groups, olefinic hydrocarbon or halohydrocarbon radicals having from 2 to 20 carbon atoms, and mixtures thereof. Hydroxy groups suitable for use in the compositions of the instant invention include hydroxyalkyl groups, hydroxyaryl groups, hydroxycycloalkyl groups, and hydroxycycloaryl groups. Preferred hydroxy (OH) groups as R 1 in the compositions of this invention include groups such as hydroxy, hydroxypropyl, hydroxybutyl, hydroxyphenyl, hydroxymethylphenyl, hydroxyethylphenyl, and hydroxycyclohexyl.
Carboxy groups suitable for use as R 1 in the compositions of the instant invention include carboxyalkyl groups, carboxyaryl groups, carboxycycloalkyl groups, and carboxycycloaryl groups. Preferred carboxy groups as R 1 in the compositions of this invention include groups such as carboxy, carboxymethyl, carboxyethyl, carboxypropyl, carboxybutyl, carboxyphenyl, carboxymethylphenyl, carboxyethylphenyl, and carboxycyclohexyl.
Ester groups can also be used as R 1 in the formulae hereinabove. These ester groups can include groups such as alkylesters, arylesters, cycloalkylesters, and cycloarylesters. Preferred ester groups suitable as R 1 in the instant invention are selected from the group consisting of ethyl acetate, methyl acetate, n-propyl acetate, n-butyl acetate, phenyl acetate, benzyl acetate, isobutyl benzoate, ethyl benzoate, ethyl propionate, ethyl stearate, ethyl trimethylacetate, methyl laurate, and ethyl palmitate.
Preferred amino groups as R 1 in the compositions of this invention are exemplified by groups having the formula NR 2 wherein R is hydrogen or a monovalent hydrocarbon radical having from 1 to 20 carbon atoms such as aminoalkyl groups, aminoaryl groups, aminocycloalkyl groups, and aminocycloaryl groups. Preferred as amino groups in the instant invention are groups such as amino, aminopropyl, ethylene diaminopropyl, aminophenyl, aminooctadecyl, aminocyclohexyl, propylene diaminopropyl, dimethylamino, and diethylamino.
Acetoxy groups suitable as R 1 in the compositions of the present invention are exemplified by groups having the formula --COOCH 3 such as acetoxyalkyl groups, acetoxyaryl groups, acetoxycycloalkyl groups, and acetoxycycloaryl groups. Preferred acetoxy groups in the compositions of the instant invention include acetoxy, acetoxyethyl, acetoxypropyl, acetoxybutyl, acetoxyphenyl, and acetoxycyclohexyl.
Sulfo groups which are preferred as R 1 in the compositions of the present invention are exemplified by groups having the formula SR wherein R is hydrogen or a monovalent hydrocarbon radical having from 1 to 20 carbon atoms such as sulfoalkyl groups, sulfoaryl groups, sulfocycloalkyl groups, and sulfocycloaryl groups. Preferred sulfo groups include hydrogen sulfide, sulfopropyl, methylsulfopropyl, sulfophenyl, and methylsulfo.
Fluoro groups are exemplified by groups such as fluoroalkyl groups, fluoroaryl groups, fluorocycloalkyl groups, and fluorocycloaryl groups. Preferred fluoro groups which are suitable as R 1 in the compositions of this invention include fluoro, fluoropropyl, fluorobutyl, 3,3,3-trifluoropropyl, and 3,3,4,4,5,5,6,6,6-nonafluorohexyl.
Alkoxy groups suitable as R 1 in component (D) of this invention include groups such as alkoxyalkyl groups, alkoxyaryl groups, alkoxycycloalkyl groups, and alkoxycycloaryl groups. Preferred alkoxy groups for R 1 in the present invention are groups such as methoxy, ethoxy, butoxy, tertiary-butoxy, propoxy, isopropoxy, methoxyphenyl, ethoxyphenyl, methoxybutyl, and methoxypropyl groups.
Epoxy groups suitable as R 1 in component (D) of this invention include groups such as epoxyalkyl groups, epoxyaryl groups, epoxycycloalkyl groups, and epoxycycloaryl groups. Preferred epoxy groups for R 1 in the present invention are groups such as epoxide, epichlorohydrin, ethylene oxide, epoxybutane, epoxycyclohexane, epoxy ethylhexanol, epoxy propanol, and epoxy resin groups.
Acrylate groups suitable as R 1 in the formulae hereinabove include groups such as acryloxy, acryloxyalkyl groups, acryloxyaryl groups, acryloxycycloalkyl groups, and acryloxycycloaryl groups. Preferred acrylate groups suitable as R 1 in the instant invention are selected from the group consisting of acryloxyethyl, acryloxyethoxy, acryloxypropyl, acryloxypropoxy, methacryloxyethyl, methacryloxyethoxy, methacryloxypropyl, and methacryloxypropoxy.
Ether groups can also be used as R 1 in the formulae hereinabove. These ether groups can include groups such as alkylethers, arylethers, cycloalkylethers, and cycloarylethers. Preferred ether groups suitable as R 1 in the instant invention are selected from the group consisting of methylethylether, methylpropylether, ethylmethylether, ethylethylether, ethylpropylether, methylphenylether, ethylphenylether, isopropylphenylether, tertiary-butylpropylether, methylcyclohexylether, and ethylcyclohexylether.
The olefinic hydrocarbon radicals of R 1 of the present invention may have from 2 to 20 carbon atoms. The olefinic hydrocarbon radicals are preferably selected from the group consisting of the vinyl radical and higher alkenyl radicals represented by the formula --R(CH 2 ) m CH═CH 2 wherein R denotes --(CH 2 ) n -- or --(CH 2 ) p CH═CH-- and m has the value of 1, 2, or 3, n has the value of 3 or 6, and p has the value of 3, 4, or 5. The higher alkenyl radicals represented by the formula --R(CH 2 ) m CH═CH 2 contain at least 6 carbon atoms. For example, when R denotes --(CH 2 ) n --, the higher alkenyl radicals include 5-hexenyl, 6- heptenyl, 7-octenyl, 8-nonenyl, 9-decenyl, and 10-undecenyl. When R denotes --(CH 2 ) p CH═CH--, the higher alkenyl radicals include, among others, 4,7-octadienyl, 5,8-nonadienyl, 5,9-decadienyl, 6,11-dodecadienyl and 4,8-nonadienyl. Alkenyl radicals selected from the group consisting of 5-hexenyl, 7-octenyl, 9-decenyl, and 5,9-decadienyl, are preferred. It is more preferred that R denote --(CH 2 ) n -- so that the radicals contain only terminal unsaturation and the most preferred radicals are the vinyl radical and the 5- hexenyl radical.
Specific examples of preferred polydiorganosiloxanes for use as Component (D) in the compositions of the present invention include ViMe 2 SiO(Me 2 SiO) x SiMe 2 Vi, HexMe 2 SiO(Me 2 SiO) x (MeHexSiO) y SiMe 2 Hex, ViMe 2 SiO(Me 2 SiO) x (MeViSiO) y SiMe 2 Vi, HexMe 2 SiO(Me 2 SiO) 196 (MeHexSiO) 4 SiMe 2 Hex, HexMe 2 SiO(Me 2 SiO) 198 (MeHexSiO) 2 SiMe 2 Hex, HexMe 2 SiO(Me 2 SiO) 151 (MeHexSiO) 3 SiMe 2 Hex, and ViMe 2 SiO(Me 2 SiO) 96 (MeViSiO) 2 SiMe 2 Vi, HexMe 2 SiO(Me 2 SiO) x SiMe 2 Hex, PhMeViSiO(Me 2 SiO) x SiPhMeVi, HexMe 2 SiO(Me 2 SiO) 130 SiMe 2 Hex, ViMePhSiO(Me 2 SiO) 145 SiPhMeVi, ViMe 2 SiO(Me 2 SiO) 299 SiMe 2 Vi, ViMe 2 SiO(Me 2 SiO) 800 SiMe 2 Vi, ViMe 2 SiO(Me 2 SiO) 300 SiMe 2 Vi, ViMe 2 SiO(Me 2 SiO) 198 SiMe 2 Vi, vinyldimethylsiloxy-terminated poly((3,3,3-trifluoropropyl)methylsiloxy) pentasiloxane, vinylmethylsiloxy-terminated polydimethylsiloxane having (3,3,4,4,5,5,6,6,6-nonafluorobutyl)methylsiloxy functional groups. vinyldimethylsiloxy-terminated polydimethyldodecasiloxane having (3,3,3-trifluoropropyl)methylsiloxy groups, vinylmethylsiloxyterminated polydimethylsiloxane having (3,3,4,4,5,5,6,6,6-nonafluorobutyl)methylsiloxy functional groups, dimethylhydridosiloxy-terminated poly((3,3,3-trifluoropropyl)methylsiloxy) pentasiloxane, dimethylhydroxysiloxy-terminated polydimethylsiloxane, and dimethylhydroxysiloxy-terminated dimethyl(aminoethylaminopropyl)methyl siloxane, wherein Me, Vi, Hex, and Ph denote methyl, vinyl, 5-hexenyl and phenyl, respectively.
The amount of Component (D) employed in the compositions of the present invention varies depending on the amount of organohydrogensiloxane, metal catalyst, and unsaturated acetate, that is employed. It is preferred for purposes of this invention that from 1 to 99 weight percent of (D), the organosilicon compound, be used, and it is highly preferred that from 70 to 95 weight percent of (D) be employed, said weight percent being based on the total weight of the composition.
The compositions of the instant invention can further comprise (E) a dispersant selected from the group consisting of one or more surfactants and one or more solvents. The (emulsifying agents) surfactants are preferably of the non-ionic or cationic types and may be employed separately or in combinations of two or more. Suitable emulsifying agents for the preparation of a stable aqueous emulsion are known in the art. Examples of nonionic surfactants suitable as component (E) of the present invention include polyoxyethylene alkyl ethers, polyoxyethylene alkylphenol ethers, polyoxyethylene lauryl ethers and polyoxyethylene sorbitan monoleates such as Brij™ 35L (from ICI Americas Inc., Wilmington, Del. 19897), Brij™ 30 (ICI Americas Inc., Wilmington, Del. 19897), and Tween™ 80 (ICI Americas Inc., Wilmington, Del. 19897), polyoxyethylene alkyl esters, polyoxyethylene sorbitan alkyl esters, polyethylene glycol, polypropylene glycol, ethoxylated trimethylnonanols such as Tergitol® TMN-6 (from Union Carbide Chem. & Plastics Co., Industrial Chemicals Div., Danbury, Conn. 06817-0001), and polyoxyalkylene glycol modified polysiloxane surfactants. Examples of cationic surfactants suitable as component (E) in the compositions of the instant invention include quaternary ammonium salts such as alkyltrimethylammonium hydroxide, dialkyldimethylammonium hydroxide, methylpolyoxyethylene cocoammonium chloride, and diplmityl hydroxyethylammonium methosulfate. Preferably, a combination of two or three nonionic surfactants, or a combination of a cationic surfactant and one or two nonionic surfactants are used to prepare the emulsions of the present invention.
Examples of the preferred surfactants for use as Component (E) in the compositions of this invention are the reaction products of alcohols and phenols with ethylene oxide such as the polyethoxyethers of nonyl phenol and octyl phenol and the trimethylnol ethers of polyethylene glycols, monoesters of alcohols and fatty acids such as glycerol monostearate and sorbitan monolaurate, and the ethoxylated amines such as those represented by the general formula ##STR1## in which R"" is an alkyl group having from about 12 to about 18 carbon atoms and the sum of a and b is from 2 to about 15. Silicone surfactants are also suitable for use as Component (E) in the instant invention. Preferred silicone surfactants include silicone polyethers such as polyalkylpolyether siloxanes and silicone glycol surfactants including silicone glycol polymers and copolymers such as those disclosed in U.S. Pat. No. 4,933,002, incorporated herein by reference. The emulsifying agents may be employed in proportions conventional for the emulsification of siloxanes, from about 1 to about 30 weight percent, based on the total weight of the composition.
Solvents may also be employed as Component (E) in the compositions of the instant invention. Preferred solvents for use as Component (E) in the instant invention include hydrocarbon solvents such as dichloromethane (methylene chloride ) and acetonitrile. It is preferred for purposes of the present invention that Component (E), the dispersant, be a mixture of water and one or more of the surfactants described hereinabove. It is also preferred that emulsification of the compositions of the instant invention is carried out by adding one or more emulsifying agents, and water be added to components (A), (B), (C), and (D) described hereinabove and the resulting composition be subjected to high shear.
The amount of Component (E) employed in the compositions of the present invention varies depending on the amount of organohydrogensiloxane, metal catalyst, unsaturated acetate, and organosilicon compound that is employed. It is preferred for purposes of this invention that from 0.25 to 99 weight percent of (E), the dispersant, be used, and it is highly preferred that from 1 to 95 weight percent of dispersant be employed, said weight percent being based on the total weight of the composition. When a surfactant is employed it is preferred that from 0.25 to 20 weight percent be used, and when a solvent is employed it is preferred that from 70 to 99.5 weight percent be used, said weight percent being based on the total weight of the composition.
The present invention further relates to a method of treating a substrate, the method comprising the steps of (I) mixing: (A) an unsaturated acetate, (B) at least one organohydrogensiloxane, (C) a metal catalyst, (D) an organosilicon compound having an average of at least one group per molecule selected from the group consisting of hydroxy groups, carboxy groups, ester groups, amino groups, acetoxy groups, sulfo groups, alkoxy groups, acrylate groups, epoxy groups, fluoro groups, ether groups, olefinic hydrocarbon or halohydrocarbon radicals having from 2 to 20 carbon atoms, and mixtures thereof, and (E) a dispersant selected from the group consisting of one or more surfactants and one or more solvents, (II) applying the mixture from (I) to a substrate, and (III) heating the substrate. Components (A), (B), (C), (D), and (E) are as delineated above including preferred amounts and embodiments thereof.
The present invention also relates to a method of making a fiber treatment composition comprising (I) mixing (A) an unsaturated acetate, (B) at least one organohydrogensiloxane, (C) a metal catalyst, (D) an organosilicon compound having an average of at least one group per molecule selected from the group consisting of hydroxy groups, carboxy groups, ester groups, amino groups, acetoxy groups, sulfo groups, alkoxy groups, acrylate groups, epoxy groups, fluoro groups, ether groups, olefinic hydrocarbon or halohydrocarbon radicals having from 2 to 20 carbon atoms, and mixtures thereof, and (E) a dispersant selected from the group consisting of one or more surfactants and one or more solvents. Again, Components (A), (B), (C), (D), and (E) are as delineated above including preferred amounts and embodiments thereof.
The present invention further relates to a method of making a fiber treatment composition comprising: (I) mixing: (i) an organosilicon compound having an average of at least one group per molecule selected from the group consisting of hydroxy groups, carboxy groups, ester groups, amino groups, acetoxy groups, sulfo groups, alkoxy groups, acrylate groups, epoxy groups, fluoro groups, ether groups, olefinic hydrocarbon or halohydrocarbon radicals having from 2 to 20 carbon atoms, and mixtures thereof, and (ii) a dispersant selected from the group consisting of one or more surfactants and one or more solvents; (II) adding to the mixture of (I) a mixture of: (iii) an unsaturated acetate, (iv) at least one organohydrogensiloxane, and (v) a metal catalyst. The mixture of Step (II) can be emulsified prior to adding the mixture of (II) to the mixture of (I). Again, Components (A), (B), (C), (D), and the surfactants are as delineated above including preferred amounts and embodiments thereof.
The compositions comprising components (A), (B), (C), (D), and optionally any surfactants or solvents (E) may be applied to the fibers by employing any suitable application technique, for example by padding or spraying, or from a bath. For purposes of this invention, the compositions can be applied from a solvent, but is preferred that the compositions be applied from an aqueous medium, for example, an aqueous emulsion. Thus, any organic solvent can be employed to prepare the solvent-based compositions, it being understood that those solvents that are easily volatilized at temperatures of from room temperatures to less than 100° C. are preferred, for example, such solvents may include methylene chloride, acetonitrile, toluene, xylene, white spirits, chlorinated hydrocarbons, and the like. The treating solutions can be prepared by merely mixing the components together with the solvent. The concentration of the treating solution will depend on the desired level of application of siloxane to the fiber, and on the method of application employed, but it is believed by the inventors herein that the most effective amount of the composition should be in the range such that the fiber (or fabric) picks up the silicone composition at about 0.05% to 10% on the weight of the fiber or fabric. According to the instant inventive method of treatment, the fibers usually in the form of tow, or knitted or woven fabrics, are immersed in an aqueous emulsion of the compositions whereby the composition becomes selectively deposited on the fibers. The deposition of the composition on the fibers may also be expedited by increasing the temperatures of the aqueous emulsion, temperatures in the range of from 20° to 60° C. being generally preferred.
Preparation of the aqueous emulsions can be carried out by any conventional technique. The compositions of this can be prepared by homogeneously mixing Components (A), (B), (C), and (D) and any optional components in any order. Thus it is possible to mix all components in one mixing step immediately prior to using the fiber treatment compositions of the present invention. Most preferably (A), (B), and (C) are emulsified and then (D) is emulsified and the two emulsions thereafter combined. The emulsions of the present invention may be macroemulsions or microemulsions and may also contain optional ingredients, for example antifreeze additives, preservatives, biocides, organic softeners, antistatic agents, dyes and flame retardants. Preferred preservatives include Kathon® LX (5-chloro-2-methyl-4-isothiazolin-3-one from Rohm and Haas, Philadelphia, Pa. 19106), Giv-gard® DXN (6-acetoxy-2,4-dimethyl-m-dioxane from Givaudan Corp., Clifton N.J. 07014), Tektamer® A.D. (from Calgon Corp., Pittsburgh, Pa. 152300), Nuosept® 91,95 (from Huls America, Inc., Piscataway, N.J. 08854), Germaben® (diazolidinyl urea and parabens from Sutton Laboratories, Chatham, N.J. 07928), Proxel® (from ICI Americas Inc., Wilmington, Del. 19897), methyl paraben, propyl paraben, sorbic acid, benzoic acid, and lauricidin.
Following the application of the siloxane composition to the substrate, the siloxane is then cured. Preferably, curing is expedited by exposing the treated fibers to elevated temperatures, preferably from 50° to 200 ° C.
The compositions of this invention can be employed for the treatment of substrates such as animal fibers such as wool, cellulosic fibers such as cotton, and synthetic fibers such as nylon, polyester and acrylic fibers, or blends of these materials, for example, polyester/cotton blends, and may also be used in the treatment of leather, paper, and gypsum board. The fibers may be treated in any form, for example as knitted and woven fabrics and as piece goods. They may also be treated as agglomerations of random fibers as in filling materials for pillows and the like such as fiberfil.
The composition of components (A), (B), (C), and (D) should be used at about 0.05 to 25 weight percent in the final bath for exhaust method applications, and about 5 gm/l to 80 gm/l in a padding method of application, and about 5 gm/l to 600 gm/l for a spraying application. The compositions employed in this process are particularly suitable for application to the fibers or fabrics from an aqueous carrier. The compositions can be made highly substantive to the fibers, that is they can be made to deposit selectively on such fibers when applied thereto as aqueous emulsions. Such a property renders the compositions particularly suited for aqueous batch treatment by an exhaustion procedure, such exhaustion procedures being known to those skilled in the art. The compositions of the instant invention are new and novel and provide a fast cure and wide cure temperature ranges for curing them on fibers or fabrics compared to the compositions of the prior art, having a temperature cure range of from 50° C. to 200° C. Further, the fibers have superior slickness and no oily feeling after cure. The compositions of the instant invention provide consistent performance, good bath life of more than 24 hours at 40° C., have good laundry and dry cleaning durability, and have very good suitability for application by spraying.
Fiber Slickness was tested by using a DuPont® unslickened fiberfil product, i.e. Hollofil® T-808, for the evaluation of slickness imparted by the application of the silicone emulsion of the present invention. A piece of Hollofil® T-808 is soaked in the diluted emulsion of interest and then passed through a roller to obtain 100% wet-pickup, i.e., the weight of the finished fiberfil is twice that of the unfinished fiberfil. After drying at room temperature, the finished sample is heated at 175° C. for 2-25 minutes. Thus prepared, the finished fiberfil usually contains approximately the same silicone level as that of the emulsion of interest.
The slickness of fiberfil is measured by staple pad friction which is determined from the force required to pull a certain weight over a fiberfil staple pad. The staple pad friction is defined as the ratio of the force over the applied weight. A 10 pound weight was used in the friction measurement of this invention. A typical instrument set-up includes a friction table which is mounted on the crosshead of an Instron tensile tester. The friction table and the base of the weight are covered with Emery Paper #320 from the 3M Company so that there is little relative movement between the staple pad and the weight or the table. Essentially all of the movement is a result of fibers sliding across each other. The weight is attached to a stainless steel wire which runs through a pulley mounted at the base of the Instron tester. The other end of the stainless steel wire is tied to the loadcell of the Instron tester.
Following are examples illustrating the compositions and methods of the present invention. In the examples hereinbelow, THF denotes tetrahydrofuran, THFA denotes tetrahydrofurfuryl alcohol, and TPRh denotes (PH 3 P)RhCl 3 (tris--(triphenylphosphine)rhodium chloride).
In the examples hereinbelow, a variety of different organosilicon compounds were used in preparing the compositions of the instant invention. Each organosilicon compound is delineated below and is designated by a corresponding letter. The letters then appear in Tables I and II below thus designating the type of organosilicon compound employed.
A--a 9,500 cps vinyldimethylsiloxy-terminated polydimethylsiloxane.
B--a 40,000 cps polydimethylsiloxane having 30% pendant vinylmethylsiloxy moieties.
C1--Silicone in water emulsion of 65 micron diameter particle size containing vinyldimethylsiloxy-terminated poly((3,3,3-trifluoropropyl)methylsiloxy) pentasiloxane.
C2--Silicone in water emulsion of 2 micron diameter particle size containing vinyldimethylsiloxy-terminated poly((3,3,3-trifluoropropyl)methylsiloxy) pentasiloxane.
D--Silicone in water emulsion containing 30,000 cps vinylmethylsiloxy-terminated polydimethylsiloxane having 30% (3,3,4,4,5,5,6,6,6-nonafluorobutyl)methylsiloxy moieties.
E--Silicone in water emulsion containing vinyldimethylsiloxy-terminated polydimethyldodecasiloxane having 40% (3,3,3-trifluoropropyl)methylsiloxy moieties.
F--Silicone in water emulsion containing 10,000 cps vinylmethylsiloxy-terminated polydimethylsiloxane having 30% (3,3,4,4,5,5,6,6,6-nonafluorobutyl)methylsiloxy moieties.
G--Silicone in water emulsion containing dimethylhydridosiloxy-terminated poly((3,3,3-trifluoropropyl)methylsiloxy) pentasiloxane.
H--Silicone in water emulsion containing 1,500,000 cps dimethylhydroxysiloxy-terminated polydimethylsiloxane.
I--Silicone in water emulsion containing 12,500 cps dimethylhyroxysiloxy-terminated polydimethylsiloxane.
J--Silicone in water emulsion containing 4,000 cps dimethylhydroxysiloxy-terminated dimethyl(aminoethylaminopropyl)methyl siloxane.
K--a 250 cps polydimethylsiloxane having 8% pendant alkylsulfocarboxy moieties.
EXAMPLES 1-10
In order to illustrate the effectiveness of the compositions of the present invention the following tests were conducted. Two catalysts were prepared, a rhodium catalyst and a microencapsulated curing catalyst. A 0.03 molar rhodium catalyst solution was prepared by dissolving 1 gram of RhCl 3 .6H 2 O (rhodium trichloride hexahydrate) or TPRh in 120 grams of THF, THFA, or linallyl acetate. A 10% and 1% platinum catalyst solution was prepared by dissolving 10 grams and 1 gram, respectively, of a platinum catalyst prepared according to Example 3 of U.S. Pat. No. 5,194,460 in 90 grams and 99 grams, respectively, of linallyl acetate.
Into a glass container was added the acetate material. With gentle mixing using a round edge three blade turbine mixing impeller, one of the catalyst solutions prepared above was added to the acetate and mixed until the mixture was homogeneous. Next, a mixture of 100 grams of a trimethylsilyl terminated polymethylhydrogensiloxane having a viscosity of 30 centistokes at a temperature of 25° C. and having the formula Me 3 SiO(MeHSiO) 70 SiMe 3 and an amount of an organosilicon compound (denoted in Table I hereinbelow) was added to the mixture and stirred gently until the mixture was again homogeneous. This was followed by adding about 1.78 grams of a polyoxyethylene lauryl ether surfactant or a methylene chloride solvent (in Example 7 a solvent was substituted for the surfactant), and about 38 grams of water containing up to about 0.22 grams of a preservative (sorbic acid) to the mixture. Mixing was then resumed at medium speed for 20 to 30 minutes. The mixture was then processed through a high shear device to produce the emulsions of the instant invention. The particle sizes of the emulsions ranged from 0.7 to 3.0 microns and the pH of the emulsions ranged from 3.0 to 4.5.
A relative ranking from 1 to 10 was established using known commercial finishes based upon slickness values obtained using the Staple Pad Friction frictional test described hereinabove. No finish was given a ranking of 1, the commercial finish was given a ranking of 6, and a premium finish was given a ranking of 10. The amount of organosilicon compound, organosilicon compound type, the amount of linallyl acetate, the amount of catalyst, catalyst type, the time it took each sample to cure in minutes (min.), and the performance of each example are reported in Table I hereinbelow.
TABLE I__________________________________________________________________________OrganosiliconCompound Amount Linallyl Catalyst Catalyst CureExampleType (g) Acetate (g) (g) Type (Min.) Rating__________________________________________________________________________1 A 10 10 0.1 RhCl.sub.3, THF 5 102 C1 3 3 0.1 RhCl.sub.3, THF 10 103 C2 3 3 0.1 RhCl.sub.3, THF 10 84 A 10 10 0.3 10% Pt, Linallyl 8 115 B 10 0 0.3 1% Pt, Linallyl 3 116 D 2.5 0 0.3 1% Pt, Linallyl 15 97 E 3 0 0.3 1% Pt, Linallyl 10 98 F 3 0 0.3 1% Pt, Linallyl 10 119 G 2 0 0.3 1% Pt, Linallyl 14 1110 K 10 4 0.1 RhCl.sub.3, THFA 10 10__________________________________________________________________________
The examples in Table I hereinabove show that the organosilicon compounds of the instant invention cure into fiber treatment compositions to give good slickness ratings.
EXAMPLES 11-13
Another fiber treatment composition was prepared by preparing a first solution by mixing 33 grams of a trimethylsilyl terminated polymethylhydrogensiloxane having a viscosity of 30 centistokes at a temperature of 25° C. and having the formula Me 3 SiO(MeHSiO) 70 SiMe 3 , 2 grams of linallyl acetate, and 0.03 grams of TPRh with 60 grams of water containing 4.8 grams of a nonionic polyoxyethylene lauryl ether surfactant and stirring. This mixture was then subjected to high shear until the desired emulsion particle size was attained.
A second solution was prepared by mixing 35 grams of an organosilicon compound (denoted in Table II) with 60 grams of water containing 4.8 grams of a nonionic polyoxyethylene lauryl ether surfactant and about .3 grams of a preservative (sorbic acid) and stirring. This mixture was then subjected to high shear until the desired emulsion particle size was attained.
In examples 11 and 12, 10 parts of the first solution was mixed with 90 parts of the second solution and the resulting mixture was stirred. In example 13, 3 parts of the first solution was mixed with 97 parts of the second solution and the resulting mixture was stirred. The typical particle size of the emulsions was below 300 nm and the pH ranged from 3.0 to 9.5.
The examples were again ranked as described hereinabove. The organosilicon compound type, the time it took each sample to cure in minutes (min.), and the performance of each example are reported in Table II hereinbelow.
TABLE II______________________________________ Organosilicon Compound CureExample Type (Min.) Rating______________________________________11 H 10 1112 I 10 1213 J 10 10______________________________________
Table II hereinabove shows that the compositions of the instant invention give excellent slickness ratings even when using a variety of catalyst types and different types of organosilicon compounds.
Comparison Example 1
A first emulsion was prepared in the following manner. About 2 weight percent of an aqueous solution of a mixture of two partially hydrolyzed PVA's (polyvinyl alcohols) having a degree of hydrolysis of 88% and a 4% aqueous solution viscosity of 5 centipoise (cP) and 24 centipoise (cP) at 25° C., respectively, and about 0.3 weight percent of a polyoxyethylene (10) nonyl phenol surfactant was mixed with 28 weight percent of water. Next, 13.5 weight percent of an organohydrogenpolysiloxane having the formula Me 3 SiO(MeHSiO) 5 (Me 2 SiO) 3 SiMe 3 , and 28 weight percent of a dimethylvinylsiloxy-terminated polydimethylmethylvinylsiloxane having a viscosity of 350 cP were mixed and stirred. Next, the PVA-surfactant mixture was added to the siloxane mixture and stirred. This mixture was then processed through a colloid mill and diluted with 28 weight percent of water containing a biocide to form an emulsion.
A second emulsion was prepared by mixing 2 weight percent of an aqueous solution of a mixture of two partially hydrolyzed PVA's (polyvinyl alcohols) having a degree of hydrolysis of 88% and a 4% aqueous solution viscosity of 5 centipoise (cP) and 24 centipoise (cP) at 25° C., respectively, about 0.3 weight percent of a polyoxyethylene (10) nonyl phenol surfactant, and 28 weight percent of water. Next, about 40 weight percent of dimethylvinylsiloxy-terminated polydimethylmethylvinylsiloxane having a viscosity of 350 cP and about 1% of a platinum-containing catalyst were mixed and stirred. Next, the PVA-surfactant mixture was added to the siloxane mixture and stirred. This mixture was then processed through a colloid mill and diluted with 28 weight percent of water containing a biocide to form an emulsion.
Next, 7.5 grams of the first emulsion, 7.5 grams of the second emulsion, and 85 grams of water were mixed together and the resulting emulsion stirred.
This silicone emulsion cured in 10 minutes and the sample was ranked according to the staple pad friction procedure delineated hereinabove. The silicone emulsion attained a rating of between 4 and 5.
Comparison Example 2
A silicone emulsion was prepared according to the disclosure of Bunge in U.S. Pat. No. 4,954,554. A first emulsion was prepared in the following manner. About 38 weight percent of a dimethylvinylsiloxy-terminated polydimethylsiloxane having a viscosity of 450 centistokes (cst) and 2 weight percent of a mixture of an organohydrogenpolysiloxane having the formula Me 3 SiO(MeHSiO) 5 (Me 2 SiO) 3 SiMe 3 and a dimethylsiloxanemethylhydrogensiloxane having a viscosity of 85 centistokes (cst) were mixed and stirred. About 2 weight percent of an aqueous solution of an intermediately hydrolyzed PVA having a degree of hydrolysis of 96% and a 4% aqueous solution viscosity of 30 centipoise (cP) at 25° C., a surfactant, and 29 weight percent of water were mixed and stirred. Next, the PVA-surfactant mixture was added to the siloxane mixture and stirred. This mixture was then processed through a colloid mill and diluted with 29 weight percent of water containing a biocide to form an emulsion.
A second emulsion was prepared by mixing about 2 weight percent of an aqueous solution of an intermediately hydrolyzed PVA having a degree of hydrolysis of 96% and a 4% aqueous solution viscosity of 30 centipoise (cP) at 25° C., a surfactant, and 51 weight percent of water. Next, about 40 weight percent of a dimethylvinylsiloxy-terminated polydimethylsiloxane having a viscosity of 450 cP and about 1% of a platinum-containing catalyst were mixed and stirred. Next, the PVA-surfactant mixture was added to the siloxane mixture and stirred. This mixture was then processed through a colloid mill and 7 weight percent of water containing a biocide was added to form an emulsion.
Next, 7.5 grams of the first emulsion, 7.5 grams of the second emulsion, and 85 grams of water were mixed together and the resulting emulsion stirred.
This silicone emulsion cured in 10 minutes and the sample was ranked according to the staple pad friction procedure delineated hereinabove. The silicone emulsion attained a rating of between 5 and 6. Thus the compositions of the instant invention outperformed the silicone emulsion previously described in the art.
It should be apparent from the foregoing that many other variations and modifications may be made in the compounds, compositions and methods described herein without departing substantially from the essential features and concepts of the present invention. Accordingly it should be clearly understood that the forms of the invention described herein are exemplary only and are not intended as limitations on the scope of the present invention as defined in the appended claims.
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The present invention relates to fiber treatment compositions comprising an unsaturated acetate, an organohydrogensiloxane, a metal catalyst, an organosilicon compound, and optionally a dispersant. The compositions of the present invention impart beneficial characteristics such as slickness, softness, compression resistance and water repellency to substrates such as fibers and fabrics.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to an over-molded product, that is, a product comprising multiple components fastened together by a molded outer material, and the method of manufacturing such a product.
PRIOR ART STATEMENT
[0002] It is desirable to close and seal various products, such as containers having covers. Typical products are disclosed in the patents to Aske, Ser. No. 3,047,703; Kirchhan, Ser. No. 4,546,874; and Baerenwald, Ser. No. 5,794,814. Such containers may be utilized to safely enclose hazardous materials or to prevent leakage into the container. These are provided by using thermoplastic materials as closure systems.
SUMMARY OF THE INVENTION
[0003] The product and method of the present invention provides for a new approach to the problem of forming seals for various products, such as containers for waste materials, which is extremely versatile and can be applied to such products for an unlimited number of industrial uses. the process utilizes a thermosetting plastic material primarily composed of a plural component liquid monomer mixture, which can be applied by a reaction injection molded (RIM) process to form an over-molded section around multiple components. The liquid plastic material is introduced into a mold which is positioned around the abutting and adjacent portions of the components at a low temperature and low pressure. A chemically driven exothermic reaction provides the energy necessary to facilitate polymerization of the liquid monomers. The process permits the formation of the over-molded sections in a large range of profile configurations and cross-sections, whether thick or thin. The components to be sealed may be made of plastic materials, composites or metals. A mechanical or physical interface is provided between the components and the over-molding material. The use of these liquid thermosetting plastic materials avoids problems which could exist if conventional injection molding were to be used, wherein it is necessary to melt solid plastic granules at temperatures between 400 and 600 degrees Fahrenheit, and then forcing the melt into mold cavities at pressures that normally run between 12,000 and 16,000 PSi. In such a process, the components to be joined would be seriously degraded. In this process, there is no chemical reaction, and thus a corresponding absence of chemical degradation of the components which would otherwise occur if the process involved molding at high temperatures and/or pressures. In addition, there is no loss of physical integrity, or degradation, such as would occur if high temperatures were involved, which would cause melting and re-solidifying of the components. The process can be utilized for such products as hazardous waste containers, high or low pressure protective containers, pressure vessels, drums, pipe joints, fastening systems, fascia, and the like. The result is a tamper-proof, weather-resistant product.
[0004] It is, therefor, a principal object of the invention to form an over-molded product comprising multiple components secured by a thermosetting plastic material.
[0005] It is another object to provide a mechanical interface between the components and the plastic material.
[0006] It is a further object to apply a liquid plastic material at low temperatures and pressures to maintain the chemical and physical integrity of the components.
[0007] These and other objects and features will be apparent from the embodiments described and shown below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is an exploded view of typical multiple components and their relation to mold members, prior to the molding step.
[0009] [0009]FIG. 2 is a view in partial section, showing the multiple components within the mold members prior to the molding step.
[0010] [0010]FIG. 3 is a view similar to FIG. 2, showing the components secured by the plastic molding material after the molding step.
[0011] [0011]FIG. 4 is a view of the finished product manufactured by the previously shown steps.
[0012] [0012]FIG. 5 is a view similar to FIG. 3 illustrating the formation of a similar product.
[0013] [0013]FIG. 6 is a view of the finished product of FIG. 5.
[0014] [0014]FIG. 7 is a view in section illustrating another product that can be made using the above shown process.
[0015] [0015]FIG. 8 is view illustrating a further product similar to that of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Referring now to the drawings, FIG. 1 is an exploded view of a typical arrangement of a mold comprising upper and lower mold members 11 and 12 typically formed of aluminum plates, having central openings 13 and 14 respectively. A typical container 15 is comprised of identical components 16 and 17 , shown as being generally cylindrical in configuration, although these could be round, oval, or any other desired shape. The container as shown is metal, but could be made of a plastic material, such as polyvinyl chloride or polyethylene, or a fiber-reinforced composite. The members have closed surfaces 18 and 19 and open surfaces 20 and 21 . The open surfaces have outwardly extending flanges 22 and 23 extending completely around the sides of the components. An inner container 25 , which contains the waste material (such as hazardous material) that is to be sealed within the container 15 , is arranged to be placed between the mold members so that it will be enclosed between the sealed components. A gasket 24 , made of a resilient polymeric material, is arranged between the mold members so that it will be utilized during the molding process, as explained below.
[0017] The components 16 and 17 are placed together between the mold members as shown in FIG. 2 with the inner container within the components, and a gasket 24 is located and aligned between peripheral grooves 35 and 36 in the mold members. The gasket is formed in a triangular cross-section with an apex 33 and a flat base 34 as shown. A series of spaced openings 37 and 38 are located in the flanged portions 22 and 23 of the components for purposed described below. As shown in FIG. 3, the mold members are clamped together by any suitable means so that the inner surfaces 26 and 27 of the flanges are abutting. The components are held in place within the openings 13 and 14 of the mold members by placing the flanges within the offset portions 28 and 29 of the mold being configured so that openings 13 and 14 of the mold members extends completely around the flanges . The gasket 24 is compressed from its triangular shape to fit within the grooves 35 and 36 . The over-molding thermosetting plastic material is introduced into the mold openings to lock the flanges together; the material being introduced through an opening 30 in either mold member. In the illustrated arrangement the opening is in the upper surface of the upper mold member, but may be located elsewhere as convenient. The components 16 and 17 are now secured together by the over-molded material 32 . which has been injected into the mold via a hose 31 leading to a supply of the material. The material is now in the form of an outer solid mass of material 39 having a generally U-shaped configuration which envelops the flanges 22 and 23 . To provide further locking of the components, the material flows through the holes 37 and 38 in the mold members. It should be understood that the inner container 25 may be configured in other shapes necessary to retain the waste material being secured. It should be further understood that the outer container 15 need not be used to retain an inner container, but may be used in other ways; for example, the components 16 and 17 may be sent to a consumer who will place the waste material, such as effluent from a sewage system, directly in the lower component, then secure the upper component to the lower one in the manner described above, thus forming a complete container.
[0018] The over-molding material is a thermosetting plastic, defined as a plastic material which undergoes a chemical change and hardens permanently when cured or heated in processing, and cannot be re-melted or re-processed. The thermosetting plastics used here are primarily composed of plural component liquid monomer mixtures. The preferred material is known as poly-dicyclo pentadiene, but other thermosetting materials, such as urethane or polyester may be used. The preferred material has a high impact resistance, and also exhibits stability in the presence of gamma radiation, making it particularly important ;when exposed to nuclear waste which the containers may enclose. If desired, other additives, such as colorants, fire retardants, or the like, may be added. While the novel process is similar to conventional reaction injection molding processes (RIM), it differs in that the material is injected at low temperatures, ranging from to 60 to 90 degrees Fahrenheit; and at low pressures below 40 pounds per square inch. This avoids physical and chemical degradation which would occur if higher temperatures and pressures were utilized as in conventional injection molding processes. In particular, it avoids the melting and re-solidifying of components made of a low melting point plastic under high temperatures. The process provides a strong mechanical interface between the components 16 and 17 and the material 32 . The completed container 15 is shown in FIG. 4. The monomers normally comprise an activator and a catalyst in equal proportions, which are mixed in a conventional mixing device before placing in the mold. FIGS. 5 and 6 depict a process and product similar to the container 15 , except that this product is in the form of a cylindrical drum 51 of the type commonly used in various industries. The drum has a circular cross-section, formed of a body 56 and a lid 57 . The body has a flange 59 extending completely around its upper open end, and a mating flange 58 extending completely around therearound. The lid has a cross-section equal to the cross-section of the body, and the flange of the lid sits against the flange of the body as shown. The mold members 52 and 53 are similar in design to the mold members 11 and 12 of the earlier described embodiment, and have openings 54 and 55 into which the over-molding material may be inserted. Seals 61 and 62 are inserted into the mold members as shown to provide extra sealing between the members. The over-molding plastic material 30 is introduced into the mold members in a manner and under the conditions described with respect to FIG. 3, and provides a molded segment 64 around the flanges to lock the lid and body together. similar to the locking described with respect to FIG. 3. Openings 62 and 63 are provided in a spaced peripheral arrangement in the flanges 58 and 59 so that the material may flow through the openings for extra locking, as with the FIG. 3 arrangement. The drum may be of any configuration useful in various industries. As is the case in the previously described embodiment, this drum may be used to enclose an inner container which holds the waste material, or my be sent to a customer who will place the waste material, such as sewage effluent, directly in the body 56 of the container, and then secure the lid 57 to the body in the manner described.
[0019] [0019]FIG. 7 illustrates another use of the novel process, showing how this process may be used in conjunction with other products in addition to the containers illustrated above. The product shown is a pipe assembly designated by reference number 70 , and consists of identical fluid transmission pipe sections 71 having integral flanged ends 73 and 74 respectively. The flanged ends are placed within the cavities of mold members which are similar to the mold members described above with respect to the earlier forms of the invention, but specifically designed to fit the flanges. Spaced openings 77 and 78 are located peripherally within the flanged ends and aligned with each other, and the surfaces 75 and 76 of the flanges are abutted. Peripherally extending seals 79 and 80 are located in the abutting ends of the flanges for placement of a seal 80 , and the mold halves are clamped together. The thermosetting plastic material 32 is introduced in a manner and under the conditions described above, and flows into the mold openings and around the flanges and through the openings 79 and 80 . The result is an over molded member 81 which extends around the flanges 73 and 74 and the end portions of the pipes to provide a finished assembly 70 . FIG. 8 illustrates how the pipe sections 71 may be joined together to form a long multiple pipe assembly 72 , which may be provided in any length that is practical for shipping. The sections may be joined together as in FIG. 7 by over-molding each of the abutting sections by using a plurality of joints 81 . It is contemplated that although the pipes may be made of various materials, one particularly useful pipe material is di-cyclo pentadiene, the same material used as the over-molding material described herein. This material is highly corrosion resistant, and could conduct corrosive waste material with a minimum of corrosion.
[0020] The products and processes shown and described above are merely exemplary. Other products and processes are considered to be within the scope of the invention.
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An over-molded product, such as a container, and a method of manufacture. The product is primarily used for enclosing hazardous materials and is formed by utilizing a thermosetting plastic material in a reaction injection molding process at low temperature and pressure to envelop adjacent portions of two or more components to form the desired product. This provides a mechanical interface but avoids a chemical reaction which would degrade the components.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is generally related to waste disposal equipment and more specifically relates to a toilet designed to conserve water.
2. Background of the Prior Art
Disposal of human waste is an increasing problem. The modern toilet, unfortunately, requires a large amount of water to operate. This water is required to: (i) remove the waste from the bowl of the toilet and (ii) flush the waste down through the domestic sewer system into sewer mains. Those skilled in the art have long known that a relatively small amount of water will suffice to flush the wastes out of the toilet bowl. Most of the water used by conventional toilets eral types of toilets designed to conserve water. One such system is a recirculating toilet. This device conserves flush water by separating solid waste from waste water, sterilizing or filtering the waste water, then recycling the water to use again as flush media. Examples of such systems may be found in U.S. Pat. Nos. 4,115,876, issued to Cole, Jr., et al. on Sept. 26, 1978; 3,673,614 issued to Claunch on July 4, 1972; 3,974,528 issued to Claunch on Aug. 17, 1976; 1,303,358 issued to Montgomery on May 13, 1919; and 4,063,315 issued to Carolan et al. on Dec. 20, 1977. Unfortunately, recirculating toilets have the disadvantage of being relatively expensive and complicated compared to ordinary flush toilets. Further, they may require the periodic addition of chemicals and other maintenance.
Other toilets designed to conserve flush liquids use a vacuum system to assist movement of waste products out of the toilet and through plumbing. Such toilets are described in U.S. Pat. Nos. 4,063,315 issued to Carolan, et al. on Dec. 20, 1977; 4,120,312 issued to Michael on Oct. 17, 1978; and 3,629,099 issued to Gahmberg on Dec. 21, 1971. One drawback of these systems is that they require a vacuum source, i.e., installation of an additional apparatus for generating a vacuum must be available.
A gravity sewage disposal apparatus conserves water by utilizing waste water from other drains (such as shower or lavatory drains) to wash excreta from a holding area into the sewer main is disclosed in U.S. Pat. No. 3,843,976 issued to Miya on Oct. 29, 1974. This device uses no fresh water or other liquids to rinse waste products from the toilet bowl. Rather, when flushed, Miya uses a foam to move excreta away from the toilet bowl to a trap. A tilting basin fills with water from other drains and tilts at a predetermined level, spilling its contents into the trap and flushing wastes down a sewer line. This system has the disadvantge of needing a special foam to combat odor and move the excreta into a trap.
Some elements of the present invention are old. For example, holding tanks for temporarily storing raw waste are old. Timer operated valves for controlling both the flow of the flush medium into the toilet bowl and the outflow of waste from the toilet to the holding tank are described in U.S. Pat. No. 4,063,315 issued to Carolan, et al. on Dec. 20, 1977. A valve for discharging waste into the sewer pipe operated in part by gravity is disclosed in U.S. Pat. No. 3,629,099 issued to Galmberg on Dec. 21, 1971. However, the Galmberg device requires a vacuum to assist in the operation of the valve.
SUMMARY OF THE INVENTION
The invention comprises a modified toilet bowl assembly in functional fluid connection with a raw waste holding tank, which, in tof waste occurs in two stages: (1) removal of waste from the toilet bowl to the holding tank; and (2) discharge of waste from the holding tank into the sewer.
When the toilet is flushed, a small amount of pressurized water sprays into the toilet bowl. An instant later, a valve in the base of the toilet bowl opens, allowing the excreta to wash into the holding tank. The base valve then closes and the toilet bowl partially fills with water for the next flush. Next, effluent from other drains, flush water, and excreta accumulate in the holding tank. When the accumulation is sufficient, a biased valve in the base of the holding tank opens, emptying the waste products into the sewer or outlet pipe.
The purpose of the present invention is to conserve fresh water by releasing only enough water to complete the first stage of flushing, i.e. the small amount of fresh water used to move waste out of the toilet bowl to the holding tank. The second phase of disposal, moving the waste from the holding tank to the sewer pipe, is accomplished in part by utilizing the accumulated waste water from other drains and in part by using the weight of the excreta itself.
Another purpose of the present invention is to save water without resorting to the use of special foaming agents or special flush fluids. Ordinary tap water is sufficient to operate the toilet. Moreover, the invention does not require a vacuum source or means to filter and recycle the flush water.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of the preferred embodiment of the present invention.
FIG. 2 is a partially cutaway top view of the toilet bowl showing the toilet bowl spray device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a toilet assembly and holding tank constructed according to the preferred embodiment of the present invention. In FIG. 1 toilet 4 has a bowl 21 that is in fluid connection through control valve 10 and pipe segment 11 to holding tank 16. Tank 16 is also in fluid connection with waste stream input lines 14 and 12. Lines 14 and 12 are equipped with check valves 15 and 13, respectively. The lower portion of holding tank 16 is in fluid communication with waste drain 18. Biased valve 17 equipped with biasing means 20A is located at the bottom of holding tank 16 and equipped to close off holding tank 16 from fluid communication with waste conduit 18. Waste conduit 18 is connected to sewer mains, not shown.
Toilet 4 may be made of porcelain or any other suitable material. It should be noted that toilet 4 does not have a p-trap, which is found in conventional toilets, but merely a straight-through fluid passage 11 from the bottom of toilet bowl 21 to holding tank 16. Valve 10, which is a remotely operated flapper valve, performs the function of a p-trap.
Holding tank 16 may be made of any material that meets National Plumbing Codes and is otherwise usable to contain sewage. The tank should be hermetic and all entry points into the tank, i.e., connecting means 11, waste input lines 14 and 12, and output sewer conduit 18, should be hermetically sealed to the tank by screw threads, soldering, or other well known expedients.
Control system 22 comprises actuator means 1, which may be a electric, pneumatic, or fluidic control. The preferred embodiment of the present invention uses hydraulic controls, valves and timers. Control means 1 is connected via control line 2 to first timer means 3 and second timer means 8. These timer means may be any convenient device such as a electronic timer or hydraulic accumulator for receiving the control impulse generated by control means 1 and then outputting a delayed control signal at a controllably later time. Input water line 5 is connected to one side of control valve 7. The output side of control valve 7 is connected through input fitting 6 to the spray nozzles inside the toilet bowl 21. These nozzles are described in greater detail in that portion of the specification discussing FIG. 2, below.
The output of timer 3 is connected functionally to valve 7. The output of timer 8 is connected functionally to valve controller 9 associated with flapper valve 10.
Functionally, actuating control means 1 sends a signal via hydraulic line 2 to timer means 3 and timer means 8. It is anticipated that this action would normally be performed after a user of the present invention deposits excreta in toilet 4.
After a relatively short period of time, timer 3 opens hydraulic control valve 7 for a short period of time. Opening control valve 7 allows water to flow into the toilet bowl through the annular spray system described in more detail in the portion of the discussion dealing with FIG. 2, below. This spray of liquid washes the excreta from the inner walls of toilet bowl 4 and causes it to come to rest on the upper side of flapper valve 10, which is closed. A small amount of water will already be in the bowl, as in a conventional toilet. Timer 3 then turns off the flow of water. The interval of time valve 7 is open is selected to use the minimum amount of water adequate to wash the excreta down to the upper surface of flapper valve 10.
Some period of time after timer 3 has opened valve 7, timer 8, which may be a hydraulic accumulator, energizes hydraulicly actuated valve operator 9 to open flapper valve 10. Alternatively, valve 10 may be opened by the accumulated weight of the water in the toilet bowl. The accumulated excreta is then carried through connector means 11 into holding tank 16. It will be appreciated that timer 8 may be set to open flapper valve 10 either while valve 7 is open or closed, depending on other system characteristics, such as the exact shape of the interior of toilet bowl 4 and/or the desirability of continuing the flow of water for a short period after flapper valve 10 has opened to remove excreta from the upper surface of said flapper valve. After the excreta and flushing water have passed into tank 16, flapper valve 10 closes. After flapper valve 10 closes, valve 7 opens and a small amount of standing water flows into the toilet bowl for the next flush.
Waste water from other utilities, such as bathing water, washing water from washing machines and sinks, and any other source of dirty water, flows into holding tank 16 through waste water input lines 14 and 12. Check valves 15 and 13 are located at the terminal end of waste water lines 14 and 12, respectively. Valves 15 and 13 act as check valves that allow water to enter holding tank 16, but hermetically seal to prevent the escape of sewer gases from the holding tank.
After a sufficient quantity of waste water from all sources, including waste water lines 12 and 14 and sewer line 11 has accumulated in tank 16, the biasing means 20A, which may be a spring, hydraulic or pneumatic actuator, or electric sensing system, opens bi-stable flapper valve 17. Opening bi-stable flapper valve 17 puts holding tank 16 in direct fluid communication with sewer 18. When valve 17 opens the accumulated waste water and sewage in holding tank 16 flows through sewer line 18 to a remote sewer system, not shown, which may be a septic tank or municipal sewer system.
Valve 17 is constructed so it opens when a predetermined amount of waste material has filled tank 16 and only returns to a closed position after substantially all this material has flowed out of the tank into sewer line 18.
FIG. 2 shows a partially cutaway top view of toilet 4. In this figure, like numbers indicate like structures.
Input water line 5 is connected to the input side of water control, remotely hydraulically, actuated valve 7. The output side of remotely actuated valve 7 is connected to input fitting 6. Input fitting 6 is in fluid communication with an annular spray ring 19. Annular spray ring 19 is provided with a plurality of spray jets 20. Structure 19 may be a hollow tube running around the underside of the periphery of toilet 4. Jets 20 are directed downward onto bowl 21 of toilet 4 so they will wash excreta deposited in the bowl onto the top of flapper valve 10.
When valve 7 is opened by a command from timer 3, water flows from delivery pipe 5 through fitting 6 and spray structure 19 out of holes 20 and wash excreta from the interior of bowl 21 onto the standing water over flapper valve 10.
It should be understood that the present invention uses only a minimal amount of water to wash excreta into holding tank 16. The majority of the water used to move the sewage through sewer pipe 18 in FIG. 1 to the main sewer system or septic tank, not shown, is provided by the other household waste water entering holding tank 16 through lines 14 and 12.
It should be further understood that the specific embodiment described in this specification is not intended to be limiting, but only shows the best embodiment known to the inventor. Many obvious adaptations of the present invention could be made by those skilled in the art without departing from the present invention. The present invention should therefore be limited only by the following claims and their equivalents.
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A waste disposal system including a toilet receptacle in controlled fluid communication with a holding tank. Just enough fluid is released into the toilet to flush wastes into the holding tank. The holding tank accumulates wastes, flush fluid and waste fluid from other sources until sufficient wastes accumulate to actuate a valve between the holding tank and a sewer.
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RELATED APPLICATIONS
[0001] This application claims priority from Mexican application Serial No. MX/a/2010/008116 filed Jul. 23, 2010, which is incorporated herein by reference in its entirety.
FIELD OF INVENTION
[0002] The present invention relates to a drying method and profile in a clothes dryer. Specifically, the present invention relates to a method and profile with a drying cycle which results in an energy and/or gas savings of the dryer in comparison to that of normal cycles, by means of heat diminishing which does not help in evaporating water from the textiles.
BACKGROUND
[0003] During the last years, and in the area of household appliances, the international community has increasingly become more conscious of environmental protection. Specifically, it is required that household appliances use less water if water is used, less gas if gas is used, and less energy, which translates into less electricity. Therefore, there exists a need for household appliances to be more energy efficient. In 2008, the European Community applied to the Escobilan for a study on the impact of household appliances on the environment, including clothes dryers. In the same year, the DOE in the United States began to develop a regulatory standard for energy efficiency of clothes dryers, which shall become effective as of Jan. 1, 2015. Thus, it is imminent that household appliances, especially dryers, reduce their energy and gas use, to comply with the future standards and to be more energy efficient.
[0004] US publication number 2006086000 makes known a dryer and a method to control the same, where an alert is generated to inform the operator that the dryer is operating abnormally and even if there exists a malfunction in an electric interrupter provided to prevent overheating of a heater in the dryer when the dryer is operating abnormally, the malfunction is prevented from causing additional risk. The heater includes a dryer, an exit duct, an electric interrupter and a control. The heater is provided in order to heat the air. The hot air flows through the exit duct. The interrupter shuts off to deactivate the heater when the heater temperature is outside of a predetermined temperature range. If the interrupter shuts off a certain number of predetermined times or more during the operation of the heater, the control determines that the air flow is abnormal and deactivates the heater.
[0005] Japanese publication number 10043499 makes known that when a cycle is selected, until an exit temperature, which is detected by an exit temperature detector which is placed near the drum's air exit, reaches a high limit temperature, two out of the three heaters are turned on and the temperature is slowly raised during a period. When the exit temperature reaches the high temperature limit, only one heater is turned on and the heating is suppressed. Thus, the exit temperature is slowly lowered for a period of time. When the exit temperature is lowered by 4° C. relative to the high temperature limit, both heaters are turned on again and the temperature rises again for a period of time. By turning on part of the heaters even during the time of lowering the temperature in such a way, the range of fluctuation of the temperature is decreased and damage to the textiles is reduced.
[0006] Japanese publication number 10043498 makes known that when a substratum temperature is lesser than the reference temperature, until the exit temperature, detected by the exit temperature detector placed close to the drum's air exit, reaches the high limit temperature TH, the three heating pieces are turned on and the temperature is raised for a period of time. When the exit temperature reaches temperature TH, two heaters are on and one is shut off. Thus the exit temperature is gently lowered for a period of time. When the exit temperature is lowered by 1° C. relative to TH, the three heaters are turned on again for a period of time. When the temperature increase continues despite a heater being turned off, all the heaters are turned off when the temperature reaches 4° C. higher than the TH for a period of time. By means of such control, the temperature fluctuation range is decreased and the damage to textiles is reduced.
[0007] Japanese publication number 07289798 makes known that during the heating process a microcomputer electrifies the heaters to heat the air transmitted, giving the motor the energy to rotate the drum which rotates a fan which stirs air, and the drying operation is completed, when the temperature difference in the exit temperature detector and the surrounding temperature detector reach the predetermined value. In this instance, when the surrounding temperature is lesser than the predetermined temperature, while the exit temperature is higher than the predetermined temperature only one of the heaters is electrified. When the exit temperature is lower than the prescribed temperature, both heaters must be electrified. Additionally, when the surrounding temperature is lower than the predetermined temperature, while the surrounding temperature is higher than the upper limit, the electricity must be suppressed to both heaters.
[0008] U.S. Pat. No. 6,199,300 makes known a method and apparatus to control the heat entrance to a dryer, where the initial heat entrance to the load of clothes is placed on the highest power until a first predetermined temperature or time condition take place. Afterwards, the heat is reduced to reduce energy consumption, while moisture is effectively removed from the clothes load. When the moisture content of the clothes load falls below a predetermined quantity, the complete heat entrance is applied to remove the remaining moisture from the clothes load.
[0009] U.S. Pat. No. 5,291,667 makes known a control system for a dryer with a microprocessor which monitors the entrance air temperature and the exiting air temperature. If the entrance temperature exceeds a high value limit a predetermined number of times, an air blocking indicator is activated. The degrees of dryness are measured by the number of times that the entrance temperature has fallen below the threshold value while the heater is turned off because the exit temperature has exceeded the desired value. A drying time is calculated and displayed for the user based on a linear function and exit temperatures measured at the beginning of the cycle and again a short time afterwards.
[0010] U.S. Pat. No. 7,444,762 makes known a clothes dryer which has a system for regulating the entering air temperature. The system includes a first detector placed in the dryer's entrance and includes a timer and thermostat, a heat source found in a heating box, adjacent to the first detector and a second detector found at the dryer's exit. The thermostat measures the dryer's entering air temperature and cooperates with the control to prevent the thermostat from reaching its limit temperature and turns off the heat source. Thus, the damage due to excessive air temperatures in the dryer is avoided.
[0011] Japanese publication number 03109100 makes known a first temperature detector found in an air discharge part. The air in a drum is suctioned through the filter flow through an exit in the drum and enters the front part of the fan. Afterwards, the air flows through the duct towards a heater, where it is heated by all the heating units of the heater. Thus, the heated air is discharged towards the drum for circulation. On the other hand, the air outside of the dryer is suctioned towards the back part of the fan through an entry point formed in the dryer's back plate and discharged through an air discharger also formed in the back plate. When the first temperature detector, which is placed close to the air discharger, sends a temperature detection signal indicating a higher value than that which was predetermined, initially, the energy supply to the heating unit ceases to decrease the quantity of heat to be generated in one step.
[0012] Other documents in the area are US publication number 2003/097764, EP number 0 965 806, JP 04200500, JP 1064700, U.S. Pat. No. 4,485,566 and U.S. Pat. No. 4,267,643.
[0013] None of the documents in previous art make known a method to create a household appliance energy efficient, specifically a dryer. Specifically, previous art does not make known a cycle which offers a savings in a dryer's energy consumption, in comparison to that of traditional cycles.
[0014] Thus, a need exists for an efficient energy or gas control for drying, so that drying may be benefitted from the discovery of an efficient moisture reduction in constant cycles with less drying energy or maximum inner temperature.
BRIEF DESCRIPTION OF THE INVENTION
[0015] The present invention relates to a method, specifically a cycle to reduce the energy and/or gas consumed by a household appliance, specifically a dryer. The cycle which takes place in the present invention reduces the heat quantity which does not help in evaporating water from the textiles. The method can be divided into two distinct sub-methods or sub-cycles which take place in parallel manner.
[0016] The present invention also relates to a textile dryer which can include a cabinet or main casing, a front panel, a back panel, a pair of lateral panels spaced between them by the front and back panels and an upper cover. Within the casing, a drum or container is found mounted for rotation around a substantially horizontal axis. A motor rotates the drum in the horizontal axis by means of, for example, a pulley and a band. The drum generally has a cylindrical shape, is has a cylindrical perforated outer wall and is enclosed in its front by a wall which defines an opening in the drum. The articles of clothing and other textiles are introduced into the drum through the opening. A plurality of dumping ribs is found within the drum to raise the articles and later allow them to be dumped again to the drum's lower part while the drum rotates. The drum includes a back wall which is supported in a rotating manner within the main casing by an adequate fixed bearing. The back wall includes a plurality of holes which receive hot air which has been treated by a heating means, such as a combustion chamber and a back duct. The combustion chamber receives air at room temperature via an entrance. Dryers can be gas and/or electric, where the electric ones have heating resistance elements found in the heating chamber positioned next to the outer perforated cylindrical wall which would replace the combustion chamber and the back duct of a gas dryer. The heated air is suctioned from the drum by a fan, same which is driven by the motor. The air passes through a filter screen which traps any type of felt particles. While the air passes through the filter screen a seal duct tramp enters and it is passed outwards of the clothes dryer through an exit duct. After the articles have been dried, they are removed from the drum via the opening.
[0017] In one embodiment, a moisture detector is used to predict the percentage of moisture content or dryness level of the articles in the container. The moisture detector typically comprises a pair of spaced bars or electrodes and also comprises circuits to provide a representation of the voltage signal of the moisture content of the articles to an electric control based on the electric resistance or ohms of the articles. The moisture detector is located on the inner lower front wall of the drum and alternatively it has been mounted on the back part of drum's wall when this wall is in resting phase. The signal from the detector can be chosen to provide a continual representation of the moisture content of the articles within an adequate range to be processed by the electric control.
[0018] The electric control is also coupled with an entering temperature detector. The entering temperature detector is mounted to the dryer on the air flow entering the drum. The entering temperature detector detects the temperature which enters the drum and sends a corresponding temperature signal to the electric control. The electric control is also coupled to the exiting temperature detector which detects the air temperature exiting the drum and sends a corresponding temperature signal to the electric control. The electric control interprets these signals to generate an air flow parameter based on the entering temperature increase and/or a size of load parameter based on the exiting temperature increase. These parameters, among others, are used to select an objective moisture signal, which in turn is used by the controller in conjunction with the filtered and/or reduced noise voltage signal of the moisture detector to control the dryer's operation.
[0019] The electric control comprises an analog to digital converter (A/D) to receive the signal representations sent by the moisture detector and the temperature detectors. The signal representation of the A/D converter and a counter/timer is sent to a central processing unit (CPU) for greater processing of the signal which shall be described below in greater detail. The CPU also receives the entering and exiting temperature signals respectively of the temperature detectors via two distinct analog to digital converters (A/D). The CPU receives energy from a source of energy, comprises one or more processing modules stored in an adequate memory device, such as a reading memory uniquely ROM, to predict a moisture percentage content or degree of dryness of the textile articles in the container as a function of the electric resistance of the articles. It should be noted, that the memory device is not necessarily limited to being ROM memory, any type of memory device can be used, for example, an erasable and programmable reading memory device (EPROM) which stores instructions and facts can also work effectively. Once it has been determined that the textile articles have reached a desired dryness level, then the CPU sends respective signals to an entry/exit module which in turn sends respective signals to de-energize the motor and/or the heating means.
[0020] The CPU and the ROM can be configured to comprise a dryer processor. The processor estimates the detention time and controls the dryer's detention based on a moisture signal received from the moisture detector. The processor filters the moisture signal and compares this to the objective moisture signal to control the dryer's operation. The processor selects a target voltage signal—or objective moisture—from a table of objective moisture signals. Alternative methods to this selection can be chosen from diffused logic.
[0021] Additionally, the electric control receives a signal from a pulse generator. This pulse generator, same which can be by electric, digital, mechanic or electro mechanic means, where in a preferred embodiment a micro control is specifically preferred: in an alternative embodiment of said pulse generator, an electric motor (AC, DC, or stepped, among others) can be coupled to a motor reducer or coupled directly to the axis of at least one lever which activates at least on pair of contacts (platinum): said pulse generator is capable of sending a signal of ignition or turn off to the CPU. The CPU processor based on the temperature signal received by the entrance and/or exit temperature detectors, as well as based on the signal received from the counter and/or timer is capable of sending a signal to the driver of each one of the actuators of the heating means in order to energize or de-energize each one of said actuators of said means of heating. The drivers can be any type of electric interrupters, such as can be a thyristor, IGBT, TRIAC (Triad for Alternative Current), a relay or any other type of electric interrupters known in the art, which control, in part, the energizing or ignition of the drivers for the heating means. Conversely, it is understood, that the concept of “actuators” encompasses any type of device or element which generates heat by any means, as can be: a gas burner coupled to a solenoid valve or similar, an electric resistance, a means of infrared, laser etc., as well as any combinations of the same; and that the heating means comprise at least one actuator.
[0022] In a first embodiment, the heating means of a dryer are composed of two actuators with at least one driver per actuator, and a drying method, during the dryer's first cycle comprised of: determining if within the control panel's options, the operator selected a drying cycle of the present invention, if this is so, they are modified, by means of the electric control, the temperature thresholds of the heating means to low heat. Having modified the thresholds, the drying cycle begins sending a pulse to the drivers by means of the electric control, according to a pulse pattern received from the pulse generator, where said pulse pattern comprises of: energizing all the actuators by at least one heating means for a first determined time interval which varies between approximately 10 seconds to 3 minutes, generating the maximum possible heat. Once this first determined time interval has lapsed, de-energizing the first actuator of at least one heating means for a second determined time interval which varies between 10 seconds to 4 minutes; once the second determined time interval has lapsed, de-energizing the second actuator of at least one heating means for a third determined time interval which varies between approximately 30 seconds to 4 minutes. In parallel manner, and during the previous steps of the pulse pattern, entrance and/or exit temperature to the drum is constantly monitored, such that the temperature detected by a first temperature detector is compared to a target temperature: in case where said detected temperature is greater than the target temperature, the CPU interrupts the signal to the drivers, and in case the detected temperature is lower than the target temperature, the CPU does not interrupt the signal to the drivers allowing said drivers to energize and activate the actuators with the described pulse pattern, and in this way, the previously described steps are repeated, from the initial drying, at least one time or until the drying is concluded. Once drying has concluded, a cooling time is allowed and the cycle ends. In an alternative embodiment to the presently described, during the cycle described above in view of different function conditions such as: the type, quantity, quality of the textiles, the restrictions in the air exit means etc., and the temperature measured by the drum's entry and/or exit temperature detectors is higher than that of the target values', the CPU interrupts the signal or previously described pulse train to a first actuator of the heating means, by means of the corresponding driver, to turn it off and lower the heat within the dryer's drum. If after a determined time interval which varies between 500 milliseconds and one minute, the temperature is still greater than the value of the lower threshold previously established, the CPU interrupts the signal or pulse train previously described to a second actuator of the heating means via its driver to also turn it off and lower with greater velocity the heat within the dryer's drum, and in its case, this is successively repeated until all heating means are turned off. The dryer still keeps functioning without generating heat until the temperature within the drum measured by means of the temperature detector, is lower than the target value, when the temperature is lower than the target value, the CPU allows the signal or pulse train of the pulse generator to pass again towards the drivers of the heating means, energizing these according to the turn or position on the time pulse profile which the pulse generator is emitting in that instant; so that based on the referred signal, the CPU determines which drivers of the actuators of the heating means are energized; so that the previous steps are repeated, from the beginning of the drying, at least one time or until drying is concluded. Once drying is concluded, a cooling time is allowed and the cycle is complete.
[0023] In a second embodiment, a dryer's heating means are composed of a number of actuators “n” with at least one driver per actuator, which in an illustrative and not limitative manner can comprise a pair of burners each coupled to a solenoid valve or burner coupled to a valve which can adopt a multitude of positions which requires various solenoids to be controlled, an arrangement with a multitude of resistances which can be controlled separately, an infrared bank where each heater or “bulb” is independently controlled, or any other similar arrangement: in this way the drying method, during a dryer's first cycle comprises: determining if within the options of the control panel, the operator selected the drying cycle of the present invention, if this is so, by means of the electric control, the temperature thresholds of the heating means are modified to a lower heating. Having modified the thresholds, the first drying cycle is started sending a pulse to the drivers by means of the electric control according to a pulse pattern received from the pulse generator, where said pulse pattern comprises of: energizing all the actuators “n” of at least one type of heating for a determined interval of time which varies between approximately 10 seconds to 3 minutes, generating the maximum possible heat. Once said determined time interval has lapsed, de-energize a first actuator of at least one heating means, so that only a number of actuators “n-1” remains energized of said at least one heating means for a determined time interval which varies between 10 seconds to 4 minutes: said determined time interval having lapsed, repeat the previous step immediately the number of necessary times in order to consecutively de-energize the actuators one by one of at least one means of heating until the number of energized actuators is “n=0”. Once the last actuator of at least one heating means is de-energized a determined time interval is allowed to lapse which varies between approximately 30 seconds to 4 minutes. In parallel manner, and during the previous steps of the pulse pattern, entrance and/or exit temperature to the drum is constantly monitored, such that the temperature detected by a first temperature detector is compared to a target temperature: in case that said detected temperature is greater than the target temperature, the CPU interrupts the signal to the drivers, and in case the detected temperature is lower than the target temperature, the CPU does not interrupt the signal to the drivers, allowing said drivers to energize and activate the actuators with the described pulse pattern, and in this way, the previously described steps are repeated, from the initial drying, at least one time or until the drying is concluded. Once drying has concluded, a cooling time is allowed and the cycle ends. In an alternative embodiment to the presently described, if during the cycle described above in view of different function conditions such as: the type, quantity, quality of the textiles, the restrictions in the air exit means etc., and the temperature measured by the drum's entry and/or exit temperature detectors is higher than that of the target values', the CPU interrupts the signal to a first actuator of the heating means (n-1), by means of the corresponding driver, to turn it off and lower the heat within the dryer's drum; if after a determined time interval which varies between 500 milliseconds and one minute, the temperature is still greater than the value of the lower threshold previously established, the CPU interrupts the signal to a second actuator of the heating means (n-2) to also turn it off and lower with greater velocity the heat within the dryer's drum, and in its case (as long as the temperature measured by the entry and/or exit temperature detector is till greater than the target temperature), this step is successively repeated as many times as necessary until the point that the CPU interrupts the signal consecutively one by one to all the actuators of the heating means (n=0). The dryer keeps functioning without generating heat until the temperature within the drum measured by means of the temperature detector, is lower than the lower threshold value previously established. When the temperature is lower than said lower threshold value previously established, the CPU allows the pulse train of the pulse generator to pass again towards the driver and the actuators of the heating means, energizing these according to the turn or position on the time pulse profile which the pulse generator is emitting in that instant; so that based on the referred signal, the electric control determines which drivers of the actuators of the heating means are energized; so that the previous steps are repeated, from the beginning of the drying, at least one time or until drying is concluded. Once drying is concluded, a cooling time is allowed and the cycle is complete.
[0024] In a third embodiment, a dryer's heating means are composed of at least one actuator with at least one driver per at least one actuator, and the drying method, during the first cycle of the dryer comprises: determining if within the options of the control panel, the operator selected the drying cycle of the present invention, if this is so, by means of the electric control, the temperature thresholds of the heating means are modified to a lower heating. Having modified the thresholds, the first drying cycle is started sending a pulse to the drivers by means of the electric control according to a pulse pattern received from the pulse generator, where said pulse pattern comprises of: energizing at least one actuator of at least one type of heating to its maximum power for a determined interval of time which varies between approximately 50 to 80 seconds, generating the maximum possible heat. Once said determined time interval has lapsed, de-energize at least one actuator of at least one heating means, for a determined time interval which varies between 30 seconds to 4 minutes. In parallel manner, and during the previous steps of the pulse pattern, entrance and/or exit temperature to the drum is constantly monitored, such that the temperature detected by a first temperature detector is compared to a target temperature: in case that said detected entry and/or exit temperature of the drum is greater than the target temperature, the CPU interrupts the signal to at least one driver, and in case the detected temperature is lower than the referred to target temperature, the CPU does not interrupt the signal to at least one driver, allowing said at least one driver to energize and activate at least one actuator with the described pulse pattern, and in this way, the previously described steps are repeated, from the initial drying, at least one time or until the drying is concluded. Once drying has concluded, a cooling time is allowed and the cycle ends.
[0025] Thus, the objective of the present invention is to provide a versatile drying cycle for a dryer, which allows energy savings during the drying cycle, and depending on the conditions of and within the dryer, allow for variation of the drying cycle.
[0026] Another objective of the present invention is to provide a dryer which can carry out a versatile drying cycle, which saves energy during the drying cycle, allowing for variations, depending on the conditions of and within the dryer, to the drying cycle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 shows a view in perspective of the textile dryer.
[0028] FIG. 2 shows a block diagram of a control system which can be adopted by the present invention.
[0029] FIG. 3 shows a flow diagram of the drying cycle according to the preferred first embodiment of the present invention.
[0030] FIG. 3 a is a flow diagram of the drying cycle according to an alternative first embodiment of the invention.
[0031] FIG. 4 shows a flow diagram of the drying cycle according to the preferred second embodiment of the invention.
[0032] FIG. 4 a is a flow diagram of the drying cycle according to an alternative embodiment of the invention.
[0033] FIG. 5 is a flow diagram of the drying cycle according to a third preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0034] The present invention relates to a method, specifically a cycle to lower the energy and/or gas consumed by a household appliance, specifically clothes dryer. The method to take place within the present invention reduces the amount of heat, translated into energy consumed, which does not help in the evaporating of water from the textiles. The method can be divided into two distinct sub-methods or sub-cycles which take place in parallel form.
Definitions
[0035] The use of the term “approximately” provides an additional range of determined time. The term is defined in the following way. The additional range of time provided by the term is that of approximately ±10%. As an example, but not in limitative manner, if it states “approximately between 30 to 40 seconds”, the exact range is between 27 and 44 seconds, or can be between 33 and 44 seconds, or can be between 27 and 36 seconds or between 33 and 36 seconds. Any of the possibilities previously described is covered by the term “approximately”.
[0036] The term “Restriction” refers to the possible restrictions found at the exit of the moist air which emanate from the inner drum towards the exterior. Among the possible restrictions is the diameter size of the exit duct, the length of the exit duct, accessories to the exit duct (elbows, reductions, valves, flow meters, inter alia), obstructions etc.
[0037] The term “Crude Voltage” refers to voltage without any type of signal conditioning or digital signal processing, but the simple voltage acquisition which is being measured.
[0038] The term “Filtered Voltage” refers to a voltage with signal conditioning and/or digital signal processing.
[0039] The term “temperature or target value” refers to a temperature measured by the temperature detectors such as thermocouples or any other temperature measuring device, which can be placed in the air flow entrance or exit or from the drum sending a signal to the CPU: the mentioned temperature range depends to a great extent on the design and construction of the clothes dryer; so that its range in illustrative but not limitative form varies between 38° C. and 150° C., preferably between 5° C. and 150° C. above the temperature threshold.
[0040] The term “temperature thresholds” refers to the temperature range or band for the dryer's proper operation, measured by the temperature detectors such as the thermocouples or any other device used to measure temperature, which can be placed in the air flow entrance or exit or from the drum, sending a signal to the CPU: the mentioned temperature range depends to a great extent on the design and construction of the clothes dryer; so that its range in illustrative but not limitative form varies between 37.77° C. and 65.55° C. (100° F. to 150° F.).
[0041] FIG. 1 shows a view in perspective of a clothes dryer 10 which can benefit from the present invention. The dryer can include a cabinet or main casing 12 , a front panel 14 , a back panel 16 , a pair of side panels 18 , 20 spaced between them by the front and back panels and an upper cover 24 . Within the main casing 12 is a drum or container 26 mounted for rotation around a substantially horizontal axis. A motor 44 rotates the drum on the horizontal axis by means of, for example, a pulley 43 and a band 45 . The drum generally has a cylindrical shape; it has an outer perforated cylindrical wall 28 and is enclosed on its front by a wall 30 which defines an opening 32 in the drum 26 . Textiles articles, such as clothes, are introduced into the drum 26 through the opening 32 . A plurality of dumping ribs (not shown) is found within the drum to raise the articles and later allow them to be dumped again to the drum's lower part while the drum rotates. The drum 26 includes a back wall 34 which is supported in a rotating manner within the main casing 12 by an adequately fixed bearing. The back wall 34 includes a plurality of holes 36 which receive hot air which has been treated by a heating means, such as a combustion chamber 38 and a back duct 40 . The combustion chamber 38 receives air at room temperature via an entrance 42 . Even though the sample dryer 10 shown in FIG. 1 is a gas one, the option of an electric dryer should also be considered, which has heating resistance elements located in the heating chamber placed next to the outer perforated cylindrical wall 28 which would replace the combustion chamber 38 and the back duct 40 of a gas dryer. The heated air is suctioned from the drum 26 by a fan 48 , same which is driven by the motor 44 . The air passes through a filter screen 46 which traps any type of felt particles. While the air passes through the filter screen 46 , a seal duct tramp 47 enters and it is passed to the outside of the clothes dryer through an exit duct 50 . After the articles have been dried, they are removed from the drum 26 via the opening 32 .
[0042] In an exemplary embodiment of this invention, a moisture detector 52 is used to predict the percentage of moisture content or dryness level of the articles in the container. The moisture detector 52 typically comprises a pair of spaced bars or electrodes and also comprises circuits to provide a representation of the voltage signal of the moisture content of the articles to an electric control 58 based on the electric resistance or ohms of the articles. The moisture detector 52 is located on the inner front wall of the filter screen 46 which is exposed to the drum's 26 mouth and alternatively they have been mounted on the back part of drum's wall when this wall is in resting phase. In some instances, the moisture detector has been used in a baffle contained in the dryer's drum. As an example, and not as a limitation, the signal from the detector can be chosen to provide a continual representation of the moisture content of the articles within an adequate range to be processed by the electric control 58 . It should be appreciated that the indicating signal of the moisture content does not need to be a voltage signal, being that, for example, through the use of a voltage which is controlled by an oscillator, the signal of moisture indicator could have been chosen as a frequency signal which varies proportionally with the moisture content of the articles in view of a signal whose voltage level varies proportionally with the moisture content of the articles.
[0043] While the textiles are dumped within the dryer's drum 26 , they contact the spaced electrodes of the stationary moisture detector 52 randomly. Thus the textiles are intermittently in contact with the detector's electrodes. The length of time of contact between the textiles and the detector's electrodes depends on various factors, such as the rotational velocity of the drum, the type of textile, the quantity or volume of clothes in the drum and the air flow through the drum. When the wet textiles are in the dryer's drum and in contact with the detector's electrodes, the resistance through the detector is low. When the textiles are dry and contact the detector's electrodes, the resistance through the detector is high and indicative of a dry load. However, situations can exist which can result in erroneous indications of the actual dryness level of the articles. For example, in a situation when the wet textiles are not in contact with the detectors, like for example in the case of a small load, the resistance through the detector is very high (open circuit), which would be falsely indicative of a dry load. Additionally if a conductive portion of dry textiles, like for example a button or a metal zipper contacts the detector's electrodes, the resistance of the detector would be low, which would be falsely indicative of a wet load. Thus, when the textiles are wet there can be times when the detector can erroneously detect a dry condition (high resistance) and, when the textiles are dry, there can be times when the detector erroneously detects a wet condition (low resistance).
[0044] Such as is shown in FIG. 2 , the electric control 58 is also coupled with an entering temperature detector 56 , such as, for example, a thermostat. The entering temperature detector 56 is mounted to the dryer 10 on the air flow entering the drum 26 . The entering temperature detector 56 detects the temperature which enters the drum 26 and sends a corresponding temperature signal 58 to the electric control. The electric control is also coupled to the exiting temperature detector 54 which detects the air temperature exiting the drum 26 and sends a corresponding temperature signal to the electric control 58 . The electric control is coupled to the exit temperature detector 54 which detects the exiting air temperature of the drum 26 and sends a corresponding temperature signal to the electric control 58 . The electric control 58 interprets these signals to generate an air flow parameter based on the entering temperature increase and/or a size of load parameter based on the exiting temperature increase. These parameters are used to select an objective moisture signal, which in turn is used by the electric controller 58 in conjunction with the filtered and/or reduced noise voltage signal of the moisture conductor 52 to control the dryer's 10 operation.
[0045] The electric control 58 comprises an analog to digital converter (A/D) 60 to receive the signal representations sent by the moisture detector 52 and the temperature detectors 56 , 54 . The signal representation of the A/D converter 60 and a counter/timer 78 is sent to a central processing unit (CPU) 66 for greater processing of the signal which shall be described below in greater detail. The CPU 66 also receives the entering and exiting temperature signals respectively of the temperature detectors 56 and 54 respectively, via two distinct analog to digital converters (A/D) 62 and 64 . The CPU 66 receives energy from a source of energy 68 , comprises one or more processing modules stored in an adequate memory device, such as a reading only memory ROM 70 , to predict a moisture percentage content or degree of dryness of the textile articles in the container as a function of the electric resistance of the articles, as well as to process elapsed time and add an additional time. It is appreciated that the memory device is not necessarily limited to ROM memory; any type of memory device can be used, such as for example, an erasable programmable reading memory (EPROM) which stores instructions and data would also work effectively. Once it has been determined that the textile articles have reached a desired dryness level, then the CPU sends respective signals to an entry/exit module 72 which in turn sends respective signals to de-energize the motor and/or the actuators of the heating means. While the drying cycle shuts down, the control can activate a whistle via an enabling/disabling whistle circuit to indicate the end of the cycle to the operator. An electronic inter phase and display panel 82 allow the user to program the dryer's operation and additionally allows for monitoring the respective cycle's progress of a dryer's operation.
[0046] The CPU 66 and the ROM 70 can comprise a dryer processor. The processor estimates the detention time and controls the dryer's 10 detentions based on a moisture signal received from the moisture detector 52 . The processor filters the moisture signal and compares this to the objective moisture signal to control the dryer's operation 10 . There exist many common methods and systems to filter the moisture signal. For more detailed information on the filtering of this signal, one can refer to Canadian Patent Application number 2,345,631 published on Nov. 2, 2001. According with the present invention, the processor can select a signal for target moisture based on a table of target moisture. Alternative methods to this selection can be chosen with diffused logic.
[0047] Additionally, the electric control receives a signal from a pulse generator 74 . This pulse generator, same which can be by electric, digital, mechanic or electro mechanic means, where in a preferred embodiment a micro control is specifically preferred: in an alternative embodiment of said pulse generator, an electric motor (AC,DC, or stepped, among others) can be coupled to a motor reducer or coupled directly to the axis of at least one lever which activates at least on pair of contacts (platinum): said pulse generator 74 is capable of sending a signal of ignition or turn off (pulse train) to the CPU 70 . The CPU processor 70 based on the temperature signal received by the entrance and/or exit temperature detectors 56 , 54 , as well as based on the signal received from the counter and/or timer 78 is capable of sending a signal to the driver 76 of each one of the actuators of the heating means 8 , 9 in order to energize or de-energize each one of said actuators 8 , 9 of said means of heating. The drivers can be any type of electric interrupters, such as can be a thyristor, IGBT, TRIAC (Triad for Alternative Current), a relay or any other type of electric interrupters known in the art, which control, in part, the energizing or ignition of the drivers for the heating means 8 , 9 . Conversely, it is understood, that the concept of “actuators” encompasses any type of device or element which generates heat by any means, as can be: a gas burner coupled to a solenoid valve or similar, an electric resistance, a means of infrared, laser etc., as well as any combinations of the same; and that the heating means 8 , 9 comprise at least one actuator.
[0048] Thus, the objective of the present invention is a drying cycle which reduces the energy and/or gas consumed by a dryer. The drying cycle, which can be seen as two distinct cycles 90 , 120 take place in parallel form.
[0049] During the first drying cycle 90 the operator selects a drying cycle to be used from the control panel 82 . If within the options selected by the operator, the drying cycle, object of the present invention is selected 91 the thresholds 92 are modified, by means of the electric control 58 , to low heat, said low temperature thresholds varying between approximately between 37.77° C. and 65.55° C. (100° F. to 150° F.). Having modified the thresholds 92 , the drying cycle begins 93 . In an alternative embodiment, the cycle determines if it is a gas or electric based dryer, or a combination of the two. If it is determined that it is a gas or a combination of gas, the type of gas dryer is determined in order to open a valve or gas actuator and ignite the gas, or rather, ignite the gas and energize the electric resistance(s). If it is determined that it is not a gas dryer, the electric resistance(s) is (are) energized. Alternatively, these steps can be pre-programmed and stored in the CPU 66 memory allowing for the type of dryer determining steps to be skipped. All the heating means 96 are turned on 8 , 9 granting the maximum gas flow through the valve or actuator so that the gas can be ignited to generate the maximum heat possible and/or activate, by means of an actuator, the resistors, in such a way that all electric resistors are ignited at their maximum level.
[0050] FIG. 3 shows a flow diagram of the drying cycle according to the preferred first embodiment of the present invention. In this first preferred embodiment, the dryer's heating means 8 , 9 are composed of two actuators with at least one driver 76 per actuator, and a drying method, during the dryer's first cycle 90 comprised of determining if within the control panel's 82 options, the operator selected 91 the drying cycle of the present invention, if this is so, they are modified 92 , by means of the electric control 58 , the temperature thresholds of the heating means to low heat. Having modified the thresholds, the drying cycle begins 93 sending a pulse to the drivers 76 by means of the electric control's 58 CPU 70 , according to a pulse pattern received from the pulse generator 74 , where said pulse pattern comprises of: energizing 96 all the actuators by at least one heating means 8 , 9 for a first determined time interval which varies between approximately 10 seconds to 3 minutes, generating the maximum possible heat. Once this first determined time interval has lapsed, de-energizing 97 the first actuator of at least one heating means 8 , 9 for a second determined time interval which varies between 10 seconds to 4 minutes; once the second determined time interval has lapsed, de-energizing 98 , 99 the second actuator of at least one heating means 8 , 9 for a third determined time interval which varies between approximately 30 seconds to 4 minutes. In parallel manner, and during the previous steps of the pulse pattern, entrance and/or exit temperature to the drum is constantly monitored 105 , such that the temperature detected by a first temperature detector is compared 106 to a target temperature: in case where said detected temperature is greater than the target temperature, the CPU 70 interrupts the signal to the drivers 76 , and in case the detected temperature is lower than the target temperature, the CPU 70 does not interrupt the signal to the drivers allowing said drivers 76 to energize and activate the actuators with the described pulse pattern, and in this way, the previously described steps are repeated, from the initial drying 93 , at least one time or until the drying is concluded 107 . Once drying has concluded, a cooling time 108 is allowed and the cycle ends 109 . In an alternative embodiment to the presently described, which is shown in FIG. 3 a , during the cycle 90 described above in view of different function conditions such as: the type, quantity, quality of the textiles, the restrictions in the air exit means etc., and the temperature measured by the drum's entry and/or exit temperature detectors 122 is higher than that of the target values', the CPU 70 interrupts the signal of the electronic control 58 to a first actuator of the heating means 8 , 9 , by means of the corresponding driver 76 , to turn it off 123 and lower the heat within the dryer's drum. If after a determined time interval 124 which varies between 500 milliseconds and one minute, the temperature is still greater 125 than the value of the lower threshold previously established, the CPU 70 interrupts the signal or pulse train emanating from the pulse generator 74 of the electric control 58 to the driver of a second actuator of the heating means 8 , 9 to also turn it off 126 and lower with greater velocity the heat within the dryer's drum, and in its case, repeating this successively until all heating means 8 , 9 are turned off. The dryer still keeps functioning 127 without generating heat until the temperature within the drum measured by means of the temperature detector, is lower than the target value, when the temperature is lower than the target value, the CPU 70 allows the signal or pulse train of the pulse generator to pass again towards the drivers of the actuators of the heating means, energizing these 130 according to the turn or position on the time pulse profile which the pulse generator is emitting in that instant; so that based on the referred signal, the CPU 70 of the electric control 58 determines 131 which actuators of the heating means are energized; so that the previous steps are repeated, from the beginning of the drying, at least one time or until drying is concluded. Once drying is concluded, a cooling time is allowed and the cycle is complete.
[0051] FIG. 4 shows a flow diagram of the drying cycle of a preferred second embodiment of the invention. In this second preferred embodiment, the dryer's heating means 8 , 9 are composed of a number of actuators “n” with at least one driver 76 per actuator, which in an illustrative and not limitative manner can comprise a pair of burners each coupled to a solenoid valve or burner coupled to a valve which can adopt a multitude of positions which requires various solenoids to be controlled, or any other similar arrangement: in this way the drying method, during a dryer's first cycle 90 comprises: determining if within the options of the control panel 82 , the operator selected 91 the drying cycle of the present invention, if this is so, by means of the electric control, the temperature thresholds of the heating means are modified 92 to a lower heating. Having modified the thresholds, the first drying cycle is started sending a pulse to the drivers 76 by means of the electric control's 58 CPU 70 according to a pulse pattern received from the pulse generator 74 , where said pulse pattern comprises of: energizing 96 all the actuators “n” of at least one type of heating means 8 , 9 for a determined interval of time which varies between approximately 10 seconds to 3 minutes, generating the maximum possible heat. Once said determined time interval has lapsed, de-energize 97 a first actuator of at least one heating means 8 , 9 , so that only a number of actuators “n-1” remains energized of said at least one heating means for a determined time interval which varies between 10 seconds to 4 minutes: said determined time interval having lapsed, repeat the previous step 97 immediately the number of necessary times in order to consecutively de-energize all the actuators one by one of at least one means of heating 8 , 9 until the number of energized actuators 98 is “n=0”. Once the last actuator of at least one heating means 8 , 9 is de-energized a determined time interval 99 is allowed to lapse which varies between approximately 30 seconds to 4 minutes. In parallel manner, and during the previous steps of the pulse pattern, entrance and/or exit temperature to the drum is constantly monitored 105 , such that the temperature detected by a first temperature detector is compared 106 to a target temperature: in case that said detected temperature is greater than the target temperature, the CPU 70 interrupts the signal to the drivers 76 , and in case the detected temperature is lower than the target temperature, the CPU 70 does not interrupt the signal to the drivers 76 , allowing said drivers 76 to energize and activate the actuators with the described pulse pattern, and in this way, the previously described steps are repeated, from the initial drying 93 , at least one time or until the drying is concluded 107 . Once drying has concluded, a cooling time 108 is allowed and the cycle ends 109 . In an alternative embodiment to the presently described, shown in FIG. 4 a , which is describes as follows: if during the cycle 90 described above in view of different function conditions such as: the type, quantity, quality of the textiles, the restrictions in the air exit means etc., and the temperature measured by the drum's entry and/or exit temperature detectors is higher 122 than that of the target values', the CPU 70 interrupts the signal of the electric control 58 to driver of a first actuator of the heating means (n-1), by means of the corresponding driver 76 , to turn it off 123 and lower the heat within the dryer's drum; if after a determined time interval 124 which varies between approximately 500 milliseconds and one minute, the temperature is still greater 125 than the target temperature, the CPU 70 interrupts the signal of the electric control 58 to a second actuator of the heating means (n-2) to also turn it off 126 and lower with greater velocity the heat within the dryer's drum, and in its case this step 126 is successively repeated as many times as necessary until the point that the CPU 70 interrupts the signal consecutively one by one to all the drivers and their respective actuators of the heating means (n=0). The dryer keeps functioning 127 without generating heat until the temperature within the drum, measured by means of the temperature detector, is lower than the objective temperature. When the temperature is lower than the target temperature, the CPU 70 allows the pulse train of the pulse generator 74 to pass again towards the driver and the actuators of the heating means, energizing these 130 according to the turn or position on the time pulse profile which the pulse generator is emitting in that instant; so that based on the referred signal, the CPU 70 of the electric control 58 determines 131 which of the actuators of the heating means 8 , 9 are energized; so that the previous steps are repeated, from the beginning of the drying, at least one time or until drying is concluded. Once drying is concluded, a cooling time is allowed and the cycle is complete.
[0052] FIG. 5 shows a flow diagram of the drying cycle of a third embodiment of the invention. In this third embodiment, a dryer's heating means 8 , 9 are composed of at least one actuator with at least one driver 76 per at least one actuator, and the drying method, during the first cycle 90 of the dryer comprises: determining 91 if within the options of the control panel 82 , the operator selected the drying cycle of the present invention, if this is so, by means of the electric control 58 , the temperature thresholds of the heating means are modified 92 to a low heating. Having modified the thresholds, the first drying cycle 93 is started sending a pulse to the drivers 76 by means of the electric control's 58 CPU 70 , according to a pulse pattern received from the pulse generator 74 , where said pulse pattern comprises: energizing 96 at least one actuator of at least one type of heating means 8 , 9 to its maximum power for a determined interval of time which varies between approximately 50 to 80 seconds, generating the maximum possible heat. Once said determined time interval has lapsed, de-energize 98 , 99 at least one actuator of at least one heating means 8 , 9 , for a determined time interval which varies between 30 seconds to 4 minutes. In parallel manner, and during the previous steps of the pulse pattern, entrance and/or exit temperature to the drum is constantly monitored 105 , such that the temperature detected by a first temperature detector is compared 106 to a target temperature: in case that said detected entry and/or exit temperature of the drum is greater than the target temperature, the CPU 70 interrupts the signal to at least one driver 76 , and in case the detected temperature is lower than the referred to target temperature, the CPU 70 does not interrupt the signal to at least one driver 76 , allowing said at least one driver 76 to energize and activate at least one actuator with the described pulse pattern, and in this way, the previously described steps are repeated, from the initial drying 93 , at least one time or until the drying is concluded 107 . Once drying has concluded, a cooling time is allowed and the cycle ends 109 .
[0053] The energy use during the two parallel drying cycles 90 , 120 depends on the state of elements, mainly of the heating means 8 , 9 during the drying cycle. Similarly, it highly depends on the moisture level and the load of clothes in the drum 26 . The damper the textiles, the greater the time shall be for the textiles to reach a dryness level of the load, and the longer the heating means and air drying 8 , 9 shall be turned on. The energy consumption of a dryer in the US is measured by the DOE procedure which establishes a calculation to measure a Factor Energy (FE) of a minimum standard of 1.363 Kg/kWh (3.01 lb/kWh) in electric dryers and a minimum of 1.209 Kg/kWh (2.67 lb/kWh) for gas dryers.
[0054] In the first embodiment of the present invention, it is calculated that the total time of the dryer's 10 operation, both means of heating 8 , 9 are turned on approximately from 5 to 80% of the total operational time. It is calculated that the total operational time for the dryer 10 , one of the two heating means 8 , 9 is turned on approximately 10 to 80% of the total operational time of the dryer. Finally, it is calculated that of the total operational time for the dryer 10 , both heating means 8 , 9 are turned off approximately between 10 and 85% of the total operational time. The energy use savings attained by the cycles 90 , 120 mentioned above, especially in light of the first cycle 90 is between 10 to 20% of the DOE standard, with a 95% level of confidence using the DOE procedure, which represents an energy savings which varies between 90 to 160 kWh/per year.
[0055] In a third embodiment of the present invention, it is calculated that the total time of the dryer's 10 operation, the means of heating 8 , 9 is turned on approximately from 30 to 50% of the total operational time It is calculated that of the total operational time for the dryer 10 , the heating means 8 , 9 is turned off approximately between 20 to 80% of the total operational time of the dryer. The energy use savings attained by the cycles 90 , 120 mentioned above, especially in light of the first cycle 90 is between 10 to 15% of the DOE standard, with a 95% level of confidence using the DOE procedure, which represents an energy savings which varies between 90 to 127 kWh/per year.
[0056] Alterations to the structure described in the present, may be foreseen by those experts in the field. However, it must be understood that the present description is related with the preferred embodiments of the invention, which is solely for illustrative purposes and should not be construed as a limitation of the invention. All the modifications which do not depart from the spirit of the invention are included within the body of the attached claims.
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In a dryer machine a drying method which involves sending a pulse according to a pulse pattern formed by: energizing each of a plurality of actuators of a heater for a first determined set time; de-energizing one actuator of the heater for a second determined set time; de-energizing another actuator of the heater for a third determined period of time; compare, during the previous steps, the temperature detected by a temperature detector versus a target temperature; in case the temperature detected is higher than the target temperature, interrupting a drive signal to drivers for the heater; in case the temperature detected is lower than the target temperature, uninterrupting the signal to the drivers; and repeat the previous steps at least one time.
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FIELD OF THE INVENTION
The present invention relates to a marker that is useful in combination with all manners of vaccines, implants or treatment drugs, applied either topically or orally, in either animals or humans. The invention particularly relates to a combined medicament/marker having a controlled clearing time.
BACKGROUND OF THE INVENTION
In the treatment of both animals and humans, it is often useful to provide a means for marking the site where a medicament is injected, inserted or otherwise applied.
More specifically, when dealing with animals which are being raised for food, it is often required that the animals be inoculated with a variety of materials in order to insure that the food harvested therefrom is wholesome. Furthermore, certain medicaments, albeit useful during the animal's growth phase, are nevertheless prohibited at the time of harvest. Regulations prescribe time limits regarding the use of such medicaments to insure a sufficient time period for clearing via natural biodegradation prior to harvest.
Industry compliance with the stated guidelines is a particularly vexing problem, which the industry has been recalcitrant in monitoring. For example, although feedlot attendants may be supplied with the required immunization or medicament, they may be derelict in their responsibilities and fail to apply the material to the animal.
Alternatively, a particular material might need to be given a clearing time period, for example 30 days prior to harvest, thereby allowing a safe clearing time from the animal's flesh. If the feed lot attendant is tardy in making the application, or simply becomes confused about the dates or inoculates a group of animals in error, harmful concentrations of the prohibited materials may find their way into the food supply.
With regard to human applications, there are instances where certain inoculations or tests are initiated and follow-up must occur at a prescribed time interval. In other instances, medicaments are provided in the form insertable implants which reside within the body for extended periods. Furthermore, in a military or possibly a hospital or nursing care environment, it might be beneficial to include a visual confirmation that an individual has received an inoculation.
In all of the above noted circumstances, the inclusion of a marking ingredient or tell-tale which has a controlled biodegradability can act as either evidence of instillation or evidence that a particular period of time has elapsed subsequent to instillation or application of the medicament.
DESCRIPTION OF THE PRIOR ART
U.S. Pat. No. 6,013,122 discloses tattoo inks which can be designed to degrade after a predetermined time. However, there is no disclosure that these inks can be used as indicators to show how long ago a medication was administered.
U.S. Pat. No. 3,416,530 discloses a tablet-like body for insertion along the scleral radius. The tablet is designed to dispense medication to the eye at a predetermined and continuous rate, and utilizes a dye, such as methylene blue, to provide a visual indication that the tablet continues to dispense the medicament. The reference fails to provide a marking device capable of providing a residual marker subsequent to medicament dosage or one that remains visible for a predetermined clearing time.
U.S. Pat. No.3,427,377 proposes a composition of penicillin and a dye of 2,4-disulfo-5-hydroxy-4′, 4″-bis-(diethylamino)-triphenyl-carbinol calcium salt, for administration to the udders of dairy animals. This formulation indicates the presence of penicillin in milk as long as the antibiotic is excreted by the udders.
U.S. Pat. No. 4,572,831 teaches a combination of flourescamine or other furanones and a visible, fugitive dye or pigment. Said composition is useful in marking skin for radiological purposes without leaving visible markings on a patient for an extended period of time.
U.S. Pat. No. 4,152,412 to Brewer discusses an injectable marking vaccine carried on a physiologically acceptable colored particle (e.g., activated charcoal) so as to provide a clearly visible mark evidencing the administration of the desired vaccine.
What is lacking in the art is a cutaneously applied biodegradable tell-tale composition, which composition includes an effective amount of a marker formulation having a pigment or dye in combination with a suitable carrier therefore, and further containing a therapeutically effective amount of one or more medicaments having a controllable period of efficacy or clearing time, and including one or more of a variety of compatible medicaments, vaccines or combinations thereof; wherein instillation/application of the tell-tale marker formulation/medicament combination provide visual evidence for gauging both the application, per se, and time since application of said medicament.
SUMMARY OF THE INVENTION
The instant invention provides a biodegradable tell-tale composition which is applied cutaneously or subcutaneously to a human or animal subject for aiding in the determination of instillation of medicament and furthermore for providing, via the biodegradable functionality, a useful tool for measuring the period of time passed since the most recent inoculation.
It is envisioned that the tell-tale composition of the instant invention will have a plurality of utilities. For example:
1) the tell-tale composition can be given by itself (single injection);
2) the tell-tale composition can be used in or as a carrier agent in a vaccine;
3) the tell-tale composition can be added in small amounts to a vaccine thereby converting it to a marker vaccine;
4) the tell-tale composition can be used in combination with a pour on medicament;
5) the tell-tale composition can be used as an added ingredient in a topdress product (dry product).
Accordingly, it is an objective of the instant invention to provide a tell-tale composition comprising one or more biodegradable tell-tale materials, in combination with a chemical agent, e.g. a medicament, thereby providing a biodegradable marker.
It is a further objective of the instant invention to teach a method wherein the tell-tale composition is utilized In the food and health industry, such that inspectors in the meat processing industries are provided with a tool for ascertaining the safety of any harvestable animal for inclusion within the human food chain.
DETAILED DESCRIPTION OF THE INVENTION
Now with reference to the instillation/application of medicaments, inclusion of a marker as taught by the instant invention will provide the harvester (packer) with a tool for identifying any animals that pass through their plants. The instant invention particularly sets forth a tell-tale or marking composition which includes a plurality of diverse medicaments, vaccines, or the like. Illustrative of those diverse medicaments, vaccines, or the like contemplated by the invention are those incorporated in Tables 1-9, which are appended hereto. In practice, one or more of said medicaments, vaccines or combinations thereof, which are exemplified by, but not limited to materials selected from the group consisting of steroidal anti-inflammatory agents, non-steroidal anti-inflammatory agents, hormones, nutrient supplements, antibiotics, medicated premixes and feeds, mammary gland antibiotics, bovine vaccines, ovine vaccines, porcine vaccines and mixtures thereof, are included in therapeutically effective amounts. This invention has utility in treating both humans or animals. The tell-tale marker composition can be formulated in any color, and can be visible under a variety of lighting conditions, e.g. full-spectrum visible light, infra-red light, ultra-violet light, monochromatic light or the like.
In a particularly preferred embodiment, the tell-tale marker color will appear under the hide, in the mouth or on the surface of the skin and also can be seen on the outer layer of the hide, skin or hair.
The marker formulation can exhibit a particular initial coloration and subsequently transform to another visually distinct coloration. It also can be injected or given orally at a given day and appear at a later date or appear in a few hours depending on the type and the purpose of the vaccine and how the marker and vaccine are designed to interact. The tell-tale is constructed and arranged to disintegrate or wear away after a given period of time has elapsed, again depending on the use of the marker.
As an example of a desired utility, in the case of swine, if a market animal is vaccinated today and it is desired that the animal be harvested in 30 days, then the marker will be designed to disintegrate in 30 days. If the animal were to be harvested prior to the expiration of the 30 day time period, the harvester will then see the marker on the carcass at the injection site and will thus be warned that the animal has been vaccinated within 30 days prior to harvest. Alternatively, absence of a visible marker at the injection site can serve as an indicator that the animal is clear of any remaining drug residue.
This invention provides the manager of an animal processing facility, e.g. a swine or beef processing facility, with a valuable safety and management tool. The visibility of the marker provides an evidentiary tool as to instillation of the medicament, thereby acting as an aid in managing feedlot personnel to insure compliance with regard to initial application. The feedlot manager can visually inspect the animals after the inoculation should have been given and confirm that instructions have been complied with by virtue of the appearance of a visible marker on the surface of the hide. It will be expected that the marker will mark the underside of the hide, the hide itself or the fat at the injection site on a particular vaccinated animal. For convenience, the injection site on an animal should always be on one particular side of the neck or behind the ear area, thus making the marker easily discoverable. If that marker was set to disintegrate after 30 days and the harvester sees no marker then he knows that animal has not been vaccinated in the last 30 days, however if the marker shows up, then it will be apparent to the harvester that a particular animal has been vaccinated with some kind of vaccine in the last 30 days or any given number of days that the marker is set for. If the marker is used in or with an implant in the ear, for example, it can change color to let the producer know that the implant is running out and needs to be replaced.
Now with reference to human use, this marker can be used in many areas of human treatment wherein vaccines or implants are used. The marker can be useful in functioning as a reactor to the presence of a disease or a reminder of an implant that needs to be replaced. It can be used to see how long the body uses the vaccine, so the marker would disintegrate after a given time period.
EXAMPLE 1
A study was conducted utilizing a marker on fat tissue that was 2.5″ thick. A 1″×16 gauge needle was utilized for instillation of the medicament. The test was done with fat tissue maintained at room temperature, e.g. approximately 78 degrees Fahrenheit.
An injection of the marker was made having a volume of about 2 mL. After one hour, the marker was approximately the size of a dime and the marker went more up and down than to the side or it followed the needle path. A second test was conducted with about 10 mL of marking agent. After one hour has elapsed, the marked area was essentially elliptical in shape and approximately 2.5 inches long. Both marks appeared to follow the needle path and were elliptical or egg shaped.
The particular marker composition can be in the form of one or more types of pigment within an acceptable vehicle or carrier which, because of their physical characteristics, can be readily eliminated from the tissue of an animal or human being. It is within the purview of the instant invention to eliminate the pigment(s) passively via absorption or dissolution into the interstitial fluid or alternatively by active degradation driven by interaction with the hosts immune system. By entrapping, encasing, incorporating, complexing, encapsulating, or otherwise associating these pigments (which are otherwise readily eliminated if placed in the tissue themselves) with an acceptable vehicle or carrier, the marker/vehicle complex so produced possesses a visible color, as well as the necessary physical characteristics to remain within the tissue for a particularly defined time period. In order to provide a controlled visual tool for determining residence time, it is contemplated to provide markers which remain in the tissue for a predetermined period of time (such as several hours, or any number of days, for example 10 days, 30 days, 3, 6, or 9 months, 1,2,5 or 10 years, etc.) and then spontaneously disappear.
These “semi-permanent” or “temporary” tell-tale compositions are formulated by a process which may include one or more of the following mechanisms, such as entrapping, encasing, completing, incorporating, or encapsulating the appropriate markers, which markers are readily eliminated from the tissue, into an appropriate vehicle in combination with one or more medicaments, vaccines or the like. The pigments are designed to slowly bioabsorb, bioerode, or biodegrade over a predetermined period of time. For example, as an aid to serving as a reminder device for an implanted birth control device having up to a five year life span, the pigment will begin to disappear during the fourth and fifth years.
When it is desirable for degradation of the tell-tale marker composition to occur within a relatively short period of time, bioabsorbable microcapsules or microflakes may be utilized. In the case of microcapsules, pigment/vehicle complexes comprise a core of pigment surrounded by the pigment vehicle, which is capable of maintaining its structural integrity until a particular threshold percentage of the pigment vehicle is dissolved, bioeroded, or bioabsorbed. At this point, the pigment vehicle no longer provides protection from elimination. The pigment is then released into the tissue, where it is eliminated over a relatively short period of time.
Alternatively, microflakes made of pigment and pigment vehicle, in which the pigment is mixed throughout the microflakes, maintain a relatively consistent pigmented surface area during the process of bioabsorption. Over a predetermined period of time, the visible pigmented surface dissolves.
The pigment vehicle for the pigment or dye comprises any biologically tolerated material that retains the pigment or dye in the tissue, for whatever time or under whatever conditions are desired. In any of these cases, the pigment vehicle carries a colored pigment or dye suitable for administration into the dermis, or subcutaneous tissue, e.g., the fatty layer underlying the dermis. The pigment vehicle is sufficiently transparent or translucent so as to permit the color of the pigment or dye to show through and be visible. Preferably, the pigment or dye comprises particles smaller than 1 micron. For producing semi-permanent tell-tales, the pigments or dyes are entrapped, encased, complexed, incorporated, encapsulated, or otherwise associated in or with pigment vehicles composed of bioabsorbable, bioerodable, or biodegradable material. The material is designed to bioabsorb, bioerode, or biodegrade over a predetermined period of time so that the pigmented material, when administered into the tissue, creates a marker which lasts only until the pigment vehicle bioabsorbs. Upon partial or complete bioabsorption of the pigment vehicle, the pigment or dye is released, allowing its elimination from the tissue.
A great many biodegradable polymers exist, and the length of time which the pigment lasts in a visible state in the tissue is determined by controlling the type of material and composition of the pigment vehicle. Among the bioabsorbable, bioerodable, or biodegradable polymers which can be used are those disclosed in Higuchi et al., U.S. Pat. Nos. 3,981,303, 3,986,510, and 3,995,635, including zinc alginate poly(lactic acid), poly(vinyl alcohol), polyanhydrides, and poly(glycolic acid). Alternatively, microporous polymers are suitable, including those disclosed in Wong, U.S. Pat. No. 4,853,224, such as polyesters and polyethers, and Kaufman, U.S. Pat. Nos. 4,765,846 and 4,882,150.
Other polymers which degrade slowly in vivo are disclosed in Davis et al., U.S. Pat. No. 5,384,333, which are biodegradable polymers which are solid at 20-37° C. and are flowable, e.g., a liquid, in the temperature range of 38-52° C. Preparation of the tell-tale entails incorporation of the dye or pigment in the polymer matrix, subsequent to which the system may be warmed to approximately 50° C., where it liquifies. The tell-tale composition may then be injected into the tissue, where it cools and resolidifies.
For this type of semi-permanent pigment vehicle, any biodegradable polymer system which has the following characteristics can be used, including homopolymers, copolymers, block copolymers, waxes and gels, as well as mixtures thereof. A preferred polymer system is a triblock copolymer of the general formula A-B-A where A represents a hydrophobic polymer block, and B represents a hydrophilic polymer. The monomers and polymers are preferably linked through ester groups. Preferred hydrophobic polymers and oligomers include, but are not limited to, units selected from polyglycolic acid, polyethylene terephthalate, polybutyl lactone, polycaprolactone, D-polylactic acid, polytetrafluoroethylene, polyolefins, polyethylene oxide, polylactic acid, polyglutamic acid, poly-L-lysine, and poly-L-aspartic acid. Preferred hydrophilic polymers include polyethylene glycol, polypropylene glycol, and poly(vinyl alcohol).
Hydrogel matrices or pigment vehicles for preparing semi-permanent tell-tale markers may be formed by crosslinking a polysaccharide or a mucopolysaccharide with a protein and loading the dye or pigment into the hydrogel matrices. Proteins include both full-length proteins and polypeptide fragments, which in either case may be native, recombinantly produced, or chemically synthesized. Polysaccharides include both polysaccharides and mucopolysaccharides.
A hydrogel in which the tell-tale pigment or dye can be incorporated to a suitable carrier is disclosed in Feijen, U.S. Pat. No. 5,041,292. This hydrogel comprises a protein, a polysaccharide, and a cross-linking agent providing network linkages therebetween wherein the weight ratio of polysaccharide to protein in the matrix is in the range of about 10:90 to about 90:10. The pigment or dye is mixed into this matrix in an amount sufficient to provide color when the hydrogel matrix is administered to the tissue. Examples of suitable polysaccharides include heparin, fractionated heparins, heparan, heparan sulfate, chondroitin sulfate, and dextran, including compounds described in U.S. Pat. No. 4,060,081 to Yannas et al. Using heparin or heparin analogs is preferred because there appears to be reduced immunogenicity. The protein component of the hydrogel may be either a full-length protein or a polypeptide fragment. The protein may be in native form, recombinantly produced, or chemically synthesized. The protein composition may also be a mixture of full-length proteins and/or fragments.
Typically, the protein is selected from the group consisting of albumin, casein, fibrinogen, gamma-globulin, hemoglobin, ferritin and elastin. The protein component may also be a synthetic polypeptide, such as poly-alpha-amino acid. polyaspartic acid or polyglutamic acid. Albumin is the preferred protein component of the matrix, as it is an endogenous material which is biodegradable in blood and tissue by proteolytic enzymes. Furthermore, albumin prevents adhesion of thrombocytes and is nontoxic and nonpyrogenic.
In forming hydrogels containing pigments or dyes; the polysaccharide or mucopolysaccharide and the protein are dissolved in an aqueous medium, followed by addition of an amide bond-forming cross-linking agent. A preferred cross-linking agent for this process is a carbodiimide, preferably the water-soluble diimide N-(3-dimethyl-aminopropyl)-N-ethylcarbodiimide. In this method, the cross-linking agent is added to an aqueous solution of the polysaccharide and protein at an acidic pH and a temperature of about 0 to 50° C., preferably from about 4 to about 37° C., and allowed to react for up to about 48 hours. The hydrogel so formed is then isolated, typically by centrifugation, and washed with a suitable solvent to remove uncoupled material.
Alternatively, a mixture of the selected polysaccharide or mucopolysaccharide and protein is treated with a cross-linking agent having at least two aldehyde groups to form Schiff-base bonds between the components. These bonds are then reduced with an appropriate reducing agent to give stable carbon-nitrogen bonds.
Once the hydrogel is formed, it is loaded with the pigment or dye by immersing the hydrogel in a solution or dispersion of the pigments or dye. The solvent is then evaporated. After equilibration, the loaded hydrogels are dried in vacuo under ambient conditions and stored.
Virtually any pigment or dye may be loaded into the hydrogel vehicles, providing that surface considerations, such as surface charge, size, geometry and hydrophilicity, are taken into account. For example, incorporation and release of a high-molecular weight dye will typically require a hydrogel having a generally lower degree of cross-linking. The release of a charged pigment or dye will be strongly influenced by the charge and charge density available in the hydrogel, as well as by the ionic strength of the surrounding media.
The rate of pigment or dye release from the vehicles can also be influenced by post-treatment of the hydrogel formulations. For example, heparin concentration at the hydrogel surface can be increased by reaction of the formulated hydrogels with activated heparin (i.e., heparin reacted with carbonyldiimidazole and saccharine) or with heparin containing one aldehyde group per molecule. A high concentration of heparin at the hydrogel surface will form an extra “barrier” for positively charged dyes or pigments at physiological pH values. Another way of accomplishing the same result is to treat the hydrogels with positively charged macromolecular compounds like protamine sulfate, polylysine, or like polymers. Another way of varying hydrogel permeability is to treat the surfaces with biodegradable block copolymers containing both hydrophilic and hydrophobic blocks. The hydrophilic block can be a positively charged polymer, like polylysine, while the hydrophilic block can be a biodegradable poly(a-amino acid), such as poly(L-alanine), poly(L-leucine), or similar polymers.
Another slow-release system useful as a marker pigment vehicle for pigments or dyes to form a semi-permanent tell-tale is a dye or pigment and an enzyme encapsulated within a microcapsule having a core formed of a polymer which is specifically degraded by the enzyme and a rate controlling skin. The integrity of the shell is lost when the core is degraded, causing a sudden release of pigment or dye from the capsule. In this type of system, the microcapsule consists of a core made up of a polymer around which there is an ionically-bound skin or shell. The integrity of the skin or shell depends on the structure of the core. An enzyme is encapsulated with the biologically-active substance to be released during manufacture of the core of the microcapsule. The enzyme is selected to degrade the core to a point at which the core can no longer maintain the integrity of the skin, so that the capsule falls apart. An example of such a system consists of an ionically cross-linked polysaccharide, calcium alginate, which is ionically coated with a polycationic skin of poly-L-lysine. The enzyme used to degrade the calcium-alginate coated with poly-L-lysine microcapsules is an alginase from the bacteria Beneckea pelagio or Pseudomonas putida . Enzymes exist that degrade most naturally-occurring polymers. For example, the capsule core may be formed of chitin for degradation with chitinase. Other natural or synthetic polymers may also be used and degraded with the appropriate enzyme, usually a hydrogenase.
A particularly preferred bioabsorbable polymer vehicle is a triblock copolymer of poly caprolactone-polyethylene glycol-poly caprolactone. This polymer contains ester bonds which hydrolyze in a hydrophilic environment. The biodegradable polymer matrix should comprise about 30-99% of the tell-tale carrier.
Several mechanisms are involved in the rate and extent of dye or pigment release. In the case of very high molecular weight pigments, the rate of release is more dependent upon the rate of pigment vehicle bioabsorption. With lower molecular weight pigments, the rate of pigment release is more dominated by diffusion. In either case, depending on the particular pigment vehicle composition selected, ionic exchange can also play a major role in the overall release profile.
All references cited herein are hereby incorporated herein in their entirety.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and drawings.
TABLE 1
ANTI-INFLAMMATORY
Steroidal Anti-Inflammatory Agents
Betamethasone
Dexamethasone
Flumethasone
Methylprednisolone
Prednisolone
Hydrocortisone
Triamcinolone
Isoflupredone
Prednisolone, Pheniramine and Vitamins
Prednisolone, Chlorpheniramine
Prednisolone, Trimeprazine
Non-Steroidal Anti-Inflammatory Agents
Phenylbutazone
Dipyrone
Flunixine
Ketoprofene
Orgotein
Tolfenamiuc Acid
TABLE 2
HORMONES
Anabolic Agents
Other Pituitary or Hypotalamic
Testosterone
Hormones
Fluoxymesterone
ACTH
Boldenone
Osytocine
Stanozolol
Cosyntropin
Testosterone and
Hyperadrenocorticism Treatment
Estradiol
Selegiline
Melengestrol
Insulin
Gonadotropine Hormones &
Beef/Pork Insulins
Releasing Factors
Pork Insulin
FSH (Folliculo-
Human Biosynthetic
Stimulating Hormone
Insulin
LH (Luteinizing
Thyroid Hormones & Anti-Thyroid
Hormone)
Products
Gonadoreline
Levothyroxine (T-4)
PMSG and HCG
Levothyroxine (T-4)
Mixture
Methinazole
Deslorelin
Adrenocortical Hormones
Progestagenes
Flurocortisone
Progesterone
Desoxycorticosterone
Medroxyprogesterone
Hormone Mixtures, Vitamines,
Megestrol
Minerals, etc.
Altrenogest
Methyltestosterone,
Estrogens
Estradiol, Thyroxine,
Diethylstilbestrol
Vitamines ADEB
Conjugated Estrogens
Antihistamines
Luteolytic Products
Dimenhydrinate
Dinoprost
Diphenhydramine
Cloprostenol
Tripelennamine
Hydroxyzine
Chlorpheniramine
TABLE 3
NUTRIENT SUPPLEMENTS
VITAMINS ONLY
VITAMIN D
VITAMIN K1
B COMPLEX VITAMINS
VITAMIN C
COMBINED VITAMINS
COMBINED B COMPLEX
COMBINATIONS OF A AND D
COMBINATIONS OF A, D AND E
VITAMINS AND MINERALS
B COMPLEX VITAMINS WITH
IRON, COPPER AND COBALT
VITAMINS (B COMPLEX) IRON,
COBALT AND CHOLINE
VITAMIN D WITH PHOSPHORUS
VITAMIN E WITH SELENIUM
VITAMINS WITH AMINO-ACIDS
B COMPLEX VITAMINS WITH
AMINO-ACIDS AND CHOLINE
VITAMINS (B COMPLEX),
AMINO-ACIDS, FE, CO, CU
VITAMINS, AMINO-ACIDS,
MINERALS, CLUCIDS
TABLE 4
ANTIBIOTICS
NATURAL PENICILLINS
QUINOLONES
COMBINED SULFONAMIDES
PENICILLIN G POTASSIUM
CIPROFLOXACIN
SULFAMETHAZINE AND
PENICILLIN G SODIUM
ORBIFLOXACIN
SULFATHIAZOLE
PENICILLIN G PROCAINE
ENROFLOXACIN
QUINOLONES
SEMISYNTHETIC
MACROLIDES
CIPROFLOXACIN
PENICILLINES
RIFAMPIN
ORBIFLOXACIN
PENICILLIN V
ERYTHROMYCIN
ENROFLOXACIN
AMPICILLIN
TYLOSIN
MACROLIDES
CLOXACILLIN
TIMICOSIN
RIFAMPIN
AMOXICILLIN
ERYTHROMYCIN
TYLOSIN
TICARCILLIN
LINCOMYCINES
TIMICOSIN
CEPHALOSPORI
CLINDAMYCINE
CLINDAMYCINE
CEPHALOTHIN
LINCOMYCINE
LINCOMYCINES
CEFAZOLIN
ANTIFUNGAL
CLINDAMYCINE
CEFTIOFURE
NYSTATIN
LINCOMYCINE
AMINOCYCLITOLS
GRISEOFULVIN
ANTIFUNGAL
STREPTOMYCINE
KETOCONAZOLE
NYSTATIN
GENTAMYCINE
SULFONAMIDES
GRISEOFULVIN
SPECTINOMYCINE
SULFADIMETHOXINE
KETOCONAZOLE
TETRACYCLINES
SULFAMETHAZINE
SULFONAMIDES
TETRACYCLINES
SALICYLAZOSULFAPYRIDINE
SULFADIMETHOXINE
DOXYCYCLINE
SULFAQUINOXALINE
SULFAMETHAZINE
OXYTETRACYCLINE
NITROFURANS
SALICYLAZOSULFAPYRIDINE
CHLORAMPHENICOLS
FUMAGILLINE
SULFAQUINOXALINE
CHLORAMPHENICOLS
COMBINED PENICILLINES
NITROFURANS
FLORFENICOL
PENICILLINE G, PROCAINE AND
FUMAGILLINE
QUINOLONES
BENZATHINE
ANTIBIOTICS AND
CIPROFLOXACIN
COMBINED SULFONAMIDES
VITAMINS
ORBIFLOXACIN
SULFAMETHAZINE AND
PEN-STREP, VITAMINS
ENROFLOXACIN
SULFATHIAZOLE
(A, D, E, K,
MACROLIDES
SULFONAMIDES COMBINED
B COMPLEX)
RIFAMPIN
WITH OTHER ANTIBIOTICS
TRIPLE SULFAS, VITAMINS
ERYTHROMYCIN
SULFAQUINOXALINE AND
(AD3,
TYLOSIN
PYRIMETHAMINE
B COMPLEX) AND MINERALS
TIMICOSIN
SULFADIAZINE AND
NEOMYCINE,
LINCOMYCINES
TRIMETHOPRIME
SULFAMETHAZINE, K,
CLINDAMYCINE
SULFAMETHOXAZOLE AND
MG, CA, NA, CL,
LINCOMYCINE
TRIMETHOPRIME
ACETATE
ANTIFUNGAL
SULFADOXINE AND TRIMETHOPRIME
ANTIBIOTICS AND BETA-
NYSTATIN
LINCOMYCINE AND
LACTAMASE INHIBITORS
GRISEOFULVIN
SPECTINOMYCINE
AMPICILLINE AND
KETOCONAZOLE
LINCOMYCINE AND
SULBACTAM
SULFONAMIDES
SPECTINOMYCINE
AMOXCILLINE AND
SULFADIMETHOXINE
TETRACYCLINES AND
CLAVULINIC ACID
SULFAMETHAZINE
NEOMYCINES
TICARCILLIN AND
SALICYLAZOSULFAPYRIDINE
TETRACYCLINES AND NEOMYCINE
CLAVULINIC ACID
SULFAQUINOXALINE
OXYTETRACYCLINE AND NEOMYCINE
NITROFURANS
ANTIBIOTICS AND ANTI-
FUMAGILLINE
INFLAMMATORY AGENTS
COMBINED PENICILLINES
TETRACYCLINE, NOVOBIOCINE AND
PENICILLINE G, PROCAINE
PREDNISOLONE
AND
BENZATHINE
TABLE 5
MEDICATED PREMIXES &
FEEDS
ANTIBIOTICS ONLY
TYLOSINE
LINCOMYCINE
PROCAINE PENICILLINE G
TIAMULIN
CHLORTETRACYCLINE
OXYTETRACYCLINE
FLORFENICOL
COMBINED ANTIBIOTICS
LASALOCIDE
AMPROLIUM WITH, OR WITHOUT
ETHOPABATE
DECOQUINATE
MEDICATED FEEDS
LEVAMISOLE
FENBENDAZOLE
TABLE 6
MAMMORY GLAND ANTIBIOTICS
ANTIBIOTICS ONLY
CEPHAPIRINE
ERYTHROMYCINE
CLOXACILLINE
OXYTETRACYCLINE
NOVOBIOCIN
PIRLIMYCINE
COMBINED ANTIBIOTICS
PENICILLINE G, PROCAINE AND
NOVOBIOCINE
PENICILLINE G, PROCAINE AND
DIHYDROSTREPTOMYCINE
PEN G POT, STREPTOMYCINE,
NEOMYCINE AND POLYMYXINE
FOUR ANTIBIOTICS AND
HYDROCORTISONE
TABLE 7
BOVINE VACCINES
BOVINE VACCINES: IBRM-PIM
BOVINE VACCINES: BVDK
BOVINE VACCINES: IBRK-PIK-BVDK
BOVINE VACCINES: IBRM-PIM-BVDM
BOVINE VACCINES: IBRM-BVDM-PIM-CFK-LPK
BOVINE VACCINES: IBEM-PIM-BVDK
BOVINE VACCINES: SVM
BOVINE VACCINES: IBRM-PIM-SVM
INTRAMUSCULAR
BOVINE VACCINES: IBRK-PIK-BVDK-SVK
BOVINE VACCINES: IBRM-PIM-BVDM-SVM
BOVINE VACCINES: IBRM-PIM-BVDK-SVM
BOVINE VACCINES: IBRM-PIM-BVDM-SVK
BOVINE VACCINES: IBRM-PIM-BVDK-SVM
BOVINE VACINES: HSK
BOVINE VACCINES; HSK-PHK BVDM-SVM-HSK
BOVINE VACCINES: IBRM-PIM-BVDK-SVM-LPK
BOVINE VACCINES: IBRK-PIM-BVDK-SVM-LPK
BOVINE VACCINES: IBRK-PIK-BVDK-SVK-LPK
BOVINE VACCINES: IBRM-BVDM-PIM-HSK-LPK-CFK
BOVINE VACCINES: IBRM-PIM-BVDK-SVM-LPK-CFK
BOVINE VACCINES: IBRK-PIK-BVDK-SVK-LPK-HSK
BOVINE VACCINES: RCM
BOVINE VACCINES: CFK
BOVINE VACCINES: CFK-LPK
BOVINE VACCINES: ECK (MASTITIS)
BOVINE VACCINES: SAK
BOVINE VACCINES: PPK
BOVINE VACCINES: BAM
BOVINE VACCINES: TVM
BOVINE VACCINES: MOK
BOVINE VACCINES: 4CLOSTRIDIUM-K - ENTK
BOVINE VACCINES: 4CLOSTRIDIUM-K - ENTK-HSK
TABLE 8
OVINE VACCINES
OVINE VACCINES: ENTK-PSTK-TTK
OVINE VACCINES: ENTK-PSTK-TTK-3 CLOSTRIDIUM-K
OVINE VACCINES: CHK
OVINE VACCINES: CFK-CHK
OVINE VACCINES: ENTK-4CLOSTRIDIUM-K
OVINE VACCINES: ENTK-TTK-3 CLOSTRIDIUM-K
OVINE VACCINES: ENTK-5 CLOSTRIDIUM-K
OVINE VACCINES: FNK
TABLE 9
PORCINE VACCINES
PROCINE VACCINES: BOK
RABIES
PORCINE VACCINES: BOK-PAK
PORCINE VACCINES: ERK
BOVINE, OVINE
PORCINE VACCINES: ERM
PORCINE VACCINES: BOK-PAK-
TETNUS
ERK
PORCINE VACCINES: ECK
BOVINE, OVINE
PORCINE VACCINES: ENTK-ECK
PORCINE VACCINES: BOK-PAK-
LEPTOSPIRA
ECK
PORCINE VACCINES: LPK
BOVINE AND PORCINE
PORCINE VACCINES: BOK-PAK-
ERK-ECK
PORCINE VACCINES: PVK
PORCINE VACCINES: ERK-PVK
PORCINE VACCINES: ERK-LPK-
PVK
PORCINE VACCINES: TGEM
PORCINE VACCINES: TGEK
PORCINE VACCINES: ROM
PORCINE VACCINES: TGEM-ROM
PORCINE VACCINES: TGEK-ROM
PORCINE VACCINES: ECK-TGEM-
ROM
PORCINE VACCINES: APK
PORCINE VACCINES: BOK-PAK-
ERK-APK
PORCINE VACCINES: ECK-TGEM-
ROM-ENTK
PORCINE VACCINES: BOK-PAK-
ENTK-ECK-ERK-ROM-TGEM
PORCINE VACCINES: BOK-PAK-
MHK
PORCINE VACCINES: STK
PORCINE VACCINES: MHK
PORCINE VACCINES: HPK
PORCINE VACCINES: HPK-MHK
PORCINE VACCINES: ERK-HPK
PORCINE VACCINES: RRSM
PORCINE VACCINES: INK
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The instant invention provides a biodegradable tell-tale composition which is applied cutaneously or subcutaneously to a human or animal subject for aiding in the determination of instillation or application of a medicament, vaccine or the like; and furthermore for providing, via the biodegradable functionality, a useful tool for measuring the period of time which has passed since the most recent inoculation.
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FIELD OF THE INVENTION
[0001] This invention relates to a technique for fabricating a downsized linear motion guide unit having a slider sliding along a track rail.
DESCRIPTION OF THE RELATED ART
[0002] For use of a linear motion guide unit having a slider sliding along a track rail, the track rail is fixed to a surface on which the linear motion guide unit is mounted (hereinafter referred to as “the mounting surface”). For fixing the track rail, typically, screw holes are drilled through the track rail at either end thereof and bolts are screwed in the screw holes for fixing the track rail.
[0003] Various types of such linear motion guide units have been developed, from one used in a large-sized machine tool to one used in a miniature industrial product. Recently, an ultra-miniature linear motion guide unit having a track rail of 5 mm or less has been developed.
[0004] Such a reduction in size of the linear motion guide unit makes it difficult to drill holes for fixing the track rail to the mounting surface. In particular, it is close to impossible to drill holes in an ultra-miniature linear motion guide unit having a track rail of 5 mm or less.
[0005] To overcome this, the track rail of the miniature linear motion guide unit may be fixed to the mounting surface in such a manner as disclosed in, for example Japanese Patent 3281157 and Japanese Unexamined Patent Publication 2005-249113. Thereby, the track rail can be fixed to the mounting surface without drilling holes in the track rail.
[0006] Specifically, as described in Japanese Patent 3281157, fitting grooves are formed in the two ends of the track rail. Fixing members are fitted into the fitting grooves, and fixed to the mounting surface. Alternatively, as described in Japanese Unexamined Patent Publication 2005-249113, external threads project from the two ends of the track rail and are screwed through a base material, and then the base material is fixed to the mounting surface. These devices eliminate the need to drill screw holes in the track rail, and make it possible to fix the track rail to the mounting surface even if it is an ultra-miniature linear motion guide unit.
[0007] However, for fixing the track rail to the mounting surface in the manner as described above, external screws or fitting grooves must be provided at the two ends of the track rail. As a result, the need for performing additional machining on the two ends of the track rail arises.
[0008] If the additional machining for forming the external screws or the fitting grooves is performed on the two ends of the ultra-miniature track rail, the additional machining affects the track rail to cause distortion or backlash, which reduces the straightness, leading to a reduction in accuracy of the track rail.
[0009] In addition, the additional machining on the track rail entails machining costs, resulting in heightened manufacturing costs.
SUMMARY OF THE INVENTION
[0010] It is an object of the present invention to provide a technique for fastening a track rail of a miniature linear motion guide unit, which can eliminate the need for additional machining on the track rail, and thus improve the accuracy of the track rail and reduce the manufacturing costs.
[0011] A first aspect of the present invention provides a miniature linear motion guide unit which comprises a track rail having raceway grooves and fixed to a mounting surface, on which the miniature linear motion guide unit is mounted, by a fixing member, and a slider straddling the track rail and sliding thereon. The miniature linear motion guide unit is characterized in that the fixing member has a recessed groove formed in an opposing mounting face facing the mounting surface and straddling the track rail, in which part of the recessed groove is in contact with the track rail when the recessed groove straddles the track rail, and a mounting hole drilled in a portion of the recessed groove of the fixing member away from the track rail, and a stopper member such as a bolt is inserted in the mounting hole and fixed to the mounting surface.
[0012] A second aspect of the present invention is characterized in that the recessed groove is maintained out of contact with raceway grooves formed in the track rail in a dimensional relationship with the track rail when the recessed groove straddles the track rail.
[0013] A third aspect of the present invention is characterized in that the fixing member has a raised portion protruding from the opposing mounting face, and an under face of the raised portion is in contact with the mounting surface when the track rail is in contact with the recessed groove, and the mounting hole is provided between the raised portion and the recessed groove.
[0014] A fourth aspect of the present invention is characterized in that the recessed grooved has a bottom face and side walls formed on opposite sides of the bottom face, and the side walls form tapered faces to gradually decrease the space between the side walls toward the bottom face, and the tapered faces are in contact with the track rail.
[0015] A fifth aspect of the present invention is characterized in that the fixing member lies along the axis of the track rail when the recessed groove straddles the track rail.
[0016] A sixth aspect of the present invention is characterized in that the fixing member lies at right angles to the axis of the track rail when the recessed groove straddles the track rail.
[0017] According to the first aspect, because the recessed groove provided in the fixing member straddles the track rail and is in contact with the track rail, the need for performing additional machining on the track rail to fix it to the mounting surface is eliminated.
[0018] In consequence, there is no possibility that the additional machining causes a reduction in the accuracy of the track rail, so that the accuracy of the track rail is maintained high.
[0019] According to the second aspect, because when the recessed groove straddles the track rail, the recessed groove is out of contact with the raceway grooves of the track rail, even when the fixing member is used to fix the track rail to the mounting surface, the raceway grooves are not distorted and deformed. In this manner, because the raceway groove is not distorted and deformed, it is possible to smoothly attach and detach the slider to and from the track rail.
[0020] According to the third aspect, after the contact between the track rail and the recessed groove has been made, the under face of the raised portion comes into contact with the mounting surface. Because of this, when the fixing member is tightened by the stopper member, the track rail is pressed into the recessed groove. This makes it possible to more strongly fix the track rail to the mounting surface.
[0021] According to the fourth aspect, the opposing side walls of the recessed groove is designed to form tapered faces such that the space between the side walls is decreased toward the bottom face, and the tapered faces are in contact with the track rail. Thus, the track rail is reliably prevented from deviating in the width direction.
[0022] Also, because the tapered faces are designed to decrease the space between the side walls toward the bottom face of the recessed groove, it is possible to facilitate the dimensional control of the recessed groove.
[0023] According to the fifth aspect, because the fixing member extends parallel to the axis of the track rail when the recessed groove straddles the track rail, the fixing member will not form an obstruction when a plurality of the track rails are arranged in parallel.
[0024] According to the sixth aspect, because the fixing member is placed at right angles to the axis of the track rail R when the recessed groove straddles the track rail, it is possible to reliably fix the fixing member to the mounting surface even when there is no extra space behind the track rail in the axis direction.
[0025] In addition, when a plurality of the recessed grooves are formed in the fixing member, it is possible to use the single fixing member to fix a plurality of track rails arranged parallel to each other.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a perspective view illustrating a linear motion guide unit of a first embodiment according to the present invention.
[0027] FIG. 2 is a partially enlarged view illustrating a track rail fixed by a fixing member.
[0028] FIG. 3 is a sectional view taken along the III-III line in FIG. 2 .
[0029] FIG. 4 is a sectional side view illustrating a track rail fixed by the fixing member.
[0030] FIG. 5 is a perspective view illustrating a linear motion guide unit of a embodiment according to the present invention.
[0031] FIG. 6 is a sectional view illustrating a recessed groove in another embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] A first embodiment according to the present invention will be described now with reference to FIG. 1 to FIG. 4 . The precondition of the linear motion guide unit according to the present invention is that it is of a miniature size, and all the structural elements themselves are of a miniature size.
[0033] A slider S running on a track rail R is composed of a casing C, a pair of end caps 1 provided at the two ends of the casing C, and a pair of end seals 2 provided on the external sides of the end caps 1 .
[0034] A guide groove extending through the end caps 1 is formed endlessly in the slider S. Rolling elements 3 such as balls or cylindrical rollers are inserted in the endless guide groove.
[0035] Raceway grooves each made up of an upper raceway face 4 and a lower raceway face 5 are respectively formed in the width-direction side faces of the track rail R. The slider S smoothly runs on the track rail R while the rolling elements 3 roll in the raceway groove.
[0036] For using the linear motion guide unit, the track rail R must be fixed to a mounting surface. At this point, a fixing member A is used to fix the track rail R to the mounting surface.
[0037] As illustrated in FIGS. 2 and 3 , the fixing member A has a recess groove 7 formed in an opposing mounting face 6 facing the mounting surface to which the track rail R is fixed. One end of the recessed groove 7 is open on the rail-side open face 8 so as to allow the recessed groove 7 to straddle the track rail R.
[0038] The recessed groove 7 has side walls 7 b formed on opposite sides of the bottom face 7 a . The two side walls 7 b are designed to form tapered faces in such a manner that the width between the opposing side walls 7 b tapers down from the opposing mounting face 6 toward the bottom face 7 a.
[0039] The width of the bottom face 7 a is designed to be slightly smaller than the width L 1 of the track rail R. Accordingly, when the recessed groove 7 straddles the track rail R, the upper edges of the two side faces of the track rail R come into contact with the respective side walls 7 b (tapered faces) in the recessed groove 7 so as to be prevented from coming closer in.
[0040] At this point, the dimensional relationship is maintained such that the side walls 7 b of the recessed groove 7 are out of contact with the raceway groove formed in the track rail R.
[0041] When the recessed groove 7 straddles the track rail R, the fixing member A is designed to extend parallel to the axis of the track rail R. At this point, the recessed groove 7 is formed to a length from the rail-side open face 8 to approximately one third the length of the fixing member A in the axis direction of the track rail R.
[0042] The fixing member A has a raised portion 9 protruding from the opposing mounting face 6 at the opposite end to the rail-side open face 8 . The dimensional relationship is maintained such that the under face of the raised portion 9 is in full contact with the mounting surface when the track rail R is installed in contact with the recessed groove 7 .
[0043] As illustrated in FIG. 4 , the fixing member A further has a mounting hole 11 drilled approximately at the mid point between the recessed groove 7 and the raised portion 9 , and a stopper member 10 such as a bolt is inserted through the mounting hole 11 . Accordingly, when the recessed grooved 7 straddles the track rail R, the mounting hole 11 is situated away from the track rail R in the recessed groove 7 .
[0044] When the recessed grooved 7 straddles the track rail R as described above, the upper edges of the two side faces of the track rail R are in contact with the respective side walls 7 b (tapered faces) in the recessed groove 7 and the bottom face of the raised portion 9 is in contact with the mounting surface. In this state, the stopper 10 such as a bolt is inserted through the mounting hole 11 and tightened therein. Thereupon, the fastening force of the stopper member 10 presses the fixing member A against the mounting surface and the side walls 7 b (tapered faces) of the recessed groove 7 against the track rail R to make contact between them. In other words, the operation of the fastening force of the stopper member 10 is divided into two, a pressing force pressing the recessed groove 7 against the track rail R and a pressing force pressing the raised portion 9 against the mounting surface.
[0045] In this manner, according to the first embodiment, the track rail R is fixed to the mounting surface by making the contact between the recessed groove 7 and the track rail R. For this reason, the track rail R can be reliably fixed without additional machining on the track rail R for fixing it to the mounting surface.
[0046] Also, the two side walls 7 b of the recessed groove 7 form tapered faces and the tapered faces are designed to be in contact with the track rail R. This makes it possible to reliably prevent the track rail R from deviating in the width direction, and also to facilitate the dimensional control of the recessed groove 7 .
[0047] Because the mounting hole 11 is provided between the raised portion 9 and the recessed groove 7 , it is possible to divide the operation of the fastening force caused by the stopper member 10 into two, a pressing force pressing the recessed groove 7 against the track rail 7 and a pressing force pressing the raised portion 9 against the mounting surface.
[0048] Accordingly, it is possible to reliably press the recessed groove 7 against the track rail R and the raised portion against the mounting surface so as to make reliable connection therebetween.
[0049] When the recessed groove 7 straddles the track rail R, the recessed groove 7 is out of contact with the raceway groove of the track rail R. Hence, even when the fixing member A is used to fix the track rail R to the mounting surface, this does not give rise to distortion and deformation the raceway groove. In this manner, because the raceway groove is not distorted and deformed, it is possible to smoothly attach and detach the slider S to and from the track rail R.
[0050] In addition, because the fixing member A is designed to extend parallel to the axis of the track rail R when the recessed groove 7 straddles the track rail R, the fixing member A will not form an obstruction when a plurality of the track rails R are arranged in parallel.
[0051] A second embodiment according to the present invention will be described below with reference to FIG. 5 . The second embodiment differs in the orientation of the recessed groove formed in the fixing member from the first embodiment, and the structure and operation of the other components are the same as those in the first embodiment.
[0052] Therefore, the same structural elements in the second embodiment as those in the first embodiment are designated with the same reference numerals and the difference from the first embodiment is described in the second embodiment.
[0053] In a fixing member B illustrated in FIG. 5 , the recessed groove 7 with side walls forming the tapered faces is formed in the opposing mounting face 6 so as to straddle the track rail R. One end of the recessed groove 7 is open on the rail-side open face 12 , and the other end thereof is open on the opposite face to the rail-side open face 12 .
[0054] When the recessed groove 7 straddles the track rail R, the raised portion 9 protrudes from the opposing mounting face 6 in such a manner as to extend parallel to the track rail R. Accordingly, after the recessed groove 7 straddles the track rail R, the fixing member B form an angle of 90 degrees with the axis of the track rail R.
[0055] In the second embodiment, the mounting hole 11 is provided between the recessed groove 7 and the raised portion 9 .
[0056] Thus, as in the case of the first embodiment, by inserting and tightening the stopper member 10 in the mounting hole 11 , the track rail R can also be fixed in the recessed groove 7 with the raised portion 9 pressed against the mounting surface.
[0057] Because the fixing member B is designed to form an angle of 90 degrees with the axis of the track rail R when the recessed groove 7 straddles the track rail R, the fixing member B can be reliably fixed to the mounting surface even when there is no extra space behind the track rail R in the axis direction.
[0058] In addition, because the recessed groove 7 has two open ends in the second embodiment the fixing member B is not necessarily fixed to the end of the track rail R. As a result, the fixing member B can be provided in an optimum position in accordance with the structure of the mounting surface, the track rail R or the like.
[0059] Further, when a plurality of the recessed grooves 7 are formed in the fixing member B, it is possible to use the single fixing member B to fix a plurality of track rails R arranged parallel to each other. Note that when a plurality of the track rails R are fixed by the single fixing member B, the mounting hole 11 is desirably provided in each position between the parallel recessed grooves 11 , that is, between the adjacent recessed grooves 7 . This is because, if the stopper member 10 is screwed in each position between the adjacent track rails R, all the track rails R can be reliably pressed against the mounting surface to come into close contact therewith.
[0060] In the first and second embodiment, the side walls of the recessed groove 7 are designed to form the tapered faces. However, the side walls of the recessed groove 7 do not necessarily form the tapered faces. For example, in another embodiment as illustrated in FIG. 6 , the side walls 7 b of the recessed groove 7 may equally be designed to form an angle of 90 degrees with the opposing mounting face 6 and the top face of the track rail R may be in contact with the bottom face 7 a of the recessed groove 7 .
[0061] In this case, by tightening the stopper member 10 , the track rail R can be fixed by being pressed against the mounting surface. However, when the side walls 7 b are designed to form the tapered faces and the upper edges of the side faces of the track rail R are contact with the tapered faces, it is possible to reliably prevent the track rail R from deviating in the width direction.
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A miniature linear motion guide unit can eliminate the need for additional machining on a track rail, and thus improve the accuracy of the track rail and reduce the manufacturing costs. A track rail (R) having raceway grooves ( 4, 5 ) is fixed to a mounting surface by a fixing member (A). A slider (S) straddles and moves on the track rail. The fixing member has a recessed groove ( 7 ) formed in an opposing mounting face ( 6 ) facing the mounting surface and straddling the track rail. Part of the recessed groove is in contact with the track rail when the recessed groove straddles the track rail. A mounting hole ( 11 ) is drilled in a portion of the recessed groove of the fixing member away from the track rail. A stopper member ( 10 ) such as a bolt is inserted in the mounting hole and fixed to the mounting surface.
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BACKGROUND OF THE INVENTION
The invention relates to an optical switching device comprising a first optical layer in which at least one optical waveguide having an entrance and an outlet is formed and a second piezoelectric layer associated with the first optical layer and electrodes for production of an acoustic wave provided on the second piezoelectric layer.
This type of acoustic-optic switching device is known in the prior art. For example, so-called "bulk-Bragg cells" are frequently used in optics in order to cause a deflection in free beam technology or to cause a frequency shift of the light wave in an acousto-optical modulator. Integrated optical Bragg cells are known from the use of piezoelectric crystalline materials, such as Lithium niobate (LiNbO 3 ) as an integrated optical waveguide (R. G. Hunsberger: "Integrated optics: Theory and Technology", Springer-Verlag, Heidelberg, 1985; M. S. Wu: "Low-Loss ZnO Optical Waveguides for SAW-AO Applications", IEEE Transactions on Ultrasonics, Ferroelectrics and Frequency Control, Vol. 36, No. 4, 442(1989)).
Moreover an optical switch in a silicon substrate in the form of an interferometer is known. Thus, for example, in the article, "5 Ghz-spaced, Eight-channel, Guided-wave Tunable Multi/demultiplexer for Optical FDM Transmission Systems", Electronic Letters 23, No. 15,788(1987) an integrated optical waveguide made from silicon dioxide doped with titanium is disclosed, which forms a Mach-Zehnder Interferometer, whose one arm can be heated with the help of a thin layer resistance. A phase shift between both partial waves can result from a definite temperature increase, which leads to an optical coupling in one of two outlet waveguides according to choice during guiding in an integrated-optical directional coupler. Inorganic light-guiding materials, such as silicon dioxide, have only a comparatively small thermo-optic coefficient so that the switching function is connected with comparatively high heat input.
The known optical switch, especially the above-mentioned bulk-Bragg cells, have the disadvantage that they are very large and are not useable in the vicinity of integrated-optical components. Moreover no switching between two spatially separated outlets during which an optical frequency shift can be performed at the same time may be accomplished with other optical switches known from the state of the art. The necessity for this exists, e.g., in heterodyne interferometery.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved optical switching device of the above-described type which is not only useful to switch a light beam on and off, but also to switch a light beam from one outlet to another.
These objects, and others which will be made more apparent hereinafter, are attained in an optical switching device comprising an optical layer in which at least one optical waveguide having an entrance and an outlet is formed, a piezoelectric layer associated with the optical layer and electrodes for producing an acoustic wave provided on the piezoelectric layer.
According to the invention, the optical switching device includes at least one other optical waveguide having an outlet provided in the optical layer and means for performing a Bragg light deflection with optical frequency shift by one of activating and deactivating the electrodes to optically couple the entrance of the at least one optical waveguide with one of the outlet of the at least one optical waveguide and the outlet of the at least one other optical waveguide.
The optical switching device according to the invention has the advantage that it is a compact structural component which not only can be used to switch on and off a light beam, but also to shift it from one outlet to another with a frequency shift at the same time.
Because of that, an optical waveguide cooperates with another optical waveguide in an optical layer, so that a light wave is deflected into the other optical waveguide in the vicinity of an acoustic wave produced by means of a piezoelectric layer. Thus a switching from one output to the other may be accomplished by a simple activation and deactivation of the acoustic wave. Particularly a compact structure using only two layers is sufficient to accomplish this.
Electrodes for producing the acoustic waves advantageously are provided on the opposite side of the piezoelectric layer from the optical layer. Understandably an electrode arrangement on the other side is also conceivable.
Embodiments in which the electrodes are arranged on both sides of the piezoelectric layer or, alternatively, one on one side and one on the other provide the advantage that, on the one hand, redundancies and operating reliability are increased, while, on the other hand, an electrode arrangement acting as a detector results, which detects whether the other electrode arrangement is activated or deactivated.
The use of an optical beam spreader, e.g. in the form of a Horn-Taper structure, or lens structures, at the entrance of the one optical waveguide, is particularly advantageous in order to improve and intensify deflection by the acoustic wave, whereby the spread light beam is concentrated or focused again to its normal size by a suitable light beam focusing device.
The layers may be applied to a common substrate with the help of thin layer technology so that a very compact structure resulted. Advantageously silicon may be used as the substrate material so that a compatible process for semiconductor manufacture is possible which allows an additional monolithic integration of electronic functions. Moreover the micromechanical structuring of substrate material can be used in order to provide local structure for optical waveguides (glass fibers) and thus in order to guarantee an adjustment-free coupling of optical waveguides in the integrated optical chip.
Advantageously the first optical layer includes doped silicon dioxide layers. The selection of separate layer systems for guidance of the light waves and for excitation of the sound waves advantageously allows the independent optimization of the optical and the piezoelectric properties of the systems.
The invention also comprises an optical by-pass circuit including an optical layer which is provided with at least one optical waveguide having an entrance and an outlet and with at least one other optical waveguide having another entrance and another outlet; a piezoelectric layer arranged on the optical layer; a common substrate made of silicon on which the piezoelectric layer and the optical layer are mounted; electrodes for producing an acoustic wave, each of which are provided on one side or the other of the piezoelectric layer; means for detecting the acoustic wave including at least one of the electrodes to generate a suitable detection signal and means for performing a Bragg light deflection with optical frequency shift by one of activating and deactivating the electrodes to optically couple one of the entrance of the at least one optical waveguide and the entrance of the at least one other optical waveguide with one of the outlets. The at least one optical waveguide crosses the at least one other optical waveguide at an angle which corresponds to a Bragg deflection angle and the optical layer includes a number of doped silicon dioxide layers.
The optical by-pass circuit according to the invention has the advantage that it is possible in a simple manner using the optical switching device according to the invention to provide a switching matrix with two entrances and two outlets. Thus coupling devices may be provided in some embodiments by which several optical entrances may be coupled according to choice with one of several optical outlets, whereby a fixed predetermined coupling between an entrance and an outlet exists in a deactivated state coupling device. Thus the switching device shifts into a stable state independently of other parameters during interference.
In an advantageous way an optical fiber is associated with one entrance and an optical fiber is associated with its corresponding outlet, while a light source is arranged at another entrance and a light detector, at another outlet. A signal processing device cooperating with the light source and the light detector is by-passed by an optical coupling between both optical fibers in the deactivated state. Interference with this device does not lead to an interruption of the transmission from one optical fiber to another.
Additional advantageous embodiments are described further in the appended dependent claims.
BRIEF DESCRIPTION OF THE DRAWING
The objects, features and advantages of the invention will now be illustrated in more detail with the aid of the following description of the preferred embodiments, with reference to the accompanying figures in which:
FIG. 1 is a schematic perspective view of one embodiment of an optical switching device according to the invention;
FIG. 2 is a block diagram showing an application of an optical switching device according to the invention; and
FIG. 3 is a schematic diagram of an optical by-pass circuit according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An optical switching device 1 is schematically illustrated in FIG. 1 and has a substrate layer 3, advantageously made of silicon, to which an optical layer 5 is applied. Particularly the known standard thin layer technology is suitable for the application process. The figure does not show that the optical layer 5 is formed as a layer system. The optical layer 5 is advantageously formed from a plurality of differently doped silicon dioxide layers, which guarantee vertical light guidance because of their different refractive indices. Lateral light guide means can also be provided in a simple way by a suitable lateral structuring of the layer system, which, e.g., can be attained by plasma etching.
A piezoelectric layer 7 is arranged on this light guiding optical layer 5. It can be made, for example, by sputtering of zinc oxide or aluminum nitride. Understandably a plurality of other material systems and layer technologies can also be used, such as deposition of lead-zirconate-titanate layers in a sol-gel process.
Besides the arrangement of the piezoelectric layer 7 on the optical layer 5 understandably also this layer may be arranged under the optical layer 5.
An electrode arrangement 9 in the form of an interdigital converter is provided on the piezoelectric layer 7. An acoustic surface wave, which propagates in the Y-direction in FIG. 1, may be excited in the piezoelectric layer 7 by coupling of a high frequency in the electrode arrangement. Both a Rayleigh-mode and also modes of higher order (Sezawa-mode) can be used here as acoustic waves. These acoustic surface waves spread in the optical layer 5 and lead there to periodic index of refraction changes. The period corresponds to the wavelength of the sound wave. The index of refraction change results, because of a periodic spatial oscillation of a dynamic optical grid in which the light waves are deflected. As a result of the large lateral spreading of the sound wave, the grid may be represented by a Bragg grid, so that the angular deflection corresponds to twice the Bragg angle 2Θ B , wherein Θ B is given by:
2·Λ·sin Θ.sub.B =λ.
Here Λ is the acoustic wavelength and λ is the optical wavelength of a light source in the optical layer 5, which is connected with the wavelength λ 0 in vacuo with
λ=λ.sub.0 /neff.
A Bragg angle Θ B of about 1.5° results with the usual light wavelengths of λ 0 ≅1.3 to 1.5 μm and acoustic surface waves with Λ≅20 μm when a silicon dioxide layer is used as the optical material with a refractive index of about 1.5.
This effect is used in the circuit device shown in FIG. 1 for switching from one outlet to the other. A light waveguide or optical waveguide 11 is also provided in the optical layer 5, which connects an entrance 13 optically with an outlet 15. This optical waveguide 11 is arranged at an angle of Θ relative to the schematically illustrated wave front 17.
An additional optical waveguide 21 is provided extending from this first optical waveguide 11 in a surface wave region 19, which opens into a second outlet 23. Also this optical waveguide is arrange at an angle of Θ relative to the wave front line 25.
An optical fiber 27 is coupled to the entrance 13 for input of the light beam, while optical fibers 29.1 and 29.2 are associated with the outlets 15 and 23. The light beam input into the optical waveguide 11 is guided directly to the output 15 with the electrode arrangement deactivated, which means in the absence of a surface wave.
When the electrode arrangement is activated the above-mentioned surface wave forms, which leads, as described above, to a deflection of the light beam about 2Θ. Thus an input light wave is deflected in the vicinity 19 about this angle and thus guided by means of the suitable arrangement of the light wave guide 21 to the output 23. Thus a switching between both outlets 15 and 23 is possible by activation and deactivation of the electrode arrangements.
FIG. 2 shows an example of an application of the optical switching device according to the invention, which is a component of a participating node of an optical communication network, e.g. a local network. In one such network several participating stations are connected by a fixed data bus with each other. This data bus is an optical fiber in an optical network.
In FIG. 2 one sees that a participating station 30 is connected with another downstream unshown participating station by an optical fiber 31.1 and with an additional upstream unshown participating station by an optical fiber 31.2. A signal processing device 33 is provided as an interface between the participating station 30 and the optical data bus 31. This signal processing device 33 controls an optical switching device 35, whose first entrance 37 is associated with the optical fiber 31.1 and whose first outlet 39 is associated with the optical fiber 31.2.
FIG. 2 however shows that the optical switching device 35 has a second entrance 41, which is associated with a light source 43, for example a laser diode. The optical switching device 35 has a second outlet 45 available which is associated with a light detector 47. Both the transmitting device 43 and also the detector 47 are connected with the signal processing device 33.
The participating node thus operates in the standard case so that the data coming over the optical fiber 31.1 are conducted to the detector 47 as shown by a dashed optical connection 51 in the optical switching device 35. The corresponding electronically converted data then reach the signal processing device 33, which filters out the information designed for the participating station 30 from the data stream, and newly added information and the data stream modified in this way is transmitted by the transmitting device 43 and over the optical connection 53 formed in the optical switching device 35 to the optical fiber 31.2 so that the data then reaches the downstream participating station.
This data transmission from the upstream to the downstream participating station depends on the operational effectiveness of the signal processing device 33. In case this fails because of a voltage interruption, the network is paralyzed, since the incoming data cannot reach the optical fiber 31.2.
In order to guarantee a friction-less operation of a network, an optical switching device is made by combination of two optical switching devices according to FIG. 1, which guarantees the two-dimensional connections 51,53 in the activated state. In the deactivated state, which for example occurs during a voltage drop, the optical switching device 35 is however switched so that a connection 54 is made between a first input 37 and a first outlet 39. Thus the data stream can flow to the downstream participating station avoiding the participating station 30 and the signal processing apparatus 33.
The exact structure of this optical switching device is shown diagrammatically in FIG. 3. This optical switching device has substantially the same layers, as the optical switching device according to FIG. 1. A more detailed illustration is therefore not necessary.
The embodiment shown in FIG. 3 differs from the optical switching device shown in FIG. 1, because of the presence of the additional optical waveguide 11.2 in the optical layer besides the optical waveguide 11.1. This optical waveguide 11.2 has an entrance 37 and an outlet 39 and it is superimposed on the optical waveguide 21 (FIG. 1) in the lower region. To guarantee the desired operation it is necessary that both optical waveguides 11.1 and 11.2 cross each other. The angle between these waveguides 11.1 and 11.2 is a Bragg-deflection angle of 2Θ B .
On activation of an electrode arrangement, which means an acoustic surface wave is present, a light beam 55 is deflected in the Bragg grid about an angle 2Θ B and is conducted to outlet 45 by means of the corresponding optical waveguide. Thus an optical connection is made between the entrance 37 and the outlet 45.
A light beam 57 is deflected about the same angle so that it is guided to the outlet 39 over the optical waveguide 21(11.2), as in the embodiment according to FIG. 1. Consequently an optical connection between the entrance 41 and the outlet 39 is obtained.
Soon the electrode arrangement 9 is deactivated, which results in the absence of the acoustic surface waves necessary for bending, so that the light waves or light beams travel to the outlets diagonally across from the entrances. That means that the entrance 37, for example, is optically connected with the outlet 39.
Thus an optical by-pass circuit is formed in a simple way by combination of two optical switching device shown in FIG. 1.
FIG. 3 allows for detection so that the optical wave must be spread out with the acoustic surface waves in the region acting to cause the deflection, so that they extend laterally over several grid periods in order to guarantee a high deflection coefficient. An arrangement is provided in which the beam spreading is caused by a "so-called" Horn-Taper structure. The light beam or wave is reduced again in its lateral extent to its original width by inverse structuring at the outlet side of the optical waveguide crossing point.
The disclosure in German Patent Application 196 16 934.8 of Apr. 27, 1996 is incorporated here by reference. This German Patent Application also discloses the invention described above and claimed in the claims appended hereinbelow and forms the basis for a claim of priority for the instant invention based on 35 U.S.C. 119.
While the invention has been illustrated and described as embodied in a optical switching device, it is not intended to be limited to the details shown, since various modifications and changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
What is claimed is new and is set forth in the following appended claims.
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The optical switching device includes an optical layer (5) provided with at least one optical waveguide (11) having an entrance (13) and an outlet (15) and at least one other optical waveguide (21) provided in the optical layer (5) with another outlet (23); a piezoelectric layer (7) arranged on the optical layer (5); electrodes (9) for producing an acoustic wave provided on the piezoelectric layer (7); and a device for performing a Bragg light deflection with optical frequency shift by one of activating and deactivating the electrodes to optically couple the entrance (13) of the at least one optical waveguide (11) with one or the other of the outlets (15, 23). The invention also relates to an optical by-pass circuit which is a combination of two optical switching devices.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is generally directed to methods and devices for testing painted surfaces to detect the type of paint, i.e. oil or water base, and presence of mildew or lead in or on the painted surface. More particularly, the invention is directed to reliable, environmentally safe and economically disposable swabs or packets which include opposing impregnated patches or pads at least one of which is surrounded by adhesive areas. The packets are retained within a non-porous airtight and resealable wrapper until opened for use. Once used, the opposing pads are closed upon one another for disposal and are retained closed by the adhesive areas surrounding one of the pads. The used packets may further be sealed for disposal in the resealable wrapper or pouch.
2. History of the Related Art
It is extremely important in preparing to repaint previously coated surfaces such as walls, ceilings, doors and window frames in both domestic and commercial structures, what type of existing coating is present, i.e. whether the previously applied paint is an oil base or water base paint. The type of existing paint will dictate what types of coatings can be applied over the existing painted surfaces and/or what additional preparation, treatment or replacement of the existing surface materials may be necessary. Currently there are no readily available or reliable consumer products which permit tests to be quickly, easily and economically made to determine what type of paint is present and whether or not lead or mildew may be present. If lead or mildew is present, surfaces must be replaced or treated prior to repainting.
U.S. Pat. No. 5,039,618 to Stone discloses a test swab cartridge and method for detecting lead and cadmium in paint. However, the use of a cartridge device requires the breaking of an internal cartridge to allow reagents to mix with fillers. In some instances, the reference discloses two internal cartridges which must be broken so that the reagents therein are mixed before the swabs can be used to test surfaces for lead or cadmium. The problem with these approaches is that they require an excess amount of reagents. Due to the strong acidic nature of some reagents, such devices are potentially toxic and hazardous to individuals.
U.S. Pat. No. 3,974,678 describes a testing device used to "determine the cure of a film or the like on a test panel." The tester is composed of a clamp for holding the panel to be tested, a weight to be placed on the panel, a quantity of absorbent material secured to the weight and a drive mechanism including an elongated reciprocally shiftable member having a distal end at which the weight is attached. The absorbent material is saturated with a supply of a predetermined chemical, corresponding to the test for which the cure of the film is to be determined. A control element is provided to cause a repetitious rubbing action on the film. As can be seen, this testing method is very complex and expensive due to the cost of equipment, setup time and the time to perform a test.
In direct contrast to the case of such limited prior art for testing for paint, the prior art for mildew testing is filled with various agents, substances or chemicals which are used to identify, remove or eliminate mildew. However, many of the agents, substances or chemicals have major shortcomings, including from at least one to almost all of the following unfavorable characteristics: very toxic, difficult to use, complex in composition, relatively expensive, requires special handling, requires special storage procedures or containers, requires special disposal procedures.
Other testing methods and procedures require access to a variety of chemical agents, cloths, wiping pads and other materials, the use of which are not practical and/or potentially hazardous. Also, prior art testing methods have not adequately addressed the need for safe disposal of testing chemicals and materials.
SUMMARY OF THE INVENTION
The test swab packets in the preferred embodiment are adhered or sealed about their periphery and include a first inner surface having a test pad material secured thereto which is substantially bordered by an adhesive area which is used to secure the test patch against a painted surface. The other portion of the inner surface of the packet is utilized as a covering surface and in some instances may include a second testing or cleaning pad material which is protected and isolated from the opposite test pad by a film or covering mounted therebetween. In the preferred embodiment, the two sections of the patch are in opposing relationship with respect to one another and are separable along at least three sides by partially perforated edges. Once used, the sides of the packets are folded upon one another and are retained closed by the adhesive areas adjacent one of the test pads. In some embodiments, the packets may be provided with a flange or strip for facilitating opening of the two sides of the packets.
The test pad areas of the swab packets may be impregnated with an isopropyl rubbing alcohol when used to determine whether or not an existing paint is a water base or oil base paint. If a test is being conducted to determine the presence of lead, the test pad will be impregnated with a substance which changes color in response to the presence of lead such as citric acid. In those instances where the swabs are being utilized to test for mildew, the pad may be impregnated with a household bleach.
In practicing the invention, the packets are opened to expose the impregnated test pads and thereafter the packets are adhered utilizing the adhesive material surrounding one of the test pads to the surface to be tested. Depending upon whether the test is being made for mildew, lead or the type of paint, i.e. water base or oil base, the pad will remain secured to the wall for different periods of time up to approximately 15 minutes. Once a test has been completed, a change in color of the pads will give the appropriate indication as to what substance or type of paint are present. Thereafter, and without having to contact the impregnated test pad areas, the swab packets are closed upon themselves and are retained closed by the adhesive strips associated therewith.
It is the primary object of the present invention to provide economical and simple testing devices and methods for determining the existing paint coatings on surfaces including walls, ceilings, doors and window frames without having to expose an individual to contact with a testing reagent chemical or toxic substance.
It is yet another object of the present invention to provide testing swabs and testing devices for determining the presence of lead or mildew and or determining the type of paint applied to a surface which includes a packet having an adhesive strip associated therewith for mounting the testing swab against the surface to be tested and which, after a test is made, allows the swab to be closed upon itself for safe disposal.
It is yet a further object of the present invention, to provide a testing device which may be economically made available for use by individuals, including homeowners, so that tests can be easily made with respect to determining whether or not lead is present on a surface so that steps may be taken to have the lead sealed or removed prior to repainting a given surface area.
It is a further object of the present invention to provide a swab testing device which may be readily disposed in a safe manner and which is usable without having to expose an individual to contact with a chemical agent and which will give generally immediate results with respect to indicating the presence of lead, mildew or the type of paint coating a particular surface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a pouch for enclosing testing swab packets of the present invention.
FIG. 2 is a front elevational view of a testing swab packet of the present invention in a closed configuration.
FIG. 3 is a front elevational view of the swab packet of FIG. 2 shown in open configuration having two testing pads, one surrounded by an adhesive strip.
FIG. 4 is an illustrational view showing the testing swab of FIG. 3 being applied to a surface area.
FIG. 5 is an enlarged partial cross sectional view of the primary pad and covering material of the swab packet of FIG. 3.
FIG. 6 is an enlarged cross sectional view of the embodiment of FIG. 5 showing the pad secured to a surface being tested.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made to the preferred embodiment of the invention. With reference to the drawings, FIG. 1 illustrates a first embodiment including an outer wrapper or bag-like container 1 used to hold the various types of identification testing swabs. The wrapper includes an adhesive resealing strip 5 which, after the test swabs have been used, provides for a simple, safe and quick disposal container for the swabs.
Shown in FIG. 1 are the three specific identification test swab packets covered in this preferred embodiment of the invention: the swab packet for testing for the presence of water base paint 2, the swab packet for testing the presence of mildew 3, and the swab packet for testing for the presence of lead 4.
Each test swab packet, as shown in FIG. 2, includes front and rear portions having edges 11 which are adhered or sealed to each other. The front of the packet has a tear open flap 6 with a pull tab 9 which allows access to a primary test pad 8 and a secondary test pad 7 which are contained within the packet. The secondary pad 7 is attached to the inside front of the tear open flap 6 and the primary pad 8 is attached to the inside of the rear portion of the airtight packet. Lines of weakness 6' are provided in the front portion to facilitate separation of the flap 6. Such lines are provided along the upper and side portions of the front portion of the packet. It is preferred that the flap remain connected to the front cover along the lower edge.
The two pads are saturated with a predetermined substance depending on the type of test and the method to be used. For example, the primary swab pad 8 could contain a reagent and the secondary swab pad 7 a filler, or the secondary swab pad 7 could contain a cleaning compound and the primary swab pad 8 a mild acid.
To determine the presence of water base paint, the user first wipes the secondary swab pad 7 across a small area of the surface being tested in order to clean the test area. Next the user wipes the primary swab pad 8, across the same test area. The user visually observes the surface of the test swab pad 8. If the swab pad contains paint pigment of the same color as the surface being tested, the test is positive and the paint on the surface tested is water base. If there is no paint pigment on the test swab pad 8 the test is negative and the paint on the surface is non-water base. In this embodiment, both the secondary swab pad 7 and the primary swab pad 8 are impregnated with a common household chemical, isopropyl alcohol, which is non-toxic and completely safe to use, as the predetermined saturating substance.
To determine the presence of mildew, both the primary swab pad 8 and the secondary swab pad 7 can be used as primary pads 8. Both are saturated with household bleach, which is non-toxic and completely safe to use, as the predetermined saturating substance. This allows the user to test two separate surfaces, or to test two separate areas on the same surface for the presence of mildew. The test swab pad 8 is first dabbed or tapped--but not rubbed--on a test area where there is a foreign substance that looks like dirt or mildew. After several minutes, the user makes a visual inspection of the test area. If the test is positive, a black, green or brown substance on the surface being tested will have vanished or will have changed color dramatically, indicating the presence of mildew. If the test is negative, there will be little or no observable change to the substance on the tested surface area, indicating the absence of mildew.
With reference to FIG. 3, when the airtight packet is opened using the pull tab 9 to open the tear open flap 6, the secondary swab pad 7 which is attached to the tear open flap 6, is exposed. The primary swab pad 8 is sealed and covered by a protective film 13 as illustrated in FIG. 4. The primary swab pad 8 has an adhesive 10 around it's periphery which is a means of holding the swab pad to the test surface, in a vertical, horizontal or inverted position for a predetermined amount of time dependent on the predetermined acidic or other saturated substance used in the primary swab pad 8. As illustrated in FIGS. 5 and 6, the primary swab pad 8 includes projections 15 that form air channels 14 to allow air to get to a test surface such as a wall "W".
In testing for lead, the user makes a small scratch, deep enough to penetrate all of the layers of surface coatings on the material being tested. If there is a surface coating such as a glaze on pottery, a small chip is made to remove the glaze. The secondary swab pad 7 is applied to the test area to remove dirt and other substances. Next, the primary swab pad 8 is stuck to the test area in contact with the scratch by means of the adhesive 10, as shown in FIGS. 5 and 6. Due to the air channel vents 14, oxygen can reach the test area under the primary swab pad 8. The primary swab pad 8 is left in place for a predetermined period of time, such as 15 minutes. Thereafter, the primary swab pad 8 is removed from the test surface and visually inspected. If there is a color change on the surface of the test swab pad 8, the test is positive and indicates the presence of lead in one of the layers of coatings on that surface. If the color on the surface of the test swab is unchanged, the test is negative.
In this embodiment, the secondary swab pad 7 is impregnated with a common household chemical, isopropyl alcohol, which is non-toxic and completely safe to use, as the predetermined saturating substance. The primary swab pad 8 is impregnated with a mild acid, such as citric acid, which is non-toxic and safe for the user.
Both the primary swab pad 8 and secondary swab pad 7, as presented in the drawings contained herein, are shown to have as their relative shape a square or rectangle for the purposes of illustration. However, in actual use, the swabs will have any shape including but not limited to: circles, triangles, trapezoids and irregular shapes. Once a test has been completed, the two sections supporting the test pads are folded upon one another and adhered to one another by the adhesive 10. The adhesive layer will seal any chemical reagent or material removed during the test process. This permits the safe disposal of the chemical reagent and any lead which may have been detected without allowing the materials to be touched by an individual's hand. It is preferred to thereafter place the used packets in the exterior pouch for further safety.
The present invention provides a very safe, economical and readily disposable testing device for indicating the presence of mildew or lead on a painted surface and also for determining the type of paint, i.e. either water base or non-water base, which has been applied to the surface. By determining the types of paints and the potential for problems with mildew and lead, the safe covering, repainting, papering or other treatment of a previously covered surface may be undertaken without detrimental results.
The foregoing description of the preferred embodiments of the invention has been presented to illustrate the principles of the invention and not to limit the invention to the particular embodiments illustrated. It is intended that the scope of the invention be defined by all of the embodiments encompassed within the following claims, and their equivalents.
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A testing apparatus and method for the immediate testing of painted surfaces to determine the type of paint and/or presence of mildews or lead wherein the apparatus includes an outer resealable wrapper and at least one test packet including a secondary swab saturated with a first predetermined substance and a primary swab saturated with a second predetermined substance. The primary swab has an adhesive border which permits the test pouch to be temporarily adhered to a surface being tested.
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This application is a continuation of application Ser. No. 47,846 filed May 8, 1987, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a method for converting lower grade, high-melt-point uintaite into higher grade, lower-melt-point materials. The method comprises three steps. In the first step, low-grade, high-meltpoint uintaite is first dissolved in a medium polarity solvent and then blended with a nonpolar saturated hydrocarbon at a volume ratio that determines the meltpoint of the final upgraded uintaite product. In the second step, residual asphaltenes are removed from the solvent-uintaite mixture. In the third step, the solvent is separated from the asphaltene-free uintaite mixture and is recycled to produce an upgraded uintaite having a desirable meltpoint.
In particular, I have found that the proportion of nonpolar saturated hydrocarbon to uintaite solution determines the amount of asphaltenes removed and therefore the meltpoint of the resulting product. When I used a 20:1 volume ratio, all of the asphaltenes were removed resulting in a uintaite which has a meltpoint nearly 100° F. below the highest grade of naturally occurring uintaite.
Uintaite is a kind of natural asphalt mined in Utah and Colorado in the United States and obtained as dark and brilliant solid in a fairly pure state. Uintaite is thought to be a thermally immature lacustrine petroleum derived from Green River shale source rock by a natural expulsion process. Uintaite has a penetration of 0-1 and a softening point of about 140° C.; also, its hardness is very high. It has extremely low adhesiveness so that it can be readily pulverized into non-sticky particles. Moreover, uintaite is highly miscible or compatible with other asphalts, paint solvents, etc., and has high weather-resistance.
Researchers in the field have disclosed many methods for extracting various fractions from bituminous materials. The most well known of these is "propane extraction" in which asphaltic materials are extracted from heavy hydrocarbons by a single solvent extraction step using propane. For example, U.S. Pat. No. 2,726,192 to Kieras discloses extracting propane precipitated asphalts with n-butanol in the range of 20:1. Kieras teaches that the temperature of the extract is progressively lowered to produce the desired resin fractions.
U.S. Pat. No. 2,940,920 discloses that solvents other than propane can be used to separate heavy hydrocarbon materials into at least two fractions at a greatly improved rate of separation and in a manner which eliminates certain prior art operating difficulties encountered in the use of propane type solvents (C 2 to C 4 hydrocarbon solvents). That patent discloses effecting the separation by using high temperature-pressure techniques and by using pentane as one of a group of suitable solvents. Such practice permits a deeper cut to be made in the heavy hydrocarbon material, but as a consequence, more resinous bodies are present in the resulting oil fraction, tending to decrease the quality of that oil.
U.S. Pat. No. 3,830,732 discloses a two-solvent extraction process for producing three fractions from a hydrocarbon charge stock containing asphaltenes, resins and oils. The charge stock is admixed with a first solvent in a volumetric ratio of solvent to charge stock of less than about 4:1 to form a mixture that is introduced into a first extraction zone maintained at an elevated temperature and pressure. The mixture separates within the first extraction zone to produce a first solvent-rich liquid phase containing oils which are free of asphaltenes and resins and a first solvent-lean liquid phase containing asphaltenes and resins. The solvent-lean liquid phase then is contacted with a second solvent containing at least one more carbon atom per molecule than the first solvent and introduced into a second extraction zone. The second extraction zone is maintained at a lower temperature and pressure than the first extraction zone to separate the solvent-lean liquid phase into a second solvent-rich liquid phase containing resins and a second solvent-lean liquid phase containing asphaltenes.
U.S. Pat. No. 3,775,292 discloses a similar process employing a two-stage solvent extraction. There, the solvent-rich fraction which contains resins and oils is admixed with additional solvent and introduced into a second extraction zone maintained at a temperature higher than in the first extraction zone. The solvent-rich phase is separated into a second solvent-rich phase comprising oils and a second solvent-lean fraction comprising resins.
It would be desirable to provide a method in which solvent extraction can be used to convert low-grade uintaite into high-grade uintaite. Accordingly, it is the principle object of this invention to provide such a method.
SUMMARY OF THE INVENTION
The invention concerns a method for upgrading low-grade uintaite to high-grade uintaite to produce a desired meltpoint of the upgraded uintaite. It comprises: (a) dissolving the uintaite in a medium polarity solvent; (b) mixing the product of step (a) with a nonpolar saturated hydrocarbon solvent at a volume ratio of dissolved uintaite to nonpolar saturated hydrocarbon solvent to produce the desired meltpoint; (c) separating residual asphaltenes from the product of step (b); and (d) heating the product of step (c) to recover said medium polar solvent and said nonpolar saturated hydrocarbon solvent to produce an upgraded uintaite product having a desirable melting point.
In a preferred embodiment, the method for upgrading low-grade uintaite to high-grade uintaite of a desired meltpoint comprises: (a) dissolving the uintaite in a medium polarity solvent comprising methylene chloride; (b) mixing the product of step (a) with a nonpolar saturated hydrocarbon solvent comprising hexane, wherein said solvent is present in a ratio of about 20:1; (c) separating residual asphaltenes from the product of step (b); (d) treating the product of step (c) to recover said medium polar solvent and said nonpolar saturated hydrocarbon solvent to produce a solid maltene fraction; and (e) dissolving the maltene fraction of step (d) in a medium polarity solvent comprising methylene chloride with a lower grade uintaite or a fraction of asphaltene, recovered in step (c), in a ratio to produce a uintaite product having the desired meltpoint.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic illustration of the process of this invention.
FIG. 2 is a diagrammatic illustration of the process of this invention depicting mixing solid maltene into dry lower grade uintaite to obtain an upgraded uintaite of a desired, predetermined meltpoint.
FIG. 3 is a diagrammatic illustration of the process of this invention depicting mixing dissolved maltene into dissolved lower grade uintaite.
FIG. 4 is a plot depicting the relationship between the solvent ratio to the final meltpoint of the upgraded uintaite product.
FIG. 5 is a plot depicting the relationship between the weight percent of maltenes to the meltpoint of the upgraded uintaite product.
FIG. 6 is a diagrammatic illustration of the process of this invention depicting mixing dissolved maltene with dissolved asphaltene from the separation zone.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to FIG. 1, the method of the present invention is illustrated. A feedstock comprising a lowgrade uintaite is introduced into a first solvent zone 12 through a conduit 10. A medium polarity solvent is introduced into first solvent zone 12 through a conduit 14 to contact and dissolve the feed to provide a mixture. The medium polarity solvent has a high enough boiling point so that it easily separates from the low-boiling saturated hydrocarbon solvent used in the second solvent zone, but has a low enough boiling point, so as not to incur excessive energy costs during separation. It is generally selected from the group consisting of methylene chloride, benzene, toluene and refinery distillation cuts comprising benzene, toluene, or xylene. The most preferred solvent is a refinery distillation cut comprising benzene, toluene, or xylene. Sufficient solvent is introduced into first solvent zone 12 to thoroughly dissolve the feed. It is to be understood that larger quantities of solvent may be used, but such use is unnecessary.
The mixture is withdrawn from first solvent zone 12 and introduced into a second solvent zone 18 via a conduit 16. A saturated hydrocarbon solvent is introduced into the second solvent zone 18 through a conduit 20 to provide a ratio by volume of feed to saturated hydrocarbon solvent in the mixture in the range of from about 1:2 to about 1:20 and preferably in the range of from about 1:5 to about 1:10. The proportion of nonpolar saturated hydrocarbon solvent to uintaite solution determines the amount of asphaltenes removed and therefore, the meltpoint of the resulting product. It is controlled by proportioning valve 20A. A 1:20 ratio, or greater, removes all asphaltenes, resulting in the lowest meltpoint uintaite possible.
The saturated hydrocarbon solvent is a lowboiling normal paraffinic hydrocarbon which can be easily separated from the medium polarity solvent of the first solvent zone. It is generally selected from the group consisting of pentane, hexane, heptane and refinery distillation cuts comprising pentane, hexane and heptane. The most preferred solvent is a refinery distillation cut comprising pentane, hexane, or heptane.
The mixture is withdrawn from the second solvent zone 18 and introduced into the separation zone 24 via a conduit 22. The separation zone 24 is maintained at an elevated temperature and pressure to effect a separation of the mixture into a fluid-like light phase comprising maltenes and solvent and a solid particular slurry phase comprising asphaltenes and some solvent which exits the separation zone 24 through conduit 26.
The separated light phase is withdrawn from the separation zone 24 through a conduit 28 and introduced into the solvent recovery zone 30. The solvent recovery zone 30 is maintained at an elevated temperature and pressure to effect a separation of the light phase into second and third light phases. The order of solvent removal is determined by the relative boiling points of the saturated hydrocarbon and medium polarity solvent used. In general, the second light phase is lower boiling than the third light phase and comprises the saturated hydrocarbon solvent which is withdrawn from the solvent recovery zone 30 through a conduit 32 for recycle to the second solvent zone 18 to aid in the preparation of the mixture produce therein. The third light phase comprises the medium polar solvent which is withdrawn from the solvent recovery zone 30 through a conduit 34 for recycle to the first solvent zone 12 to aid in the preparation of the mixture produced therein.
The upgraded uintaite solid is withdrawn from the solvent recovery zone 30 through conduit 36 and recovered.
Turning now to FIG. 2 an alternate embodiment of the present invention is illustrated. In this embodiment, the weight proportion of low-grade uintaite to upgraded uintaite determines the meltpoint of the resulting product. The upgraded uintaite solid is introduced into a solids mixing zone 38 through conduit 36. A low-grade uintaite feed is introduced into the mixing zone 38 through conduit 40 to contact and admix with the upgraded uintaite to produce a homogeneous mixture.
The solid mixture is withdrawn from the mixing zone 38 through a conduit 42 and introduced into third solvent zone 44.
A medium polarity solvent is introduced into third solvent zone 44 through a conduit 46 to contact and dissolve the solid mixture. The medium polarity solvent is the same as in the first solvent zone. Sufficient solvent is introduced into third solvent zone 44 to thoroughly dissolve the feed. Larger quantities of solvent may be used, but such use is unnecessary.
The mixture is withdrawn from the third solvent zone 44 through a conduit 48 and introduced into the second solvent recovery zone 56. The second solvent recovery zone 56 is maintained at an elevated temperature and pressure to effect a separation of the mixture into two light streams and one heavy stream. The light streams are recovered through conduits 60 and is recycled to the third solvent zone to aid in the preparation of mixture produced therein.
The upgraded uintaite solid is withdrawn from the solvent recovery zone 56 through conduit 62 and recovered.
Turning now to FIG. 3, a second alternative embodiment of the present invention is illustrated. In this embodiment, a feedstock comprising a low-grade uintaite is introduced into a first solvent zone 12 through a conduit 10. A medium polarity solvent comprising toluene is introduced into first solvent zone 12 through a conduit 14 to contact and dissolve the feed to provide a mixture. Sufficient solvent is introduced into first solvent zone 12 to thoroughly dissolve the feed. Larger quantities of solvent may be used, but such use is unnecessary.
The mixture is withdrawn from first solvent zone 12 and introduced into a second solvent zone 18 via a conduit 16. A saturated hydrocarbon solvent comprising pentane is introduced into the second solvent zone 18 through a conduit 20 to provide a ratio by volume of feed to saturated hydrocarbon solvent in the mixture in the range greater than 1:10 and preferably in the range of from about 1:15 to about 1:20. Larger quantities of solvent may be used but such use is unnecessary.
The mixture is withdrawn from the second solvent zone 18 and introduced into the separation zone 24 via a conduit 22. The separation zone 24 is maintained at an elevated temperature and pressure to effect a separation of the mixture into a fluid-like light phase comprising maltenes and solvent and a fluid-like heavy phase comprising asphaltenes and some solvent which exits the separation zone 24 through conduit 26.
The separated light phase is withdrawn from the separation zone 24 through a conduit 28 and introduced into the first solvent recovery zone 29. The first solvent recovery zone 29 is maintained at an elevated temperature and pressure to effect a separation of the saturated hydrocarbon solvent.
The saturated hydrocarbon solvent is withdrawn from the first solvent recovery zone 29 through a conduit 31 for recycle to the second solvent zone 18 to aid in the preparation of the mixture produced therein.
A feedstock comprising a low-grade uintaite is introduced into a third solvent zone 37 through a conduit 35. A medium polarity solvent, comprising toluene is introduced into the third solvent zone 37 through a conduit 39 to contact and dissolve the feed to provide a mixture. Sufficient solvent is introduce into the third solvent zone 37 to thoroughly dissolve the feed.
The dissolved uintaite from the first solvent recovery zone 29 is withdrawn via conduit 33 and introduced into mixing zone 43. The dissolved uintaite from the third solvent zone 37 is withdrawn via conduit 41 and introduced into mixing zone 43 where it is admixed with the dissolved uintaite from the first solvent recovery zone 29. By using proportioning valve 41A to control the ratio of upgraded uintaite to low-grade uintaite, the desired meltpoint of the final upgraded uintaite product can be achieved.
The mixture of dissolved uintaites is withdrawn from the mixing zone 43 and introduced into the second solvent recovery zone 49 via conduit 47. The second solvent recovery zone 49 is maintained at an elevated temperature and pressure to effect a separation into a light stream and a heavy stream. The light stream comprises the medium polar solvent which is withdrawn from the second solvent recovery zone 49 through a conduit 53 for recycle to the third solvent zone 37 to aid in the preparation of the mixture produced therein. Alternatively, the medium polarity solvent can be recycled to the first solvent zone 12 via conduit 57.
The upgraded uintaite solid is withdrawn from the solvent recovery zone 49 through conduit 55 and recovered. Turning now to FIG. 6, another alternative embodiment of the present invention is illustrated. This embodiment is similar to that disclosed in FIG. 3 except that a portion of the asphaltenes 26, from the separation zone 24, is the low grade uintaite feed (35) that is introduced into the third solvent zone 37.
To further illustrate the process of this invention and not by way of limitation, the following examples are provided.
EXAMPLES
Example 1
A natural uintaite (Harrison Vein, CRC 42504-1) of meltpoint 346° F. (determined by ASTM No. E-28-67) was dissolved in a minimum volume of a medium polarity solvent (methylene chloride). This solution was then added to n-hexane at the various volume to volume ratios shown in FIG. 4. The heavy component enriched in uintaite asphaltenes was allowed to settle from each mixture and each upper liquid phase enriched in uintaite maltenes was decanted off. The solvents were removed from each upper liquid phase leaving a solid modified uintaite enriched in maltenes. The meltpoint of each modified uintaite was determined by ATM No. E-28-67 and the results plotted in FIG. 4 as a function of the n-hexane/uintaite solution volume to volume ratio used in the processing. FIG. 4 shows that as greater volume to volume ratios are used, lower meltpoint (higher grade) modified uintaites are produced. When solvent ratios greater than 7/1 are used, the resulting modified uintaite product has meltpoints lower than any natural uintaite. When solvent volume ratios of 20:1 are used, the lowest possible meltpoint (180° F.) product is obtained: higher solvent ratios did not lower product meltpoint further in this case. Moreover, FIG. 4 shows that by selecting a specific processing volume ratio, uintaite of a desired (predetermined) meltpoint can be obtained.
Example 2
Processed uintaite of meltpoint 180° F. (prepared as described in Example 1), referred to as uintaite maltenes below, was mixed with uintaite asphaltenes (recovered as a byproduct of the Example 1 process) in the various weight to weight ratios shown in FIG. 5. In this example, the uintaite asphaltenes are equivalent to a low-grade uintaite. The various asphaltene-processed uintaite mixtures were each thoroughly dissolved in a minimum volume of toluene. The toluene was then removed under reduced pressure and the meltpoint of the resulting solid product was measured using ASTM No. E-28-67. FIG. 5 shows that at the weight proportion of maltene to asphaltene is increased a product of improved, lower meltpoint is obtained. FIG. 5 shows that by choosing specific weight to weight ratios, uintaite products of a desired (predetermined) meltpoint can be prepared. Moreover, this process could be used to improve meltpoint characteristics of stocks of lower grade uintaite materials.
The foregoing examples illustrate the effectiveness of the present invention in reducing the melting point of uintaite and therefore producing an upgraded uintaite product.
While the invention has been described with respect to what at present are preferred embodiments thereof, it will be understood, of course, that certain changes, substitutions, modifications and the like may be made therein without departing from its true scope as defined in the appended claims.
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I disclose a method for upgrading low-grade uintaite to high-grade uintaite having a desired meltpoint. It comprises dissolving the uintaite in a medium polarity solvent, mixing the dissolved uintaite with a nonpolar saturated hydrocarbon solvent at a volume-to-volume ratio that determines the meltpoint of the upgraded uintaite product, separating residual asphaltenes from the mixture, and recovering the medium polarity solvent and nonpolar saturated hydrocarbon to produce an upgraded uintaite having the desired meltpoint.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and benefit of from Korean Patent Application No. 10-2015-0086875, filed on Jun. 18, 2015, the disclosure of which is incorporated herein in its entirety by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to dryers, and more particularly, to air flow path configurations in dryers.
BACKGROUND OF THE INVENTION
[0003] In general, a drum-type washing machine has the dual functions of washing and drying laundry.
[0004] FIG. 1 shows a configuration a drum-type washing machine. It includes a dryer 30 configured to capture moist air from a tub 20 and return high-temperature and dry air back into the tub 20 . The tub 20 includes a drum 21 for accommodating laundry.
[0005] The dryer 30 includes a condensing duct 40 with one side coupled to the tub 20 ; a blast fan 50 coupled to the other side of the condensing duct 40 ; and a drying duct 60 with one side coupled to the condensing duct 40 via the blast fan 50 and the other side coupled to the tub 20 . The drying duct 60 includes a heater 70 embedded therein. The moist air in the tub 20 is captured into the condensing duct 40 and is condensed and turned into low-temperature dry air. The condensed low-temperature dry air is transformed into high-temperature dry air by the heater 70 within the drying duct 60 . The high-temperature dry air is then introduced into the drying duct 60 via the blast fan 50 and supplied back to the tub 20 .
[0006] FIG. 2 is a diagram illustrating the configuration of a condensing duct 40 in a conventional drum-type washing machine 10 shown FIG. 1 . Damp air flows from the tub 20 to the condensing duct 40 through an inlet 41 and comes into contact with cooling water flowing in the condensing duct 40 . The damp air is cooled off by the cooling water and thus condensed. The damp air with reduced humidity is discharged to the drying duct 60 through an outlet 42 and the blast fan 50 .
[0007] In the condensing duct having the above-described structure, the contact time between the air and the cooling water may not be long enough to allow the air to be condensed sufficiently. To solve this problem, Korean Patent Laid-open publication No. 10-2012-0073583 discloses a technique of improving the drying effect by providing a bypass to increase a contact time between air flowing within the condensing duct and cooling water supplied into the condensing duct. The drawback to this technique is that the air and the cooling water come into direct contact with each other, and the cooling water may be drawn into the drying duct when the air is sucked into the drying duct from the condensing duct by the blast fan. However, the cooling water vapor may cause unwanted corrosion of various components, such as the blast fan, the drying duct and other components. Furthermore, the vapor may return to the tub through the blast fan and the drying duct and consequently counteract the drying efficiency.
SUMMARY OF THE INVENTION
[0008] Embodiments present disclosure provides a drying assembly capable of improving drying effect by increasing a contact area between air and cooling water while adopting a non-contact type drying mechanism. The air and the cooling water do not come into direct contact with each other. Thus, the drying assembly and adjacent components can be protected from being corroded by water vapor. Further, the present disclosure also provides a manufacturing method for the drying assembly.
[0009] However, the problems sought to be solved by the present disclosure are not limited to the above description and other problems can be clearly understood by those skilled in the art from the following description.
[0010] In accordance with an exemplary embodiment of the present disclosure, there is provided a drying assembly comprising: a tub which can contain wash water therein; a condensing duct coupled to one side of the tub and having therein an empty space through which air flows; an air inlet opening which is provided at one side of the condensing duct coupled to the tub, and through which the air is introduced into the condensing duct; an air outlet opening which is provided at the other side of the condensing duct opposite from the one side coupled to the tub, and through which the air is discharged out of the condensing duct; a blast fan provided at the other side of the condensing duct where the air outlet opening is provided, a drying duct one side of which is coupled to the blast fan and the other side of which is coupled to the tub; a heater provided within the drying duct; and a rib provided within the condensing duct and having therein a hollow space into which the cooling water is introduced.
[0011] In one embodiment, the rib may have a spiral shape.
[0012] In one embodiment, the rib may further include an inlet through which the cooling water is introduced into the hollow space and an outlet through which the cooling water is discharged out of the hollow space.
[0013] In one embodiment, the drying assembly may further comprise a cooling water storage unit including a storage tank for storing the cooling water therein, a cooling water injection port and a cooling water discharge port, wherein the cooling water is supplied into the hollow space within the rib from the storage tank through the cooling water injection port which is coupled to the inlet of the rib, and the cooling water is discharged out into the storage tank from the hollow space within the rib through the cooling water discharge port which is coupled to the outlet of the rib.
[0014] In one embodiment, the cooling water injection port may be disposed at a lower end portion of the cooling water storage unit, and the cooling water discharge port may be disposed at an upper end portion of the cooling water storage unit.
[0015] In one embodiment, the air inlet opening may be disposed at a lower end portion of the condensing duct, and the air outlet opening may be disposed at an upper end portion of the condensing duct.
[0016] In accordance with another exemplary embodiment of the present disclosure, a manufacturing method for a drying assembly comprises: installing a rib having a hollow space therein, and provided with an inlet through which cooling water is introduced into the hollow space and an outlet through which the cooling water is discharged out of the hollow space; installing a condensing duct having an empty internal space in which the rib is installed, and provided with an air inlet opening through which air is introduced and an air outlet opening through which the air is exhausted; coupling a tub to one side of the condensing duct where the air inlet opening is provided; and coupling a blast fan to the other side of the condensing duct where the air outlet opening is provided; and coupling one side of a drying duct equipped with a heater to the blast fan and the other side to the tub.
[0017] In one embodiment, the manufacturing method may further comprise installing a cooling water storage unit which includes a storage, a cooling water injection port and a cooling water discharge port and is configured to circulate the cooling water through the hollow space within the rib, and installing the cooling water injection port to the inlet of the rib, and coupling the cooling water discharge port to the outlet of the rib.
[0018] According to the exemplary embodiment of the present disclosure, by adopting the non-contact type drying mechanism in which the air and the cooling water do not come into contact with each other, the drying assembly and components around it can be advantageously protected from being corroded by moisture, and drying efficiency can be improved.
[0019] The foregoing is a summary and thus contains, by necessity, simplifications, generalizations and omissions of detail; consequently, those skilled in the art will appreciate that the summary is illustrative only and is not intended to be in any way limiting. Other aspects, inventive features, and advantages of the present invention, as defined solely by the claims, will become apparent in the non-limiting detailed description set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Embodiments of the present invention will be better understood from a reading of the following detailed description, taken in conjunction with the accompanying drawing figures in which like reference characters designate like elements and in which:
[0021] FIG. 1 shows a configuration a conventional drum-type washing machine;
[0022] FIG. 2 is a diagram illustrating the configuration of a condensing duct 40 in the conventional drum-type washing machine shown FIG. 1 ;
[0023] FIG. 3 illustrates the configuration of an exemplary drying assembly according to an embodiment of the present disclosure;
[0024] FIG. 4 illustrates an exemplary condensing duct enclosing a rib according to an embodiment of the present disclosure;
[0025] FIG. 5 is a cross sectional view of the rib inside the condensing duct of FIG. 3 and FIG. 4 ;
[0026] FIG. 6 is a diagram illustrating an exemplary condensing duct coupled to a cooling water storage unit according to an embodiment of the present disclosure;
[0027] FIG. 7 is a flowchart describing an exemplary manufacturing method of a drying assembly according to an embodiment of the present disclosure.
DETAILED DESCRIPTION
[0028] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the preferred embodiments, it will be understood that they are not intended to limit the invention to these embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the appended claims. Furthermore, in the following detailed description of embodiments of the present invention, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be recognized by one of ordinary skill in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure aspects of the embodiments of the present invention. The drawings showing embodiments of the invention are semi-diagrammatic and not to scale and, particularly, some of the dimensions are for the clarity of presentation and are shown exaggerated in the drawing Figures. Similarly, although the views in the drawings for the ease of description generally show similar orientations, this depiction in the Figures is arbitrary for the most part. Generally, the invention can be operated in any orientation.
[0029] FIG. 3 illustrates the configuration of an exemplary drying assembly according to an embodiment of the present disclosure. FIG. 4 illustrates an exemplary condensing duct 120 of the drying assembly in FIG. 3 with a rib 150 according to an embodiment of the present disclosure.
[0030] Referring to FIG. 3 and FIG. 4 , the drying assembly 100 includes a tub 110 , the condensing duct 120 , a blast fan 130 , a drying duct 140 , a heater (not shown) and the rib 150 . During operation, the tub 110 contains wash water. A drum (not shown) for accommodating laundry therein is disposed within the tub 110 .
[0031] The condensing duct 120 has a hollow structure and has an air inlet opening 121 directing to the tub 110 and an air outlet opening 122 directing to the blast fan 130 . Damp air flows from the tub through the condensing duct 120 where it is converted to low-temperature dry air through condensation by cooling water. The low-temperature dry air is then discharged to the drying duct 140 via the blast fan 130 .
[0032] The blast fan 130 and the tub 110 are coupled to opposite sides of the condensing duct 120 . The blast fan 130 is configured to discharge the low-temperature dry air from the condensing duct 120 to the drying duct 140 .
[0033] The drying duct 140 has one side coupled to the blast fan 130 and the other side coupled to the tub 110 . The drying duct 140 is configured to convert the low-temperature dry air introduced by the blast fan 130 into high-temperature dry air and then discharge the high-temperature dry air into the tub 110 .
[0034] A heater (not shown) may be embedded in the drying duct 140 and serve to heat the air.
[0035] The rib 150 is hollow and disposed inside the condensing duct 120 and allows the cooling water to flow through. The rib 150 has an inlet 151 on one end for introducing the cooling water into its internal space 153 and an outlet 152 on the other hand for discharging the cooling water.
[0036] The operation of the drying assembly 100 according to an embodiment of the present disclosure is described as follows. Moist air within the tub 110 is drawn into the condensing duct 120 by the blast fan 130 and condenses into low-temperature dry air through heat transfer with cooling water present inside the condensing duct 120 . The condensed low-temperature dry air is driven into the drying duct 140 by the blast fan 130 and turned into high-temperature dry air by the heater (not shown) inside the drying duct 140 . The blast fan 130 then draws the high-temperature dry air from the drying duct 140 back into the tub 110 .
[0037] FIG. 5 is a cross sectional view of the rib disposed inside the condensing duct of FIG. 3 and FIG. 4 .
[0038] Referring to FIG. 4 and FIG. 5 . Damp air is introduced into the condensing duct 120 through its air inlet opening 121 and exchanges heat with cooling water flowing inside the rib 150 in a non-contact manner. That is, the air and the cooling water exchange heat with each other while the air is in contact with an external wall surface 154 of the rib 150 and the cooling water is in contact with an internal wall surface 155 of the rib 150 . As a result, the temperature of the air can decrease. The cooled air can contain less moisture compared to the air before being subjected to the cooling. Thus, the cooled air becomes dry. The low-temperature dry air obtained through this condensation process is then discharged into the drying duct 140 through the air outlet opening of the condensing duct 120 . Since the hollow space 153 within the rib 150 in which the cooling water flows is isolated from the inside of the condensing duct 120 in which the air flows, the blast fan 130 does not draw the cooling water into the drying duct 140 when it draws the air from the condensing duct 120 into the drying duct 140 . As air flowing through the condensing duct does not encounter water vapor generated from the cooling water, the overall drying efficiency of the dryer can be improved. Furthermore, the blast fan 140 , the drying duct 140 and their adjacent components remain protected from corrosion that would have been caused by water vapor in the conventional art, as described above.
[0039] In some embodiments, the rib 150 has a spiral shape, as shown in FIG. 4 . With this spiral shape, a heat exchange area between the cooling water flowing inside the rib 150 and the air flowing inside the condensing duct 120 can be increased, so that drying efficiency can be improved. In addition, the spiral shape prolongs heat exchange time, which further contributes to drying efficiency.
[0040] In this embodiment, the condensing duct 120 of FIG. 4 has the air inlet opening 121 on its lower portion and the air outlet opening 122 on its upper portion. In this configuration, the air flows upward (from the lower end of the condensing duct 120 toward the upper end) is impeded by its gravity, which further prolongs the time for the air travelling through the condensing duct 12 . Thus, the heat exchange time between the air and the cooling water inside the rib 150 also increases. As a result, drying efficiency can be further improved.
[0041] FIG. 6 is a diagram illustrating an exemplary condensing duct coupled to a cooling water storage unit according to an embodiment of the present disclosure.
[0042] Referring to FIG. 6 , a cooling water storage unit 160 is installed within the condensing duct 120 and configured to supply cooling water into the rib 150 . The cooling water storage unit 160 includes: a storage tank 161 for storing cooling water; a cooling water injection port 162 coupled to the inlet 151 of the rib 150 ; and a cooling water discharge port 163 coupled to the outlet 152 of the rib 150 . The cooling water stored in the storage tank 161 is supplied into the rib 150 through the cooling water injection port 162 . The supplied cooling water flows in the hollow space 153 and is then discharged out into the storage tank 161 the rib 150 through the cooling water discharge port 163 which is coupled with the outlet 152 of the rib 150 .
[0043] In this embodiment, the cooling water injection port 162 is disposed on the lower end of the cooling water storage unit 160 , and the cooling water discharge port 163 is disposed on an upper end of the cooling water storage unit 160 . If the cooling water injection port 162 is located above the cooling water discharge port 163 , the cooling water introduced from the cooling water storage unit 160 into the rib 150 would flow downwards from the upper end of the rib 150 toward the lower end. If a flow rate of the cooling water is too low, some region in the hollow space 153 may not be filled with the cooling water. As a consequence, heat exchange between the air and the cooling water within the condensing duct 120 may not be adequate. In this embodiment, however, since the cooling water supplied into the hollow space 153 of the rib 150 from the cooling water storage unit 160 flows upwards from the lower end of the rib 150 toward the upper end, the entire region of the hollow space 153 is filled with the cooling water. Thus, heat exchange between the air and the cooling water within the condensing duct 120 is efficient.
[0044] FIG. 7 is a flowchart for describing an exemplary manufacturing method of a drying assembly according to an embodiment of the present disclosure.
[0045] Referring to FIG. 3 , FIG. 4 and FIG. 7 , the drying assembly 100 has tub 110 and a drum (not shown) for accommodating laundry. The drying assembly 100 includes a condensing duct 120 , a blast fan 130 , a drying duct 140 and a heater (not shown).
[0046] To manufacture the drying assembly 100 according to the exemplary embodiment of the present disclosure, a hollow rib 150 is coupled to an inlet and an outlet used for water to flow in and out (S 100 ). Then, a condensing duct 120 with the rib 150 disposed inside is installed (S 200 ). The condensing duct 120 includes an air inlet opening 121 through which air is injected, and an air outlet opening 122 through which the air is discharged. Then, the tub 110 is coupled to the condensing duct 120 on the side where the air inlet opening 121 is disposed. The blast fan 130 is installed on the other side of the condensing duct 120 where the air outlet opening 122 is located (S 300 ). Then, one side of the drying duct 140 including the heater (not shown) is coupled to the blast fan 130 , and the other end of the drying duct 140 is coupled to the tub 110 (S 400 ).
[0047] According to one exemplary embodiment, a drying assembly 100 may further include a cooling water storage unit 160 . Referring to FIG. 6 , the cooling water storage unit 160 includes a storage tank 161 for storing cooling water therein, a cooling water injection port 162 coupled to an inlet 151 of the rib 150 and a cooling water discharge portion 163 coupled to an outlet 152 of the rib 150 .
[0048] In addition, the cooling water storage unit 160 is installed (S 500 ). The storage unit 160 includes the storage tank 161 , the cooling water injection port 162 and the cooling water discharge port 163 . Then, the cooling water injection port 162 is coupled to an inlet 151 of the rib 150 , and the cooling water discharge port 163 is coupled to an outlet 152 of the rib 150 (S 600 ). Through this process, the drying assembly 100 according to the present exemplary embodiment can be manufactured.
[0049] Although certain preferred embodiments and methods have been disclosed herein, it will be apparent from the foregoing disclosure to those skilled in the art that variations and modifications of such embodiments and methods may be made without departing from the spirit and scope of the invention. It is intended that the invention shall be limited only to the extent required by the appended claims and the rules and principles of applicable law.
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A dryer including an air condensing unit that can use cooling water to reduce air moisture by condensation in a non-contact manner. The air condensing unit includes a condensing duct and a hollow rib enclosed inside the condensing duct. During a drying process, cooling water flows through the hollow rib and, at the same time, air coming from the tub flows through the hollow rib and is cooled off by the cooling water. The cooled air exits the condensing duct and flows back to the tub after travelling through a drying duct that includes a heater.
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BACKGROUND OF THE INVENTION
Until recently, virtually all the oil produced in the world was recovered by primary methods, which relied on natural pressures to force the oil from a petroleum reservoir. Natural pressures within a petroleum reservoir cause oil to flow through the porous rock into wells and, if the pressures are strong enough, up to the surface. However, if natural pressures are initially low or diminish with production, pumps or other means are used to lift the oil. Recovery of oil using natural pressures is called primary recovery, even when the oil has to be lifted to the surface by mechanical means.
As new fields have become increasingly difficult and more costly to find and oil prices have risen, the stimulus to increase recovery from known fields has steadily become stronger. Enhanced oil recovery research has been conducted for many years and commercial application of these procedures is becoming more and more feasible. Enhanced oil recovery processes begin with four basic tools: chemicals, water, gases and heat. Of importance are the in-situ combustion method, which uses heat as a basic tool, and miscible recovery, using carbon dioxide as a basic tool.
The in-situ combustion method produces heat energy by burning some of the oil within the reservoir rock itself. Air is injected into the reservoir and a heater is lowered into the well to ignite the oil. Ignition of the air/crude oil mixture can also be accomplished by injecting heated air or by introducing a chemical into the oil-bearing reservoir rock. The amount of oil burned and the amount of heat created during in-situ combustion can be controlled to some extent by varying the quantity of air injected into the reservoir.
The physics and chemistry of in-situ combustion are extremely complex. Basically, the combustion heat vaporizes the lighter fractions of crude oil and drives them ahead of a slowly moving combustion front created as some of the heavier unvaporized hydrocarbons are burned. Simultaneously, the heat vaporizes the water in the combustion zone. The resulting combination of gas, steam and hot water aided by the thinning of the oil due to the heat and the distillation of the light fractions driven off from the oil in the heated region moves the oil from injection to production wells.
Carbon dioxide miscible recovery may be used, although carbon dioxide may not be initially miscible with crude oil. But, when the carbon dioxide is forced into an oil reservoir, some of the smaller, lighter hydrocarbon molecules in the contacted crude will vaporize and mix with the carbon dioxide, forming a wall of enriched gas consisting of carbon dioxide and light hydrocarbons. If the temperature and pressure of the reservoir are suitable, this wall of enriched gas will mix with more of the crude forming a bank of miscible solvents capable of efficiently displacing large volumes of crude oil ahead of it. Additional carbon dioxide is injected to move the solvent back toward the producing wells.
Traditionally, carbon dioxide is found in underground deposits and can be produced through wells similar to gas wells. Normally, however, the carbon dioxide must be transported to the oil reservoir, which can add significantly to the cost of this enhanced oil recovery process.
Natural gas and air have also been used in the miscible gas injection processes to aid in the secondary recovery of oil from known reservoirs. In addition, chemicals, such as alkalis, polymers and surfactants have been used in conjunction with water flooding to aid in recovery of crude.
A problem with the methods of enhanced oil recovery presently known is that at a given reservoir, only one method of enhanced oil recovery will be used at a time.
SUMMARY OF THE INVENTION
A method for recovering crude oil from multiple reservoir zones is disclosed in the present invention. A plurality of wellbores are drilled into a single reservoir having multiple zones separated by an impermeable barrier, such as shale. Each wellbore is configured to have separate conduits for each recovery zone. One zone uses an in-situ combustion method for enhanced oil recovery. The by-products of this recovery method are processed and carbon dioxide is separated from other gases. The carbon dioxide is forced into another oil zone under pressure to pressurize the zone and produce unrecovered crude.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of a prior art method of enhanced oil recovery.
FIG. 2 is an illustration of enhanced oil recovery from two zones simultaneously.
FIG. 3 is an illustration of an alternate method of enhanced oil recovery from two zones simultaneously.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a typical arrangement for enhanced oil recovery. Although only two oil wells are shown, the illustrated method of enhanced oil recovery is suitable for use on a plurality of wells. Each of the two wells illustrated represent one of two functions, an injection well and a production well. Oil well 12 represents an injection well in which pure oxygen, enhanced oxygenated air or air is injected through opening 14 to hydrocarbon zone 16. While the oxygen-rich fluid is being injected through well 12, the residual hydrocarbons in zone 16 are ignited by methods well known in the art. This results in a burning front 18 which forces ahead an oil bank 20 with an area of light hydrocarbons 22 and an area of hot water and steam advancing towards production well 26. As oil bank 20, light hydrocarbons area 22 and hot water and steam area 24 advance towards production well 26, an area of coke is left in its wake, which is ignited by burning front 18 when combined with oxygen-enriched fluid through injection well 12. Normal reservoir temperature is approximately 70° F., while the temperature of the burning front 18 may be between 600° and 1200° F.
As a result of this in-situ combustion method, a combination of oil, water and product gases will be produced at production area 28 of production well 26.
FIG. 2 illustrates an injection well 40 and a production well 42. Injection well 40 is illustrated as having two casings 44 and 46, casing 46 being within casing 44. Casing 44 provides a fluid path from the earth's surface to hydrocarbon zone 48. Casing 46 provides a fluid path from the earth's surface to hydrocarbon zone 50.
Similarly, production well 42 is illustrated as having casings 52 and 54. Casing 54 is located within casing 52 and provides a fluid path from hydrocarbon zone 50 while casing 52 provides a fluid path between the surface and hydrocarbon zone 48. The dual casing injection well 40 and the dual casing production well 42 are both used in conjunction with two different methods of enhanced oil recovery. For purposes of discussion, an in-situ combustion method of enhanced oil recovery is used in conjunction with hydrocarbon zone 48 whereas a carbon dioxide miscible enhanced oil recovery method is used in conjunction with hydrocarbon zone 50.
Although casing to the lower hydrocarbon zone 50 is illustrated as being located within the casing to the upper hydrocarbon zone 48, casings 44 and 52 may be extended to the lower hydrocarbon zone 50, the only important aspect being that production from hydrocarbon zone 48 and hydrocarbon zone 50 be isolated within the well, such as packing blocks within the casing, or any other methods well known in the art. As explained in conjunction with FIG. 1, a production well such as production well 42 will produce oil and product gases through outer casing 52 from an in-situ combustion method. The oil and product gases from hydrocarbon zone 48 will be produced at outlet 56 and are carried to oil separator 58 through conduit 64. The resultant gases from oil separator 58 are conveyed to carbon dioxide separator 60 wherein carbon dioxide is separated and conveyed to conduit 46 of injection well 40. The carbon dioxide is injected into hydrocarbon zone 50 through casing 46 for a carbon dioxide miscible enhanced oil recovery process.
In the carbon dioxide miscible process, carbon dioxide is forced into an oil reservoir. Although carbon dioxide may not be initially miscible with crude oil, some of the smaller, lighter hydrocarbon molecules in the crude oil of hydrocarbon zone 50 will vaporize and mix with the carbon dioxide, forming a wall of enriched gas consisting of carbon dioxide and light hydrocarbons. This wall of enriched gas will mix with more of the crude forming a blank of miscible solvents capable of efficiently displacing large volumes of crude oil ahead of it. The solvent is then moved toward production well 42 by injection of additional carbon dioxide to force the solvent wall to push the crude oil to casing 54. Crude oil from hydrocarbon zone 50 is thus produced at production area 62 at the end of casing 54.
Thus, the use of one method of enhanced oil recovery in hydrocarbon zone 48 that is in-situ combustion method produces by-products, namely, carbon dioxide, which may be used to produce crude oil from hydrocarbon zone 50 from the same production well by using the carbon dioxide miscible enhanced oil recovery process.
FIG. 3 illustrates an alternate method of the preferred method of the present invention. In FIG. 3, the carbon dioxide from carbon dioxide separator 60 is injected down casing 54 into hydrocarbon zone 50. A carbon dioxide miscible enhanced oil recovery method is still used in hydrocarbon zone 50 with the exception that casing 46 is used as the production casing and casing 54 is used as the injection casing.
The method of the present invention for simultaneous recovery of hydrocarbons from two hydrocarbon zones may be accomplished by using both casings in a well for production or by using one casing for production and one casing for injection or alternating a casing between injection and production to maximize the crude recovered from a hydrocarbon-bearing zone.
While the present invention has been illustrated by way of preferred embodiment, it is to be understood that the present invention is not limited thereto but only by the scope of the following claims.
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A method for simultaneous recovery of crude oil from multiple zones in a reservoir is disclosed wherein multiple wells, each in fluid communication with at least two hydrocarbon zones separated by an impermeable barrier, are used to produce oil in an enhanced recovery process. The end product from recovery in one zone is used to augment the recovery process in another zone.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority to U.S. Provisional Application No. 62/049,651 filed on Sep. 12, 2014, and U.S. Provisional Application No. 62/128,296, filed Mar. 4, 2015, and is a continuation-in-part of U.S. application Ser. No. 14/217,058, filed Mar. 17, 2014, which claims the benefit of priority to U.S. Provisional Application No. 61/790,771 filed on Mar. 15, 2013, the disclosures of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
The first portion of the background is most closely related to a single element preturbine oxidation catalyst element for EMD turbocharged engines using twisted exhaust runners. Oxidation catalysts (OC) are used to reduce the emissions of unburned hydrocarbons (HC), carbon monoxide (CO) and certain types of particulate matter (PM). Of the aftertreatment systems used on lean burn engines, this is the simplest system as it is completely passive and practically maintenance free. In the art these are also commonly referred to as diesel oxidizing catalysts (DOC). When dealing with both diesel engines and gas engines the shortened term oxidation catalyst (OC) is the more appropriate term.
A very common use of an OC has been in the aftertreatment of diesel truck engines where the OC is placed downstream of the turbocharger, and upstream of the diesel particulate filter (DPF). Because locomotives have become so tightly packaged, there is minimal room for a downstream OC in the locomotive application. A solution to this called a V-Cat has been patented and developed by Miratech. With a V-Cat system the OC is built into the exhaust manifolds on the engine upstream of the turbocharger, hence a pre turbine OC. For packaging reasons, this system had a single OC substrate for each cylinder. ASME Paper JRCICE2007-40060 titled ‘Exhaust Emissions From a 2,850 kW EMD SD60M Locomotive Equipped With a Diesel Oxidation Catalyst’ describes the application and testing of prototype V-Cat system on a 16 cylinder EMD engine in an SD60M locomotive.
The primary parameter that determines the emissions reduction efficiency of an OC is its temperature. Results of the V-Cat testing in the ASME paper indicate the CO reduction efficiency reaches 90% at around 200 C, the peak HC reduction efficiency is approximately 50% at 320 C.
Not only does the preturbine placement of this OC system on the turbocharged EMD engine offer a solution to the packaging problem, preturbine placement of the OC has several other benefits.
As the efficiency of the OC is affected by temperature, its pre turbine placement will substantially increase its overall operating temperature. Notch 4 has a temperature drop across the turbo of 41 C. Notch 4 is when the preturbine temperature finally reaches 310 C where the OC starts to reduce HC at 50% efficiency. If the OC were downstream of the turbo in this case, it would be operating at the mid 40% range. At notch 8, the temperature difference across the turbo is 137 C.
These increases in preturbine temperature will be even more important in the future when methane becomes a regulated emission. Typical OC systems do not efficiently remove methane until 400 C. With a preturbine OC system this would start at notch 4, with a downstream OC this may not start until notch 7. When hydrocarbon emissions are regulated for natural gas engines, they regulate only non-methane hydrocarbons. In natural gas engines the methane component of total HC is typically close to 90%. Although methane is not a criteria pollutant with direct human health risks, air agencies are paying more attention to methane emissions as a potent greenhouse gas with regulations for it pending in the near future.
One interesting finding in the ASME report is that the preturbine OC actually increased the turbo inlet temperature and overall engine efficiency because of the energy released when it oxidized the CO, HC and PM matter. This led to an actual increase of engine thermal efficiency at some points even though the additional back pressure of the OC would typically cause a decrease in efficiency due to reduced airflow.
Another advantage of a preturbine OC over a downstream OC is the effect of the OC system back pressure. Downstream of the turbo, whatever back pressure the OC causes would be multiplied by the pressure ratio of the turbo turbine. So if the OC caused a pressure drop of 1.1 kPa and the turbo had a pressure ratio of 2.7, the back pressure increase in the exhaust manifold would be 2.9 kPa. In the case of the preturbine DOC, the OC pressure drop is not multiplied.
As noted, the V-Cat system tested in the ASME paper had a single OC substrate per cylinder. This system is now in production and sold exclusively by EMD the manufacturer of the EMD engines. Because of the way the exhaust manifold segments are tightly packaged across the top of the engine and there is only a short 4 inch length of common exhaust plenum before the turbo charger inlet plumbing, there was no easy way to package a single large substrate that all of the exhaust would flow through equally. The solution was to have a single OC substrate for each cylinder and therefore each cylinder would experience the same pressure drop and the engine would run smoothly. If a single large substrate was attempted and each cylinder was affected differently, performance would suffer as some cylinders would get more intake air than others.
In the report the pressure drop was measured across one substrate with the engine running, the measured pressure drop was 1.1 kPa. While accurately measured, this pressure drop is not representative of the instantaneous pressure drop that affects the scavenging of the cylinder and how much intake air is brought into the cylinder. Because the exhaust valves are open substantially and flowing exhaust for less than a ⅓ of the crank rotation, it is likely that this measured average pressure is actually ⅓ of what would be allowed with a single substrate for all of the cylinders when the exhaust pulses are all combined together into one average exhaust manifold mass flow.
Early versions of this single substrate per cylinder OC system suffered substrate failures that were attributed to the pulsing effect of the exhaust gases flowing rapidly through the substrate for only ⅓ of the crank rotation. This resulted in the substrates breaking up into small pieces and flowing through the exhaust manifold towards the turbo inlet. Fortunately the EMD engine has a built in debris screen installed in front of the turbo inlet to prevent material such as this from damaging the turbine blades. Later designs of the preturbine OC system overcame this problem by adding additional material and substrate supports to enhance the durability of the substrates.
While the existing preturbine OC solution for the EMD engine solves the packaging problem, it would be preferable if a more economical and simpler single substrate solution could be found that did not have to replace every one of the existing exhaust manifolds.
The second portion of the background is most closely related to adjustable inlet guide vanes for improved emissions in EMD locomotives. Two aftertreatment systems have been developed and tested for emissions reductions in EMD powered locomotives, and both test programs noted a spike in particulate matter (PM) emissions for notch 6 engine loading. Miratech has developed and patented a preturbine diesel oxidizing catalyst (DOC) system call the V-Cat, testing results were published in ASME Paper JRCICE2007-40060 titled ‘Exhaust Emissions From a 2,850 kW EMD SD60M Locomotive Equipped With a Diesel Oxidation Catalyst’. This system was focused on reducing PM emission and from Notch 3 to Notch 8, the system efficiency averaged over 55% except for Notch 6 where the reduction plummeted to approximately ½ that value at 27%. Overall this system reduced PM by 52%.
Engine, Fuel and Emissions Engineering has trademarked its Compact SCR and the final report documenting its system on a Metrolink passenger locomotive is available on their website at www.efee.com. Unlike the preturbine V-Cat system, the Compact SCR system was located downstream of the engine turbocharger exhaust outlet and its primary function was to reduce oxides of nitrogen (NOx). It has a secondary function of reducing PM and was capable of reducing PM by 61% on the locomotive duty cycle. The testing with the Compact SCR resulted in a similar PM emissions spike at Notch 6 as seen in the V-Cat DOC testing. Further the NOx reduction efficiency of the Compact SCR system at throttle setting of idle through Notch 2 were very low.
The notch 6 increase in PM emissions and the low load reduction in NOx reduction efficiency are due to two different characteristics of the EMD 2 stroke locomotive engine. The notch 6 PM increase is due the engine air fuel ratio starting to be less lean than optimum which decreases combustion efficiency of the diesel spray and increases soot which is a major part of diesel PM. On the other hand the low load reduction in SCR efficiency is because the engine air fuel ratio is becoming too lean and the exhaust temperature is very low.
These varied air fuel ratios are a function of the design of the turbocharged EMD 2 stroke engine. The EMD system has a unique combination supercharger and turbocharger. It is driven by the engine geartrain through a one way clutch up until the point that there is enough exhaust energy to drive the turbocharger faster than the gear train. The point where the turbo spools up is typically notch 7 and that is where the boost builds up and the engine runs a leaner air fuel ratio that produces less PM. At very low loads the engine is also at low RPM, but at these lower speeds the intake ports are open for a longer time giving the reduced boost pressure more time to drive fresh air into the cylinder. Also at these lower loads the engine actually needs less air because it is making less power and consuming less fuel. This causes the engine to take in even more air than is needed and this excess air in the combustion chamber lowers the exhaust temperature. At idle this problem is at its worst as the low RPM allows a long time for scavenging and the minimal engine fuel consumption further drives down the exhaust temperature. From a peak exhaust temperature over 500 C at notch 8, the exhaust temperature is just over 110 C at idle and 160 C at Notch 1 .
Energy Conversion Inc. (ECI) in Tacoma, Wash. has had to overcome an additional problem in its conversion of these EMD 2 stroke engines to natural gas. In order to prevent detonation at high loads with natural gas, it was required to lower the compression ratio of the engine. Lowering the compression ratio at idle exacerbated the low RPM combustion temperature issue and in order to get lower emissions at idle, ECI incorporated a bank idling system where it only injected fuel into the cylinders on one side of the engine. This allowed each cylinder to operate with twice the amount of fuel and generate twice the amount of power. Every two minutes the engine would swap banks and run on the other half of the engine.
In addition to the bank idling technique, ECI devised an inlet throttle system to restrict the amount of air that the engine took in at idle to further increase the combustion temperature and increase the exhaust gas temperatures. This system had a set of rotating vanes pointing inward from a ring. This ring would be in front of the turbocharger compressor and had an open and closed setting. In the open setting the vanes would turn so that they were lined up in the direction of airflow and offered minimal resistance to the airflow. In the closed position an air actuator would rotate the vanes almost 90 degrees until the vanes touched and closed off the air passage except for the small round opening left over at the tips of the vanes.
This inlet restriction system developed by ECI is similar to variable angle inlet guide vanes used on some gas turbine engines and large stationary compressor equipment. When the guide vanes are in the neutral position they have no effect on the compressor upstream of them. When the guide vane are rotated from the neutral position they will add swirl to the flow, this swirl will have a different effect on airflow through the compressor depending on whether the swirl is turning the airflow with or against the rotation direction of the compressor impeller. If the flow is swirling in the direction of the centrifugal impeller rotation then the amount of pressure rise across the impellor will decrease as the impellor will not be able to put as much work or energy into the flow. This would tend to decrease the amount of mass flow across the compressor and the boost pressure leaving it. If the inlet guide vanes were turned in the opposite direction, the resulting airflow swirl would turn the air against the impeller rotation. This would increase the amount of work or energy that the impellor will impart into the airflow increasing the pressure rise. If the centrifugal impellor was part of a turbocharger, this increase in pressure rise would result in slowing down the impeller and turbine. This could be a form of limited waste gating for limiting or reducing the turbocharger shaft speed.
In addition to the lower compression ratio causing lower combustion temperatures at lower loads, the ECI natural gas conversion systems changed the airflow configuration of the engine enough that the stock EMD turbocharger could overspeed at notch 8. In order to control overspeed ECI added a waste gate system to bypass some of the high temp exhaust gasses and reduce turbine speeds.
Another system implemented by ECI in its conversion system is improved aftercooling of the intake air to reduce detonation at high loads. At low loads this improved intake air cooling would exacerbate the low combustion temperature issues at lower throttle settings. The solution was to revert the aftercooling system back to the original system for notches 3 down to idle where heated engine coolant is used to warm up the intake air. This required adding an actuated coolant control valve and some plumbing to control whether heated or cooled water was flowing to the liquid cooled aftercoolers.
What would be beneficial in these applications would be an airflow control system that reduced the excessively lean low load mixtures, increased boost and airflow at notch 6 , and limited turbine speed in dual fuel engines at notch 8 .
The third portion of the background is most closely related to a sonic and dual stage gas inlet valve. In the case of the ECI conversions systems for 2 stroke locomotive engines, a system called low pressure direct injection (LPDI) is used where the natural gas is injected directly into the cylinder during the compression stroke. What this leads to is a mixing challenge where the air and fuel have limited time to mix as the piston rises up to top dead center right before ignition.
This mixing challenge is why SwRI on their single cylinder development EMD 710 engine decided to do premixing of the air and fuel even though it would not be practical on an ‘in service’ engine as too much unburned fuel would blow through the cylinder into the exhaust while scavenging.
The in cylinder mixing issue can make prechamber operation difficult if a rich pocket of air and gas gets pushed into the prechamber which already has excess fuel in it. In this instance the prechamber will misfire and there will be no combustion for that stroke. For this reason ECI installed ‘jet caps’ on the first iteration spark ignited prechamber (SIP) system on the Napa Valley Wine train. The jet cap is an additional cap fixed over the end of the main Gas inlet valve (GIV). The GIV had a poppet valve at the end that controlled the flow of fuel gas into the combustion chamber. With the ‘jet cap’ in place, after the gas flowed thru the GIV body and past the poppet valve, it then had to flow through a small orifice at the end of the ‘jet cap’. This addressed several issues, all the gas was converged into one flow stream that now had higher velocity and was pointed away from the prechamber.
Another difference between the ECI kit and the system tested at SwRI is that the ECI system has to operate at very high Lambdas. Lambda is the ratio of the actual air/fuel ratio divided by the stoichiometric air/fuel ratio. Typical 4 stroke diesel engines operate at Lambdas around 1.9 at low load to 1.4 at full power. The SwRI single cylinder development engine didn't have to operate below 50% power. At low loads, an EMD 2 stroke locomotive operates at Lambda's above 3 and at idle the Lambda can exceed 4. At these very high lambdas it would require a larger prechamber that will produce fewer NOx emissions and have a lower thermal efficiency.
A solution to the very high Lambda value is to restrict inlet flow with a throttling system at low loads. This will allow operating the engine all the way from idle to full load with smaller volume prechambers that put out less NOx emissions and operate at higher thermal efficiency.
In a uniflow 2 stroke engine, scavenging is a process of blowing inlet air over the top of the piston at bottom dead center. This entering intake air pushes the spent combustion gasses out through the open exhaust ports at the top of the cylinder. The amount of in cylinder air motion and mixing as the piston rises in the compression stroke is proportional to how much velocity the inlet air carried in with it due to excess intake air box pressure. When the inlet is throttled to help reduce the low load air fuel Lambda, a large portion of this mixing energy is lost.
It is possible to reduce the inlet air box pressure to a low enough value that not enough inlet air enters to thoroughly scavenge the cylinder and some amount of exhaust gas will remain in the cylinder when the exhaust valves close. This effect can be desirable or have negative effects. This left over combustion gas is much hotter and less dense than the incoming air, so the resulting in cylinder air mass will now be lower and the average in cylinder temperature will be hotter at the beginning of the compression stroke. This has the double effect of both lowering the Lambda for easier combustion with less ignition energy using a smaller prechamber, and also faster and more efficient combustion because the compressed air fuel mixture is already much hotter at ignition.
This is referred to as internal exhaust gas recirculation (EGR) where exhaust gas is purposely left behind to achieve these effects. In a uniflow 2 stroke, the downside of this is much less air velocity at intake port closing. This lowered in cylinder velocity and mixing energy reduces the amount of air and fuel mixing when the natural gas is injected at low loads.
A supersonic injector for gaseous fuel engines as described in U.S. Pat. No. 6,708,905 would be a solution that offers improved mixing and a bonus of lower temperature gas when injected. This particular device has two drawbacks. First it has many machined parts with complicated features that will be costly. Second, the design has a built in cavity where residual natural gas will be compressed into and remain unburned during the combustion event. Most of the compressed gas in this cavity will become methane exhaust emissions. This release of unburned methane is both a pollution emissions problem and an energy efficiency problem.
What is desired is an economical and practical way to achieve the benefits of a high velocity and focused sonic injection nozzle without the added cavity for residual unburned methane, better mixing in the combustion chamber of a natural gas engine with direct gas injection which would allow operating a uniflow 2 cycle engine to be throttled past the point that internal EGR effects are improving combustion.
The fourth portion of this background is most closely related to prechamber cooling sleeves. Prechamber ignition systems are used to ignite air fuel mixtures that are too lean for a spark plug to ignite. The type of prechamber discussed here is a small prechamber at less than 5% of the combustion chamber clearance volume. Combustion inside of the prechamber will be easier to start and burn much more rapidly because the air fuel mixture is hotter and typically richer than the air fuel mixture in the main combustion chamber.
The cooling of a prechamber is one of the challenges, and the most challenging part of the prechamber to cool is the nozzle or tip area. This is because there is combustion happening on both sides of it. With insufficient cooling it has been documented that overheating prechambers will often melt the tip of the prechamber. Sometime before the tip actually melts, it will cause preignition which will limit how much power the engine can produce or cause the engine to run improperly during some conditions.
An improved prechamber would be a design that has better cooling for the prechamber body, prechamber tip and nozzle area while also being more economical to make.
The fifth portion of this background is most closely related prechamber cylinder deactivation on spark ignited prechamber EMD engines. Both the roots blown and turbocharged EMD engines would be good candidates for cylinder deactivation. Currently ECI used skip firing in their Spark Ignited Prechamber systems to improve combustion at very low loads where the engine operates very lean. In skip fire, the engine controller will skip actuating the main injector for a certain cylinder. This will cause the other cylinders to have to operate at a higher power to make up the lost power from the deactivated cylinders. When operating at higher power the other cylinders will need more fuel to generate it and this increase in fuel to those cylinders is what decreases how lean those cylinders are before ignition which generates higher heat release rates making the combustion events more consistent, and efficient. The control system has a strategy to alternate the deactivated cylinders to prevent any one cylinder from becoming significantly cooler than the others and also to prevent lube oil build up in that cylinder.
To keep the system simple, only the main gas injector is turned off for the cylinders that are skipped. All of the engine prechambers are still fed natural gas and the spark plugs are still fired. In the case where the prechamber supply pressure can be held constant over the entire engine operating range, the prechamber fuel supply system consists of only a single mechanical pressure regulator with a fixed setting.
Because the prechamber is still fed fuel, but the main chamber is not, there is no guarantee that the mixture in the prechamber is being burned when a cylinder is deactivated, even when the spark plug is still being fired. A portion of the fuel burned in the prechamber during normal combustion was not injected by the prechamber fuel system, but was brought in from the main chamber. When the cylinder is deactivated the air pushed into the prechamber by the piston will not have any fuel so the overall mixture in the prechamber may be too lean for the spark to burn. This is greatly dependent on engine speed and load while being skip fired. Because skip fire happens at low load it's likely that the extended time the system gets to fill the prechamber offsets this deactivated cylinder issue, but at the same time the operating cylinders are running richer and having the deactivated cylinders prechambers rich enough to fire may make the activated prechambers too rich causing misfires or combustion instability.
With these issues in mind, prechambers that are fed fuel in deactivated cylinders are likely to generate more NOx or HC or both. The generation of Non-Methane HC emissions is especially problematic as after the spark plug initiates combustion in the prechamber some unburned natural gas is pushed out of the prechamber into the main chamber before it is burned inside the prechamber.
The sixth portion of this background is most closely related to continuous water injection for ECI converted engines. Water injection has been used in engines to reduce engine knock at higher power levels as far back as World War 2. It was commonly used to allow aircraft engines to generate extra power during takeoff and other possible events that needed the most power possible.
It has also seen some use in racing applications, typically in sprint type racing where the time duration of full power and water injection use is limited, thus avoiding a bulky and heavy water storage system.
There are several issues that make water injection not worth the effort of implementation in most mobile applications; one is the volume and weight of the consumable water and second is the need to refill the container that would store it. Once these issues are overcome, then there is the environmental issue of keeping the stored onboard water from freezing when the vehicle is not in operation.
Another issue is the challenge of corrosion to the hardware that would be used to inject it, especially if the injector is designed to open and close rapidly for each cylinders combustion cycle.
Finally is the corrosion issue as related to any other parts. If after shut down an injector would leak water into the engine cylinder during engine storage, that cylinder will have internal corrosion and suffer significant maintenance issues.
Several Papers have indicated that direct injection of water into the engine cylinder has several advantages in addition to reducing engine knocking SAE paper 2009-01-1925 Effect of In Cylinder Water Injection Strategies on Performance and Emissions of a Hydrogen Fueled Direct Injection Engine is one good example. In this paper it is indicated that water injection both lowered NOx emissions and increased the indicated thermal efficiency when the water injection happened during the compression stroke. This effect was much less when the water was injected during the intake stroke on the four stroke engine tested.
When converting a diesel engine over to operate on natural gas, the compression ratio is typically reduced. If it wasn't reduced the engine may be limited to only generation of 60% of its original diesel operation rated power. The addition of water injection could allow the retention of higher compression ratios.
BRIEF SUMMARY OF THE INVENTION
The first portion of the summary is most closely related to a single element preturbine oxidation catalyst element for EMD turbocharged engines using twisted exhaust runners. With one revised exhaust manifold segment there is a way to use a single OC substrate without significantly affecting the exhaust flow of the cylinder closest to the turbocharger. This single substrate would replace the debris screen at the inlet to the turbo. This substrate would be installed in the last exhaust manifold segment before the turbo. Room for the substrate would be created by modifying the exhaust manifold runners for the last two cylinders.
The typical exhaust runners are a 9″×4″ rectangular tube. The 9 inch dimension on the runner is along the axial flow path of the exhaust manifold segment. By having the rectangular tube transition from a 9″×4″ shape to a 4″×9″ shape as it meets the exhaust manifold segment, it will free up approximately 5″ of axial length for a 5 ″ long OC substrate.
This single substrate system will save the cost of making 3 extra exhaust manifold segments and 15 extra OC substrates.
By averaging the exhaust pulses all together in one flow, it minimizes the pulsing effect on the substrate and the substrate experiences relatively consistent and smooth exhaust flow.
By replacing the original debris screen it removes the effect of the pressure drop of the screen which helps to offset the pressure drop of the OC substrate on engine performance.
The holes in the OC substrate will be smaller than the holes in the original debris screen so it will be more effective at stopping smaller bits of debris from damaging the turbine blades and reducing the turbo performance.
The long OC substrate in front of the turbo converging duct acts as a flow straightener removing any swirl in the flow that may have been caused by the exhaust runner pulses entering the exhaust manifold close to the turbo inlet.
The second portion of the summary is most closely related to adjustable inlet guide vanes for improved emissions in EMD locomotives. With minor development and the addition of a modulated position actuator, the ECI inlet throttle system could be used to variably reduce the airflow in the EMD engine in very small increments. If the modulated position actuator had more than 90 degrees of travel it could also be used to increase boost at notch 6 and decrease turbine speed at notch 8.
The beneficial effects of restricted airflow at idle has been demonstrated with the inlet throttle restrictor fully closed in previous ECI natural gas conversions. In notches 2 and 3 where the engine loading is getting higher and detonation is not a threat it is beneficial to have higher intake air temperature so that the natural gas will combust easier. Current ECI dual fuel systems do not consume natural gas in notches 1 or 2 , and at notch 3 natural gas substitution is limited to 65% because the combination of very lean mixtures and low compression make it difficult to ignite the natural gas. Because of the way 2 stroke engines scavenge, it would be possible with a variable inlet guide vane system to drop the intake air pressure and flow enough that all of the burned exhaust gases were not pushed out by the incoming intake air. This is referred to as internal exhaust gas recirculation (EGR) and has several benefits when used at low loads. Because the left behind exhaust gases are much hotter than the incoming intake air, the in cylinder temperatures of the mixed intake and EGR gases will be higher. Also because the EGR gases were hotter, they would be less dense. As the cylinder pressure when the intake ports and exhaust valves are closed will be almost the same, this hotter less dense mixture will have less mass. This will make the air fuel ratio less lean. The combination of a less lean mixture that is also hotter at the start of ignition will improve the combustibility of the natural gas and will increase the amount of gas at notch 3 that can replace diesel fuel, and will also allow the substituting of some natural gas for diesel fuel at notches 2 and 1 , possibly even at idle. If the system is effective enough it could eliminate the need for the coolant diverter valve used to help preheat the intake air.
This variable inlet restriction would also be a benefit to a diesel fueled EMD engine that is using a Compact SCR system, as it can drive the exhaust temperature up at idle, and notches 1 through 3 where the Compact SCR system was not functioning or was less than 30% efficient.
These increases in combustion efficiencies at low loads due to the less lean mixtures and potential internal EGR will not only reduce emissions, they will increase thermal efficiency at these low loads.
The third portion of the summary is most closely related to a sonic and dual stage gas inlet valve. What is proposed here is a gas inlet valve (GIV) that utilizes the valve head and valve seat at a narrower angle than 120 degrees on the prior art GIV to accelerate the incoming natural gas flow and direct it further away from cylinder walls.
This configuration has several advantages. First it merely requires a change in operating pressure and revised machining on two components to gain this effect.
Second, as the gas exits from an annulus instead of a hole, the gas exits as a cone formed from a sheet of gas with both an inner surface and outer surface. This surface is where the mixing happens and this design will have over twice the surface area for entraining the surrounding air.
Third, as the nozzle is formed by the movement of the poppet valve from the seat, the stoke can be adjusted to different sonic throat areas. Allowing longer valve opening times at higher pressures and lower flows.
This design completely eliminates the issue of residual unburned gaseous fuel remaining inside of a cavity in the GIV or Jet Cap after combustion.
These sonic GIV units can operate with any gaseous fuel including propane and hydrogen.
The fourth portion of this summary is most closely related to prechamber cooling sleeves. Proposed is a two piece prechamber body and nozzle design that enhances the cooling of the prechamber by incorporating a separate cooling sleeve to insure that an adequate amount of cooling fluid makes it to the bottom of the prechamber, and then evenly flows around the periphery of the prechamber to a point past the top of the inner prechamber combustion chamber wall.
The fifth portion of this summary is most closely related to an OPOC variable compression ratio mechanism While the OPOC engine being developed by ECO Motors is not an EMD 2 Stroke engine as currently used in locomotives. It does offer interesting possibilities as a power plant for genset type locomotives or as a Head End Power generator engine for passenger locomotives. The value of the OPOC's low weight and volume compared to its power output are even higher for these application when there is an effort to operate the locomotive on an alternate fuel. A typical diesel engine design converted to natural gas will need to be scaled up 30% bigger in size to make the same power.
Because of the unique nature of the OPOC engine design, it is possible to incorporate an infinitely adjustable variable compression ratio (VCR) using an outer wrist pin with an offset inner wrist pin bore.
A sliding spline fit is used to control the rotation of the outer wrist pin, because this is a two stroke engine, the piston will always be under compression when operating so that all of the VCR component slop should be taken up. The only wear items would be the parts of the sliding spline and they are replaceable without having to remove the piston.
The sixth portion of this summary is most closely related to group cylinder deactivation on prechamber ignited EMD engines. Proposed is the deactivating of groups of cylinder in the EMD engine by not firing the main GIV injector and also by interrupting the flow of fuel to the prechambers. The configuration of the EMD and its firing order make this a reasonable prospect.
In another embodiment, the simple control valve that turns on and off the supplemental fuel to the groups of prechambers could be replaced by an advanced prechamber fuel pressure control module (PPCM) which would offer other engine operating advantages. Proposed is an integrated pressure supply module using two or more PMW valves to control the prechamber pressure supply. This would be a single module that only needed a low voltage power source and the operating pressure command. It would then read the operating pressure of its own gas rail pressure sensor and control the valves. At higher flows with multiple valves, one or more of the valves could be left open full time and then one or two of the other valves manipulated in a PWM fashion. This ability to leave a valve open full time minimizes the wear on the valve and extends its service life. With multiple valves the job of operating in PWM mode can be alternated between valves to equalize valve life.
On an engine platform like a locomotive where steady state loads are common, this alternating the duty cycle of valves allows the PPCM to also check the valves against each other. This allows determining if one valve of the set is malfunctioning, and if the PPCM has an extra valve capacity it could send a warning fault code that it needs service in the future while still functioning.
When used for cylinder deactivation on an EMD engine, comparing the operation of each PPCM to each other to maintain the same prechamber rail supply pressure would be a good way to detect prechamber check valve issues. If one PPCM indicated a higher or lower duty cycle or flow, then that would indicate something was wrong in the group of prechambers belonging to that PPCM. Many issues could cause this fault, a disconnected prechamber feed line, a stuck prechamber check ball, a leaking prechamber ball and seat or a clogged prechamber body feed hole are some possibilities.
Now that prechamber fuel supply can be varied and banks of prechambers are being turned on and off with some form of cylinder deactivation, it will be beneficial to vary the prechamber fuel supply pressure when turning on the prechambers. When a bank of prechambers is turned back on, they will have cooled down from operating temperature and will have trouble firing a leaner mixture. At this point the PPCM should be commanded to operate at a slightly higher pressure temporarily so that the mixture is closer to stoichiometric and will be ignited by the spark plug easier and burn quicker. Once the prechamber is hot, the PPCM can be instructed to lower the supply pressure so the prechambers run leaner and produce less NOx.
The seventh portion of this summary is most closely related to continuous water injection for ECI converted EMD engines. If it were possible to directly inject water into an Energy Conversions Inc (ECI) converted EMD engine, it may be possible to make enough power with the stock piston compression ratio that a piston change can be avoided during conversion. This saves a significant amount of labor and cost, plus has the benefit of higher efficiency and/or lower NOx emissions.
Effective direct injection of water into an ECI converted EMD 2-stroke engine could be accomplished by injecting the water into the body of the hydraulically actuated natural Gas Inlet Valve (GIV). This will mix it with the fast moving natural gas that is then injected into the engine cylinder during the compression stroke. This allows direct injection of the water without having to create a new custom cylinder head with an additional passage for an additional injector with access to the combustion chamber. This is most applicable to engines using Low Pressure Direct Injection Systems (LPDI) where the natural gas is injected into the engine during the compression stroke at only a few hundred psi, whereas High Pressure Direct Injection (HPDI) operates its injectors at pressures above 4000 psi and would be a challenge to combine the water with the gas and also only open for a few degrees of crank rotation.
Unlike 4 stroke engines, the airflow is only at a high velocity as it goes though the liner ports. In a typical port injected engine, the water can be sprayed into the air in the inlet port which is only momentarily stationary and will then all be at a high velocity as it is inducted into the engine cylinder. In the uniflow 2 stroke airbox the airflow for the most part travels slowly up until it radially approaches the liner ports at which point it will achieve its highest velocity. This is because the air in a 4 stroke engine goes through a nearly constant cross section intake runner up to the combustion chamber, where as a uniflow 2 stroke engine has a larger plenum of intake air around the liner that only speeds up as the flow streams merge on their way to a liner port. While fumigating a 4 cycle engine intake runner can be effective, this makes fumigating the airbox area of a uniflow 2 stroke with atomized water challenging without risk of water separating out and causing puddles.
Unlike on road truck diesel engines and automobiles that attempt to operate at high loads at as low an RPM as possible. In a locomotive operating cycle the engines speed or RPM will increase as load is increased. Because the water is only needed at higher RPM, it may be possible to use a Continuous Injection System (CIS) to inject the water into the GIV. At higher RPM the GIV may spend up to 35% of its time open and flowing gas. Intuitively it would seem that pulsing of the water would be needed, but similar to early versions of port fuel injection, the water mist in the GIV could be sprayed continuously. In the case of port fuel injection, air would be flowing by the injectors less than 25% of the time and it would not be flowing fast. In the case of the 2 stroke GIV system, the GIV could be open longer and the natural gas and atomized water mixture would be flowing at sonic speed.
This eliminates the cost and complexity of having a high speed on-off water injector at each cylinder. It also reduces the needed water line size to each injector as the fluid flows continuously instead of only 25% or less of the time.
The ECI conversion system combined with CIS water injection has another water injection system benefit. Because the ECI conversion system regulated the main natural gas supply to 110 psi, and then reduces it to actual GIV operating pressure using the Gas Flow Control Valve (GFCV), it would be possible to purge the water injection system of all water after engine shutdown by taking main pressure 110 psi natural gas and purging the water injection system with it. By doing this at a higher RPM, but lower load, the GFCV will be operating the GIV's at much lower pressure and the incoming natural gas will force the water through the system after a certain amount of time. In order for this to work, the areas that need to be cleared of water need to flow downhill to the water injection nozzle at the GIV.
If this purge gas were to be fed to the water injection through a specific fixed orifice it would be possible to sense when the water lines and injector nozzles were clear of water by sensing the pressure drop in the water injection manifold. As natural gas will flow much more quickly through the water injection nozzles than the actual water would, once the system is free of water, the pressure in the water injection manifold will drop. Further by monitoring this pressure, system health and clogged nozzles can be detected. Both by the rate of manifold pressure drop and how much it dropped.
The eighth portion of this summary is most closely related to groupings and configurations of prechamber orifices for turbulent jet ignition (TJI).
In order to adequately capture the effect of TJI, the orifice has to be small enough to quench the burning air and fuel mixture as it exits the prechamber passing thought the orifices. In order to do this, orifices as small as 0.050 inch diameter may be needed. As the size of the orifice gets smaller, the prechamber jets will penetrate less distance into the combustion chamber and have a reduced effect in two ways. First the ignition will happen closer to the center of the combustion chamber reducing the effectiveness of the multiple ignition points to decrease the total burn duration.
The second negative effect of the smaller orifice jet is that there will be less accumulated partially burned air and fuel in the pockets that are formed by the small jets. These pockets of combustion radicals may end up being dilute enough or in a small enough local quantity to not ignite consistently or ignite with enough energy to initiate rapid combustion of the lean air fuel mixture around the pocket. Proposed is to have groups of a higher number of smaller nozzles configured so that two or more nozzles converge in the combustion chamber. This will help over come the penetration and concentration issues with smaller nozzles while keeping the delayed combustion benefits of the smaller nozzle quenching effects on delayed combustion for more rapid heat release rates.
In another embodiment all or some of the prechamber jets can be offset from the prechamber axis to generate swirl in the prechamber combustion chamber. With the spark plug typically on one side of the prechamber and the supplemental fuel injected on the opposite side, the mixture in the prechamber combustion chamber may remain significantly stratified if the air and fuel mixture from the main chamber is injected straight up into the chamber. In the worst case, this stratification of the charge can lead to possible misfires at certain engine loads. Charge stratification will also result in slower and inconsistent heat release in the prechamber.
In one embodiment, a prechamber assembly includes a cylinder head including a coolant cavity, a prechamber body located within the cylinder head, the prechamber body including a nozzle, and an annular sleeve radially surrounding a portion of the prechamber body. The sleeve includes a plurality of coolant inlet holes. A portion of the prechamber body is radially spaced from the sleeve to form a coolant sleeve annulus extending along a length of the prechamber body above the coolant inlet holes. The coolant cavity and the coolant sleeve annulus are in fluid communication through the plurality of coolant inlet holes.
In a further embodiment, the sleeve further includes a plurality of coolant outlet holes, and the plurality of coolant inlet holes is positioned towards the end of the coolant sleeve annulus closest to the nozzle. In another embodiment, the coolant outlet holes are in fluid communication with a coolant return cavity. In other embodiments, the prechamber assembly includes a coolant comprising water.
In another embodiment, the prechamber body includes a feed groove distal from the nozzle and in fluid communication with the cooling cavity, and the coolant cavity spans from the feed groove to the plurality of coolant inlet holes. In a still further embodiment, the prechamber assembly further includes a coolant comprising engine oil. In some embodiments, the sleeve and the nozzle are integral.
In a further embodiment, a prechamber assembly includes a cylinder head including a coolant cavity and a prechamber body located within the cylinder head. The prechamber body comprises a nozzle that includes a plurality of jets directing flow through the nozzle at an angle other than parallel or perpendicular relative to a longitudinal centerline axis of the nozzle. The plurality of jets are clustered in groups radially spaced apart from each other around the longitudinal centerline axis of the nozzle. In some embodiments, the groups of jets are equally spaced radially. In other embodiments, flow through the jets of each group of jets converges at a distance from the nozzle. In a still further embodiment, each group of jets comprises two jets. In another embodiment, the nozzle further includes a centerline jet aligned along the centerline axis. In further embodiments, the nozzle further includes a centerline group of jets aligned approximately parallel to the centerline axis, wherein flow through the centerline group of jets converges at a distance from the nozzle.
In a still further embodiment, a prechamber assembly includes a cylinder head including a coolant cavity; and a prechamber body located within the cylinder head, the prechamber body including a nozzle. The nozzle includes a plurality of jets, each jet aligned along a respective axis that is offset from a centerline axis of the nozzle such that the jet axes do not intersect the centerline axis. In some embodiments, the nozzle includes a mixing area, and wherein each jet axis of the plurality of jets is offset an equal distance from the centerline axis such that flow through the plurality of jets causes a rotating flow about the centerline axis in the mixing area of the nozzle.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a typical 16 cylinder EMD turbocharged engine as used in locomotives.
FIG. 2 is a side view of the same engine in FIG. 1 except that the exhaust system has been revised to accommodate a single substrate OC system.
FIG. 2A is an isometric view of a prior art exhaust runner.
FIG. 2B is an isometric view of an embodiment of an exhaust runner of the engine of FIG. 2 .
FIG. 2C is an isometric view of an embodiment of an OC substrate of the engine of FIG. 2 .
FIG. 3 is a side view of the prior art Miratech preturbine V-Cat system.
FIG. 4 is a side view of an EMD 16 cylinder illustrating the location of the Variable Inlet Guide Vane Unit.
FIG. 5 is an isometric view of the turbocharger and the Variable Inlet Guide Vane Unit with its blades closed.
FIG. 6 is an isometric view of a prior art Variable Inlet Guide Vane Unit with the blades partially open.
FIG. 7 is an isometric view of an ECI manufactured gas inlet valve (GIV).
FIG. 8 is cross section view of a conventional poppet valve in the open position of a prior art GIV.
FIG. 9 is a cross section view of the revised poppet valve and valve seat insert to achieve sonic gas injection flow.
FIG. 10A is a cross section view illustrating a dual stage hydraulic valve assembly in the closed state.
FIG. 10B is a cross section view illustrating a dual stage hydraulic valve assembly in the fully open state.
FIG. 10C is a cross section view illustrating a dual stage hydraulic valve assembly in the partially open state.
FIG. 11 is a cross section view of an EMD cylinder head with a prechamber installed.
FIG. 12A is an enlarged view of the prechamber body of the EMD cylinder head of FIG. 11 .
FIG. 12B is an enlarged, fragmentary view of the prechamber body of FIG. 12A .
FIG. 13A is a Section View of a truck engine cylinder head with a prechamber assembly installed.
FIG. 13B is an enlarged view of the XXX of the truck engine cylinder head of FIG. 13A .
FIG. 14 is an exploded view of an OPOC engine Variable Compression Ratio system.
FIG. 15A is a table illustrating the firing order variations for a 12 cylinder EMD 2-stroke engine.
FIG. 15B is a table illustrating the firing order variations for a 16 cylinder EMD 2-stroke engine.
FIG. 16A is a section view of a prechamber nozzle with grouped and offset TJI jets.
FIG. 16B is an isometric view of a prechamber nozzle with a single axial TJI jet.
FIGS. 17-22C illustrate additional views of nozzles including TJI jets.
DETAILED DESCRIPTION
To facilitate an understanding of the present disclosure, a number of terms and phrases are defined below:
Gaseous Fuel: The predominant gaseous fuel used in internal combustion engines is natural gas consisting mostly of methane, but with minor modifications these engines could consume any gaseous fuel including but not limited to propane, natural gas and hydrogen. In this document the term natural gas and gaseous fuel are used interchangeably.
Hydrocarbon (HC): Emissions resulting from incomplete combustion.
Main Charge: The air fuel mixture in the main combustion chamber space between the piston top and the cylinder head. If an opposed piston engine, this would be the space between the opposed piston faces.
Particulate Matter (PM): Particulate matter is a criteria pollution emitted from many sources. In this document we will commonly refer to it simply as PM. It could include both diesel soot PM that is considered toxic in California or the type of PM created by the consumption and combustion of lube oil from an engine. While still considered PM as a criteria emission, the PM from lube oil consumption is considered less toxic than diesel soot.
The first portion of the detailed description is most closely related to a single element preturbine oxidation catalyst element for EMD turbocharged engines using twisted exhaust runners. FIG. 1 is a side view of a typical 16 cylinder EMD turbocharged engine as used in locomotive and marine applications. In this prior art configuration Engine 2 has an exhaust system along the top of it. The exhaust system is composed of three exhaust collector segments 4 and one turbocharger adapter exhaust collector segment 8 that collect the exhaust gases from the 16 engine cylinders into one combined exhaust mass flow. Each one of these exhaust collector segments connects to 4 of the engines 16 cylinders, with exhaust gases flowing from an individual engine cylinder to an exhaust collector segment through an exhaust runner 6 . The standard exhaust runner 6 is a 4 inch by 9 inch rectangular tube as illustrated in FIG. 2A . The longer 9 inch dimension is shown along FIG. 1 as going left to right and the four inch dimension is normal to FIG. 1 . The exhaust gasses flow in a direction from the bottom of the Figure through an exhaust runner 6 up into an exhaust collector segment. Each exhaust collector segment has two pairs of exhaust runners 6 , only one is visible as the second exhaust runner 6 of each pair is directly behind the first exhaust runner 6 . In some version of the EMD engines, the pairs of exhaust runners 6 are combined together into one larger runner. Sometimes this larger runner would have a shared wall in between, keeping the exhaust gases from the two cylinders separate until they mixed with the combined exhaust flow in the exhaust collector segments. In other cases this was missing or removed and the exhaust gases from the pair of engine cylinders would mix in the combined exhaust runner 6 volume before mixing with the combined exhaust flow in the exhaust collector segments. This would appear the same in FIG. 1 and functionally does not affect this description of the prior art.
The three exhaust collector segments 4 and one turbocharger adapter exhaust collector segment 8 are connected to each other by flexible bellows 5 at three places. The now combined exhaust gasses flow from the turbocharger adapter exhaust collector segment 8 thru debris screen housing 10 and small flexible bellows 12 into the turbocharger inlet 14 . As the combined exhaust mass flows through the debris screen housing 10 , it must pass through debris screen 16 . Debris screen 16 is a metal plate installed in debris screen housing 10 with a large number of small holes that will allow the exhaust gases to flow through it, but will block any small solid parts from traveling with the exhaust gases into the turbocharger and damaging the turbine blades. This debris screen 16 does cause a small pressure drop in the exhaust system which reduces engine performance and efficiency, but it prevents damage to the turbocharger assembly in the case of a component failure elsewhere in the engine. This is a valuable trade off as the turbocharger is one of the most expensive parts of the engine.
FIG. 2 is a side view of the same engine in FIG. 1 with a revised exhaust system to include a single substrate OC system. Engine 2 ′ has similar components in its exhaust system upstream of turbocharger adapter exhaust collector segment 8 ′ and downstream of debris screen housing 10 ′. The primary difference is the deletion of the debris screen 16 and the addition of the OC substrate 18 into modified turbocharger adapter exhaust collector segment 8 ′.
Turbocharger adapter exhaust collector segment 8 ′ has been modified to allow the OC substrate 18 as shown in FIG. 2C to slide into it. The primary modification to make this possible is the reshaping of exhaust runner 6 ′. Where exhaust runner 6 had a consistent 9 inch by 4 inch rectangular shape along its path as shown in FIG. 2A , the cross section of exhaust runner 6 ′ will change along its length as shown in FIG. 2B . It will start with the same 9 inch by 4 inch shape at the engine cylinder port, but as it travels towards the turbocharger adapter exhaust collector segment 8 ′ its shape will transform as depicted in FIGS. 2 and 2C . The goal is to have a similar cross section area along the exhaust flow path of exhaust runner 6 ′, but have the length and width dimension transition from 9 inches by 4 inches at a runner first end 6 ′- a to something close to 4 inches by 9 inches at a runner second end 6 ′- b . This will allow the creation of a cylindrical pocket that allows OC substrate 18 to slide in. The pocket does not need to be cylindrical, but the changing cross section of the exhaust runners 6 ′ is what allows a single OC substrate 18 to fit between the exhaust runner 6 ′ and the small flexible bellows 12 .
Referring to FIG. 2C , the OC substrate 18 is likely to be a round metallic substrate approximately 18″ in diameter and 5″ thick. These sizes and substrate material composition will vary depending on system design. OC substrate 18 may slide all the way into either turbocharger adapter exhaust collector segment 8 ′ or into debris screen housing 10 ′, but is most likely to protrude partially into each. Other shapes of substrate and pockets to fit it in may not be cylindrical, but may be oval or rectangular.
In this embodiment it is designed that the OC substrate 18 slides into a pocket created in turbocharger adapter exhaust collector segment 8 ′ and is retained in that pocket by debris screen housing 10 ′. In another embodiment, turbocharger adapter exhaust collector segment 8 ′ and debris screen housing 10 ′ may be combined into one assembly with OC substrate 18 sliding into this assembly from direction normal or close to normal to the axis of exhaust gas flow. This would require some kind of cover plate to be used to cover the pocket opening similar to the cover plates used in the Miratech V-Cat design.
FIG. 3 is a side view of the prior art V-Cat system 80 patented and manufactured by Miratech. The V-Cat system 80 comprises four exhaust collector segments 82 which replace the three exhaust collector segments 4 and one turbocharger adapter exhaust collector segment 8 from FIG. 1 . In each exhaust collector segment 82 are four individual OC substrates to service the exhaust gases of four engine cylinders. A pair of OC substrates is captured on each side of a exhaust collector segment 82 by a cover 84 . Each exhaust collector segment 82 has four exhaust runners 86 similar to the exhaust runners 6 in FIG. 8 and FIG. 9 .
It is a cover similar to cover 84 that could be used to retain a single OC substrate 18 into a combined turbocharger adapter exhaust collector segment 8 ′ and debris screen housing 10 ′.
The second portion of the detailed description is most closely related to adjustable inlet guide vanes for improved emissions in EMD locomotives.
FIG. 4 is a side view of a 16 cylinder EMD engine 2 . Turbocharger 15 is mounted to engine 2 . Variable inlet guide vane unit 6 is mounted to the compressor inlet of turbocharger 4 . Even with as much value and performance that the variable inlet guide vane units adds, FIG. 4 illustrates what a small and easy to package system the variable inlet guide vane unit is. No parts on the engine need to be replaced, only the intake pipe bringing in outside air to the turbocharger compressor inlet. On the other hand this unit may allow the simplification and cost reduction of the ECI conversion kit by eliminating the waste gate assembly the aftercooler diverter valve and its extra plumbing.
FIG. 5 is an isometric view of the engine turbocharger 24 and the variable inlet guide vane unit 26 . In this view the guide vanes 28 are in the fully closed position, this leaves a small flow area 30 formed by the blade tips. In the prior art version of this device the valve was either fully open or fully closed, manipulation of this state was done by actuator 32 .
New embodiments of this system will have actuator 32 upgraded to have variable positions. In one embodiment a 90 degree variable position actuator may be used and the fully closed position will not have the guide vanes 28 rotated so far that they touch. This now allows the vanes when rotated 90 to have traveled past neutral and be positioned at an angle to cause increased boost at notch 6 or act as a waste gate limiting turbine rpm at notch 8 .
A further embodiment will have an actuator like the Delphi Smart Remote Actuator that has 120 degrees of travel. With this variable actuator, the guide vanes 28 can be rotated fully closed and still have the range to rotate 30 degrees past neutral well into the range where notch 6 boost is increased.
FIG. 6 is an isometric view of a prior art inlet guide vane unit 26 ′ with the guide vanes 28 ′ partially open.
The third portion of the detailed description is most closely related to a sonic and dual stage gas inlet valve that could also be used for continuous water injection.
FIG. 7 is an isometric view of a standard ECI GIV assembly 40 . It illustrates the relationship between the GIV body 41 the valve seat insert 42 and the poppet valve 43 . In this view the poppet valve is in the fully extended position. This particular valve assembly is designed to inject natural gas into and EMD 2 Stroke natural gas engine on the compression stroke. It is possible to use this direct injection valve design and any embodiment of the current invention in any reciprocating engine using any gaseous fuel. This GIV could also be used for direct and continuous water injection. Gaseous fuel is supplied to the GIV at natural gas inlet 46 , secondary inlet 47 is where a supplemental water injector could be located. The mixed gaseous fuel and water mist could then exit the GIV into the combustion chamber at natural gas exit 48
FIG. 8 is a cross section view of the prior art GIV assembly 40 from FIG. 7 . FIG. 8 illustrates the poppet valve 43 and valve seat insert 42 when the poppet valve is fully extended. This valve is typical in construction to the exhaust and intake valves in most reciprocating piston engines. The valve seat area 44 is around 0.065″ wide and the valve seat angle is 60 degrees from the valve axis. The intent of this valve system is specifically to allow the most airflow to pass through it with the minimal amount of pressure drop during the time is has available to be open. There is minimal consideration as to what the characteristics the exiting airflow has and the pressure drop across these valves is typically under 2:1 for conventional engine intake and exhaust valves and up to 4:1 for the GIV units used on turbocharged EMD engines with a natural gas feed pressure of 80 psi.
FIG. 9 is a cross section of the new poppet valve 43 ′ and valve seat insert 42 ′ design. Just the modification of these two parts converts ECI's standard GIV into a version that creates a sonic cone of injected gaseous fuel. The view on the left shows the valve in the closed position. Significantly different from FIG. 8 is that the flow cone angle is 50 degrees instead of 120. The valve seat angle is actually 25 degrees from the axis of poppet valve 43 ′ instead of 60 degrees in the prior art design. The cone angle could be more or less than and 50 degrees. The narrower this angle is, the further into the cylinder bore that the gaseous fuel travels before it impinges on the cylinder wall for improved mixing.
FIG. 10A is a cross section view of a hydraulic actuator for the GIV assembly 40 with two discrete open positions. This view illustrates the GIV assembly 40 in the closed position. In this view the plunger 51 is inside of the plunger body 50 , and it is the plunger 51 that the hydraulic fluid pushes down on to open up the poppet valve 43 . These two parts are consistent with the standard prior art version of GIV assembly 40 . What is added in this embodiment is the plunger follower 52 , the plunger stop body 55 and the movable plunger stop 54 .
FIG. 10B the GIV assembly 40 is in the full open position. The plunger 51 was forced down by the hydraulic fluid until it contacted the movable plunger stop 54 . The movable plunger stop 54 is resting on the top surface of the plunger stop body 55 . When the plunger 51 started to move in the downward direction, it contacted, pushed down on and moved the plunger follower 52 . The plunger follower 52 was in contact with the top of the poppet valve 43 and pushed it down also. All three parts continued to move downward until the plunger motion 51 was stopped as it contacted the movable plunger stop 54 .
FIG. 10C illustrates the GIV assembly 40 in the partially open position. To stop the poppet valve 43 in this position, pressurized hydraulic fluid is fed into the plunger stop hydraulic port 53 . This pressurizes the plunger stop hydraulic cavity 57 and this pressure forces the movable plunger stop 54 to move up until it contacts the bottom of the plunger body 50 . With the movable plunger stop 54 in this position, the plunger 51 now travels a shorter distance before contacting the movable plunger stop 54 which will now limit the poppet valve 43 opening to a reduced stroke in the partially open position. The movable plunger stop 54 is able to keep the plunger 51 from moving it down because it has more surface area exposed to the hydraulic fluid pressure in the plunger stop hydraulic cavity 57 .
This system could be designed to have more than one movable stop by multiplying certain features in this design.
The standard way to operate an ECI low pressure direct injection EMD conversion is to have the valves stay open for set amount of time for each piston stroke. This time period is set by the amount of time available at high RPM to inject gas after the intake ports are closed. After this time period is set, the engine load is controlled by adjusting the gas supply pressure to the injectors. As the load and RPM decreases and less fuel is required, the supply pressure is decreased. It would be possible to maintain a constant pressure and then reduce the injection time as fuel demand decreased, but that may decrease the amount of air and fuel mixing because the high velocity fuel gas was injected for a shorter period of time.
On a fuel system using standard poppet valves that achieve sonic flow at the valve periphery this would be a measurable effect.
This is the primary advantage of the GIV with multiple valve stroke settings. It reduces the total amount of injector feed pressure, instead of reducing the pressure for all 8 throttle notches in a locomotive. The pressure could be reduced incrementally for Notches 7 and 6 , and then Notch 5 will have the GIV assembly 40 operate at reduced poppet valve 43 lift and a slightly longer valve open time because the RPM is now lower. From this point both the valve open time and gas supply pressure will be reduced incrementally down to the minimum flow needed at idle. The goal is to have the GIV fuel gas feed pressure remain high enough that good mixing is maintained, but balance that with manipulation of the valve open time to maximize the amount of time the high velocity injected gas is mixing with the air in the combustion chamber.
As an example, instead of having a constant 80 milliseconds of injection time starting at a pressure of 300 and dropping to 100 at notch 1, now the highest 3 throttle notches will have an 80 ms injection time and pressure will drop to 250 in notch 6. At throttle notch 5 the injection time is raised to 115 ms, the poppet valve 43 lift is 40% of full open and the injector feed pressure is raised back to 300. By notch 3 the injection time has be lowered back to 80 ms and pressure feed pressure has only been reduce down to 275. By throttle notch 1, the pressure has been further reduced to 220. By ending at a 220 psi supply pressure instead of 100 psi, the exit velocity of the gas leaving the GIV should still be sonic. If it had dropped down to 100 psi, it would likely have become subsonic in the GIV.
An interesting further use of this concept would be in large ship engines. Both 2 stroke and 4 stroke engines that are diesel pilot ignited would benefit from added swirl in the combustion chamber. Any number of these GIV's could be placed offset from the engine cylinder axis and tilted at an angle to induce a swirl to the air in the combustion chamber. If more than one supersonic GIV is used, they should have a similar angle in reference to the engine cylinder axis so that they induce swirl in the same direction. This swirl of air around the engine cylinder axis in the combustion chamber improves the combustion of the diesel pilot helping to lower PM or NOx emissions. This is because the swirl improves the air utilization during mixing controlled combustion as the surface of the diesel fuel jet is in contact with more air molecules than it would be if the air was stationary.
Another interesting possibility will be the incorporation of sonic flow GIV's with an opposed piston engine. If only one sonic GIV was used per cylinder there would be the risk of the gas flow impinging on the opposite cylinder wall. This may or may not have detrimental effects such as a colder spot at the cylinder wall with possible lubrication or thermal stress issues. If cylinder wall impingement is to be avoided or for improved mixing, two of these sonic GIV's could be placed directly opposite of each other across the combustion chamber, in this case the two cone shape flows would collide in the middle of the chamber causing a great amount of turbulence and entraining significantly more intake air in the cylinder before the cold gases reach the cylinder walls.
The fourth portion of this detailed description is most closely related to prechamber cooling sleeves including single and double pass variations.
FIG. 11 is a cross section of a cylinder head 58 illustrating the placement of the prechamber 59 in relation to the cylinder head 58 and the piston 70 ′. The o-ring 61 at the top creates a cavity between the prechamber 59 outer surface and the cylinder head 58 pocket wall, this cavity is sealed at the bottom where the lower tapered section of the prechamber 59 is forced against the bottom of the cylinder head 58 pocket. This seal at the bottom is designed to resisted blow by of combustion gasses when the engine is operating so it will not have an issue keeping the prechamber coolant out of the engine cylinder.
At the top of the prechamber 59 is the cooling fluid inlet 60 . Pressurized Cooling fluid is injected here and an internal passage brings the cooling fluid to an exit port on the outer surface of the prechamber below the o-ring 61 . The prechamber cooling fluid can be many different fluids including water, but in this preferred embodiment it would be engine oil to eliminate the need for return plumbing to a separate cooling fluid reservoir.
In this embodiment, the cooling fluid is injected into a feed groove 67 around the prechamber 59 . This feed groove 67 acts as a manifold and helps distribute the cooling fluid around the entire circumference of the prechamber body 59 before it starts to flow through the narrow cavity between the prechamber body 59 and cylinder head 58 wall. This is considered the first pass of the coolant in a double pass prechamber cooling system.
In this prechamber embodiment is a diesel injector, this prechamber configuration uses a micropilot of diesel fuel to start ignition. This invention would work in a similar fashion with a spark plug ignited prechamber with or without additional fuel being added to the prechamber 59 .
Another embodiment not depicted could replace the single feed groove 67 around the prechamber body 59 with a spiral groove. The upper portion of the prechamber body 59 has a thicker wall section and in this area of the prechamber body a spiral groove could be cut into the outer surface of the prechamber. Possibly 10 to 15 turns, it would appear similar to an acme square thread except the eternal thread feature would be thin compared to the size of the passage. This spiral passage would slow the cooling fluid down allowing it more time to absorb heat from the prechamber body. The spiral groove feature could also give the cooling fluid more than twice the surface area to transfer heat.
FIG. 12A is a close up cross section of the lower half of the prechamber body 59 . FIG. 12B is a detail view of FIG. 12A . Clearly visible is the prechamber nozzle 68 that slides over the prechamber body 59 from the bottom. The prechamber nozzle 68 is designed to contact the prechamber body 59 at two points with press fit pilots. There is a press fit pilot at the top of the prechamber nozzle 68 ; this pilot is in a low stress area and only seals against the cooling fluid going from the coolant first pass straight to the coolant collection groove. This is also the area that the prechamber nozzle 68 and the prechamber body 59 could be optionally welded together.
If the prechamber body 59 upper half was equipped with an optional spiral coolant groove it would end before the optional weld area.
The second contact point between the prechamber nozzle 68 and the prechamber body 59 is the press fit at the bottom of the prechamber nozzle 68 . This press fit is important as it seals the prechamber combustion area from the coolant cavity around the prechamber 59 . The thermal expansion stress from the prechamber body 59 heating up and the forces of combustion both enhance the sealing capacity.
With or without the optional spiral cooling groove, the coolant first pass 64 starts at the point the cooling fluid is first injected at feed groove 67 on the exterior of the prechamber 59 and continues down the length of the outer surface of both the prechamber body 59 and prechamber nozzle 68 . As the cooling fluid moves along the coolant first pass 64 , it will be simultaneously absorbing heat from the prechamber 59 and prechamber nozzle 68 and transferring that excess heat to the cylinder head 58 surface.
Just before the contact point where the prechamber nozzle 68 seals to the cylinder head 58 , there is a ring of radial coolant inlet holes 66 . These radial coolant inlet holes 66 are at the end of the coolant first pass 64 and the start of the cooling sleeve annulus 65 . These radial coolant inlet holes 66 are equally spaced small holes around the prechamber nozzle 68 and the pressure drop that the cooling fluid experiences as it transitions these radial coolant inlet holes 66 equalizes the flow around the perimeter of the prechamber nozzle 68 . This encourages the flow before and after the radial coolant inlet holes 66 to be more evenly distributed even if the thickness of the first and second coolant passes may vary slightly due to machining tolerances of the prechamber 59 or the head 58 .
Once the cooling fluid enters the cooling sleeve annulus 65 , it will flow upwards around the outside of the prechamber 59 and the inside surface of the prechamber nozzle 68 . This cooling fluid ends up collecting in coolant return groove 62 and exiting prechamber 59 through coolant exit port 63 . This cavity for cooling sleeve annulus 65 should be thinner than that of coolant first pass 64 so that the cooling fluid travels faster and picks up less heat. The goal is to absorb only the amount of heat required out of the prechamber 59 body, but not so much that it can over heat the cooling fluid or over cool the prechamber body. When the coolant fluid is oil, overheating will result in the oil coking in this area and the corresponding overheating and failure of the prechamber due to lack of cooling fluid. A slower velocity along the outside of the prechamber nozzle 68 in the coolant first pass 64 will allow the cooling fluid to absorb more heat from the prechamber nozzle 68 and transfer it to the cylinder head 59 wall.
There are three general goals of prechamber cooling; keeping the spark plug from overheating, keeping the prechamber nozzle 68 from getting hot enough to cause pre-ignition, while keeping the prechamber 59 inner combustion chamber walls hot enough to insure easy and rapid combustion internally.
The coolant first pass around the top of the prechamber 59 is the area that will control spark plug temperature. The optional spiral cooling groove could enhance that cooling if needed. Prechamber nozzle 68 will get cooling from both coolant passes and will transfer some heat to the cylinder head 58 at its contact point. The heat transfer between contacting metal surfaces can be an order of magnitude less than the heat transfer through conduction of the base metal. Although the prechamber nozzle 68 to cylinder head contact 58 point is a cooling path, it is likely that significantly more heat from the nozzle is conducted up through the nozzle and absorbed by the cooling fluid that passes by two surfaces on the nozzle. The prechamber 59 wall around the prechamber combustion chamber is left as thick as possible to reduce the heat conduction rate and it is only cooled by a single pass of the cooling fluid.
By the time the coolant has gotten to the end of the second pass in a double pass cooling sleeve, it may have gotten too hot to be effective. This will cause the lower part of the prechamber to be cooled more effectively and the cooling fluid could actually be over heated by the time it reaches the end of the cooling sleeve annulus 65 .
In another embodiment a second set second radial inlet coolant holes 65 would function as bypass coolant holes that could allow some coolant to bypass the bottom of the prechamber body and start further up the coolant sleeve annulus 65 . These holes would allow some coolant to travel an abbreviated distance through the coolant sleeve annulus 65 of the nozzle 68 , therefor increasing the total amount of coolant fluid mass and decreasing the average temperature of the coolant that is used in last sections of the cooling sleeve annulus 65 of the double pass system. This also would slightly raise the temperature of the material at the start of the second pass as there would be less coolant going by.
In another embodiment, the addition bypass coolant holes can be at multiple axial distances from the first radial cooling inlet holes 66 for even more even distribution of coolant temperature along the cooling sleeve annulus.
Although nozzle 68 in this embodiment is pictured with an integrated cooling sleeve, alternate embodiments could have the cooling sleeve manufactured as a separate part from nozzle 68 with minimal change in the performance of the prechamber cooling system.
FIG. 13A is a preferred embodiment of a prechamber 59 ′ for installation into a Detroit Diesel Series 60 diesel truck cylinder head 58 ′ instead of an EMD locomotive engine. In cylinder head 58 ′ there is a coolant cavity 92 that contains jacket water coolant for cooling the cylinder head. Typically this coolant will be a mixture of glycol and water. There are also two fuel return cavities 91 that would have been used to supply and return fuel for the diesel fuel injectors. In this embodiment those diesel injectors have been replaced by prechamber 59 ′. In this embodiment, it will be jacket water coolant instead of oil that will be used to cool the prechambers, and this coolant will have to be captured and returned to the engine cooling system. In this embodiment fuel return cavities 91 are used for the collection and transfer of prechamber cooling fluid out of the engine back to the jacket water cooling radiator system.
FIG. 13B is a detail view of FIG. 13A and illustrates a prechamber cooling system that has a separate nozzle 68 ′ and cooling sleeve 93 . In this case the coolant is in a single pass configuration starting from the coolant cavity 92 , flowing through the radial coolant inlet holes 66 ′, up through the coolant sleeve annulus 65 ′ and exiting the prechamber 59 ′ through radial coolant exit holes 94 into fuel return cavity 91 ′.
The fifth portion of this detailed description is most closely related to a variable compression ratio mechanism for an OPOC engine. This variable compression ratio system would operate on the outer pistons in the OPOC design.
FIG. 14 is an exploded view of the VCR system. The outer wrist pin 71 slides into the piston 70 . There is an offset hole in the outer wrist pin 71 that the inner wrist pin (not shown) would be captured by. It is by rotating this outer wrist pin 71 around the inner wrist pin that the compression ratio is varied. The outer wrist pin 71 has a set of teeth machined into it and these teeth match the teeth cut into the rack gear 72 . The rack gear is free to slide axially along a bored hole in the piston 70 , as the rack gear 72 moves relative to the piston 70 it rotates the outer wrist pin 71 adjusting the compression ratio. The rack gear 72 has a female threads cut into it and the rack gear threaded insert 73 has a matching male thread on its OD that interfaces with the rack gear 72 internal thread. The rack gear threaded insert 73 is axially restrained in the piston 70 between a boss inside and the threaded insert retainer 74 that bolts to the back of the piston. It is the rack gear threaded insert 73 that positions the rack gear 72 axially in the piston 70 to set the compression ratio. The VCR actuator 75 is attached to the engine end cover and is fixed in place relative to the reciprocating motion of piston 70 . It has a male splined shaft 76 that interfaces with the female internal splines inside the rack gear threaded insert 73 . As the piston reciprocates inside its cylinder, the rack gear threaded insert 73 slides back and forth over the VCR actuator male splined shaft 76 . It is the VRC actuator that sets the compression ratio in each cylinder. In this embodiment there is an actuator for each cylinder in the engine. It would be possible to belt drive multiple spline rod assemblies with one actuator.
In this design both the VCR actuator 75 male splined shaft 76 and the rack gear threaded insert 73 can be replaced as service items without disassembling the engine.
The sixth portion of this detailed description is most closely related to grouped cylinder deactivation on prechamber ignited EMD 2 stroke engines.
FIG. 15A illustrates the firing order of a 12 cylinder EMD 2-stroke engine. The top table is for firing all of the cylinders, the lower table illustrates just one bank firing. In the lower table the engine is broken down into two half engine banks with a top half and bottom half with either half being able to be deactivated leaving behind the rest of the engine to operate on cylinder to cylinder engine timing as even as the full engine was operating. If the top half of the engine operated by itself the firing order would be 1, 7, 3, 9, 2, 8 with degrees between firings 45, 75, 45, 75, 45, 75. Additionally, 9 of the cylinders could be deactivated leaving three cylinders still firing with 120 degree spacing if the three firing cylinders were all from the same quadrant of the engine, either 1, 2, 3 or 4, 5, 6 or 7, 8, 9, or 10, 11, 12.
FIG. 15B is a similar set of engine firing order tables, except for a 16 cylinder engine. In this case, when operating either the top half or bottom half of the engine, the cylinder firing spacing is an even 45 degrees. When only 4 cylinders in one quadrant are operated the cylinder spacing is still even at 90 degrees.
By being able to operate only 25% of the engine or 50% of the engine cylinders, the engine can be tuned to operate at more optimum air fuel ratios all the way down to idle and the prechambers can be turned off in banks with a simple isolation valve for each group of cylinders.
Programming the ECU to not fire the GIV's in the deactivated cylinders is only a matter of software changes. Turning off the prechamber fuel feed to the opposing banks requires some additional hardware, but that can be as simple as two or four electrically controlled valves, one for the fuel supply to each bank of prechambers.
As more advanced systems are proposed to get even lower emissions from these conversion systems, it will be likely that the prechamber supply pressure will not be constant. When the increased complexity of prechamber fuel pressure control is added, that would be a good time to institute this additional layer of control and hardware needed to turn on and off different prechamber feeds.
For simplicity of control or in early deactivation systems, all of the spark plugs can be fired, even those in deactivated cylinders. In more advanced systems it is likely that the spark plugs would not be fired when the cylinders are deactivated to extend the spark plug service lives. When turning on and off the prechamber fuel supply, it may be beneficial to turn the spark plugs on a few cycles early, and when turning off the prechamber fuel supply it would be beneficial to fire the spark plugs a few cycles later.
FIGS. 16A, 17, 18A-18C, 19A-19C, 20, 21, and 22A-22B illustrate a new prechamber nozzle 69 ″ design that uses 6 radial located groups of three 0.050 TJI jets 96 to replace one set of 6 individual larger orifice jets. These three TJI jets 96 in each group converge together at a point some distance, possibly ¾ of an inch, away from the nozzle. This new concept is likely to have both the quenching effect and good combustion chamber penetration. Because the three jets converge they will penetrate further into the combustion chamber similar to a larger single jet. It is likely that the efficiency of the group of jets with regard to penetration would be slightly less than a single larger jet of either the same effective area or combined flow rate. This seeming negative could have a silver lining in that it has the needed penetration, all of the burning gases quenched and at the same time a more concentrated pocket of partially burned combustion radicals to stimulate very rapid combustion throughout the chamber once ignition is started.
FIG. 16A the Nozzle 69 ″ is illustrated with groups of 3 TJI jets 96 converging into a combined jet. In practice good results could be attained with only two TJI jets 96 in each group or four or more if needed. The concept is to have as many orifice jets as needed converge into a single flow to achieve the required penetration and local combustion intensity.
In another embodiment, it is proposed to have some or all of the TJI jets 96 be offset from the centerline axis of nozzle 69 ″. If a set of jets enters the nozzle throat with the same offset they will give the flow entering the prechamber through the nozzle throat 97 a rotational flow along with the axial flow component. This swirling effect will have multiple benefits.
The first and most intuitive benefit of the swirling flow be improved mixing at the top of the prechamber combustion chamber reducing the stratification of the air and fuel around the spark plug.
Another non-intuitive benefit of the swirling flow entering the prechamber combustion chamber will be the larger effective volume of the flow as it has an axial velocity component and a rotational velocity component. This will require an increase of the mixing throat 97 diameter to have the same effective pressure drop and flow accelerating capability as a smaller throat diameter with a purely axial flow. On the other hand, after combustion when the rotational flow component is much less, the pressure drop across the throat will be less insuring more pressure drop across the jet orifices and higher velocity, mass flow and penetration of the jets. Essentially the mixing throat 97 will now effectively be less restrictive in the most beneficial direction.
A potential issue being explored with multiple small jets in a prechamber nozzle designed for Turbulent Jet ignition is that complete quenching of the burning gasses as they exit may sometimes cause a misfire. At high loads where the in cylinder main chamber temperatures are higher because the gasses have less time to transfer heat to the surrounding metal, the TJI prechambers may exhibit stable combustion.
Proposed is to have TJI jets in both a smaller diameter and a larger diameter. FIG. 16B illustrates one embodiment with groups of smaller diameter TJI jets 96 around the nozzle and then one larger diameter axial TJI jet 98 in the center. In this case the intent is that the axial TJI jet 98 is large enough in diameter to start combustion on its own, and the smaller TJI jets 96 discharged quenched air and fuel forming areas of ready to burn pockets. When the main combustion event is initiated by the larger torch nozzles, these pockets will subsequently ignite providing more rapid heat release. Pure TJI with all quenched jets would offer even higher heat release rates by delaying combustion even further, but could suffer from misfire. This system would overcome some misfire potential at some difficult engine operating points such as very low power. Also in some engines pure TJI may have heat release rates that are too rapid. This system could be used to mitigate that giving some of the benefit of TJI without the excessive heat release rate.
In another embodiment, is to the single axial TJI jet 98 is eliminated and one of the quenched TJI jets 96 in one or several of the radial groups has a larger diameter so as to lose the quenching effect and act as a torch jet.
In another embodiment, the axial jet 98 could be replaced by a set of group of smaller diameter axial jets 98 similar to the radial groupings of TJI jets 96 . These axial jets 98 could remain parallel to each other in the axial direction of each be angled slightly off axis to converge.
A second significant benefit of the axial jets 98 is to improve mixing internal to the prechamber. By adjusting the number and diameter of these axial jets 98 both the mixing benefit and the torch effect can be optimized.
It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages.
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A prechamber assembly includes a cylinder head including a coolant cavity, a prechamber body located within the cylinder head, the prechamber body including a nozzle, and an annular sleeve radially surrounding a portion of the prechamber body. The sleeve includes a plurality of coolant inlet holes. A portion of the prechamber body is radially spaced from the sleeve to form a coolant sleeve annulus extending along a length of the prechamber body above the coolant inlet holes. The coolant cavity and the coolant sleeve annulus are in fluid communication through the plurality of coolant inlet holes.
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FIELD OF INVENTION
[0001] This invention relates to a mobile communication device having a functional cover for controlling sound applications by means of measuring motion of said functional cover. In particular, the present invention relates to a functional cover for a mobile communication device measuring motion and providing a control signal to the mobile communication device in accordance herewith.
BACKGROUND OF INVENTION
[0002] A functional cover is an enhancement product or peripheral for a mobile communication device such as a mobile or cell phone, a personal digital assistant, a portable computer or any combination thereof. The functional cover has electrical functionality and interface enabling data transfer between the mobile communication device and the functional cover.
[0003] International patent application WO 03/075548 discloses a functional cover for use with a wireless terminal, which functional cover comprises one or more keys adapted to play at least one sound. The keys may be adapted for sound creating purposes, which may comprise music composing applications, sound creating applications, gaming applications, ring-tone creation and application, system sound creation and application, or sending sounds with a multimedia messaging service (MMS) message.
[0004] Further, patent application Ser. No. 10/096,491 discloses a mobile communication device comprising a memory for storing a plurality of sequences for the activation of lights and means for selectively assigning a stored sequence to a particular event such as incoming calls, incoming calls or message from a particular caller or caller group, key lock, key unlock, power on/off, calendar alarm and etc. The mobile communication device may comprise means for recording an audio signal and means for transforming said audio signal into a control signal for activation of the lights, which are mountable in an exchangeable/removable front or back cover.
[0005] The above referenced international and American patent applications, which hereby are incorporated into present specification by reference, provide means for establishing utilisations of a functional cover in connection with a mobile communication device. The patent applications, in particular, provide means for recording a sound and utilising said sound for various purposes such as for converting said sound to a signal for controlling activation of a light or for saving said sound as part of a tune. That is, the prior art enables an operator to generate a particular sound by operating a keyboard or to generate a particular light response associated with an operation of the mobile communication device by operating a keyboard. Hence there is a need for providing further user interface platforms enabling an operator to activate the mobile communication device besides voice or keyboard activations.
SUMMARY OF THE INVENTION
[0006] An object of the present invention is to provide a functional cover for controlling sound applications on a mobile communication device in accordance with motion of said functional cover.
[0007] Further, it is an object of the present invention to provide a mobile communication device having a functional cover for controlling sound applications on said mobile communication device in accordance with motion of said functional cover.
[0008] A particular advantage of the present invention is provision of a user interface enabling a user to control an application by moving a functional cover mounted on a mobile communication device.
[0009] A particular feature of the present invention is provision of means for generating a sound or audio effect caused by motion of the functional cover.
[0010] The above objects, feature and advantage together with numerous other objects, advantages and features, which will become evident from below detailed description, are obtained according to a first aspect of the present invention by a functional cover for connecting to a mobile communication device and comprising an accelerometer for measuring movement of said functional cover and providing a movement signal, a memory for storing an instruction set, and a processor for selecting an instruction from said instruction set in said memory in accordance with said movement signal.
[0011] The functional cover according to the first aspect of the present invention provides an additional interfacing means for controlling actions of the functional cover or mobile communication device.
[0012] The functional cover according to the first aspect of the present invention may be adapted to control sound applications in accordance with motion of the functional cover and further may be adapted to generate a sound in accordance with motion of the functional cover. The combination of the being able to control sound by motion and to control applications relating to sound control provides an excellent and simple interface for the user of a mobile communication device and enables the user to adopt a particular personalized sound configuration for a mobile communication device.
[0013] The functional cover according to the first aspect of the present invention may further comprise a synthesizer for generating an electrical audio signal in accordance with the movement signal and a loud speaker unit adapted to receive the electrical audio signal and generate a sound in accordance herewith. The synthesizer may be operable to generate a control signal and the loud speaker unit may comprise an amplifier for amplifying the electrical audio signal and adapted to receive the control signal. The control signal may be operable to control frequency, clang, tone, pitch, loudness, volume, treble, and/or bas of the electrical audio signal.
[0014] The accelerometer according to the first aspect of the present invention may comprise a first sensor measuring movement along a first axis, which is aligned longitudinally to the functional cover and a second sensor measuring movement along a second axis perpendicular to the first axis. Hence the accelerometer in this configuration provides a two-dimensional measurement of movement, which is advantageous, for example, for controlling a game played on the mobile communication device and/or for generating a particular audio effect.
[0015] The accelerometer may further comprise a third sensor measuring movement along a third axis perpendicular to the first and second axis. This configuration of the functional cover provides a three-dimensional measurement of movement, which may advantageously be used, for example, for generating a drum sound while moving the functional cover attached to the mobile communication device as a drum stick.
[0016] The audio effects (sounds) may be sounds which may be applied to music from a second functional cover attached to the mobile communication device comprising a MP3 player. Alternatively, the audio effects may further be sounds of a StarWars™ lightsaber or sword whistling through the air, as the mobile communication device with its attached one or more functional covers is moved.
[0017] Further, the audio effects may advantageously be combined with gaming operations. This may, for example, advantageously be implemented in a car driving game, where the manoeuvring of the car is handled by the movement of the functional cover, which provides shrieking noises when the car makes sharp turns.
[0018] The first, second and third sensor for measuring movement along the first, second and third axis, respectively, may be utilised for sound application control such as bas, treble, pitch, clang, and volume control of sound generating application or any combination thereof. The movement of the functional cover may thus advantageously be used for controlling a wide variety of applications per se and a combination of applications.
[0019] The memory according to the first aspect of the present invention may further comprise flash memory capacity. Alternatively or additionally, the memory may comprise optical, magnetic or electric recording means such as magneto-optic storage devices.
[0020] The processor according to the first aspect of the present invention may comprise a micro-controller. The processor may in fact be implemented by any of the street processors, however, advantageously the processor is incorporated in a micro-controller together with local memory facility such as ROM and RAM for storing interface protocols and together with a signal conversion means such as analog to digital converter and sample and hold unit. The processor may connect to the memory through a high speed data carrying bus.
[0021] The processor may further comprise an interface element for controlling communication between the functional cover and a mobile communication device in accordance with a communication protocol. The interface element may comprise hardware and software modules, which hardware modules may comprise connectors and wiring and which software modules may comprise applications accessing a local memory for interface protocol data.
[0022] The instruction set according to the first aspect of the present invention may comprise internal or external operation system instructions, application instructions or any combination thereof. The instruction set stored in the memory may, in fact, comprise any user defined actions to be taken when the functional cover moves in the first, second and/or third direction. This effect provides a particularly versatile mobile communication device when attached to the functional cover according to the first aspect.
[0023] The above objects, advantages and features together with numerous other objects, advantages and features, which will become evident from below detailed description, are obtained according to a second aspect of the present invention by a mobile communication device comprising connector means for connecting to a functional cover according to the first aspect of the present invention.
[0024] The mobile communication device according to the second aspect of the present invention provides a significant improvement to prior art interface technologies used for mobile phones.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The above, as well as additional objects, features and advantages of the present invention, will be better understood through the following illustrative and non-limiting detailed description of preferred embodiments of the present invention, with reference to the appended drawing, wherein:
[0026] FIG. 1 , shows a flow chart of operation of a functional cover according to a first embodiment of the present invention connected to a mobile communication device,
[0027] FIG. 2 a , shows a mobile communication device connected to a functional cover according to the first embodiment of the present invention,
[0028] FIG. 2 b , shows a block diagram of the function cover according to the second and third embodiments of the present invention,
[0029] FIG. 3 , shows a mobile communication device according to a fourth embodiment of the present invention, and
[0030] FIG. 4 , shows a block diagram of a control system of the functional cover according to the fourth embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0031] In the following description of the various embodiments; reference is made to the accompanying drawing which form a part hereof, and in which by way of illustration various embodiments is shown in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural and functional modifications may be made without departing from the scope of the present invention.
[0032] FIG. 1 , shows a flow chart of operation of a functional cover according to the preferred embodiment connected to a mobile communication device, which operation is designated in entirety by reference numeral 100 .
[0033] The operation of the functional cover starts in step 102 . The starting process includes powering up the functional cover and possible authentication of the functional cover. Since the functional cover utilises movement or motion for controlling sound applications the operation 100 comprises a conditional loop 104 during which the functional cover awaits movement of the functional cover. When the functional cover detects movement the functional cover generates a movement signal during step 106 . The processor of the functional cover interprets the movement signal during step 108 and identifies a corresponding instruction in an associated memory. The processor further identifies during step 110 whether the instruction is associated with an external or internal application. If the instruction is internal, the processor of the functional cover 112 processes it in step 112 . On the other hand if the instruction is external, the instruction is communicated to the connecting mobile communication device during step 114 . In step 116 the external processor, i.e. a processor of the mobile communication device processes the instruction. Subsequently, in step 118 the processor of the mobile communication device communicates an acknowledgement of reception of the instruction or a return instruction for the processor of the functional cover. The processor of the functional cover determines in step 120 whether the operation is to return to a movement detecting mode, namely to loop 104 , or to end in step 122 .
[0034] FIG. 2 a , shows a mobile communication device 200 connected to a functional cover 202 . Movement or motion of the mobile communication device 200 and thereby of the functional cover 202 generates an audio effect from the loud speaker 204 of the mobile communication device 200 . This audio effect is visualized by waves 206 and the movement is visualized by arrows 208 . The movement may be in the plane indicated in FIG. 2 a and, in addition hereto, in a plane perpendicular to the arrows 208 . The movement causes an accelerometer, shown in FIG. 2 b as reference numeral 212 , to generate a movement signal, which is processed by a local processor of the functional cover 202 . The local processor interprets the movement signal and identifies a corresponding instruction in an instruction set in a memory. The instruction may relate to a sound application for controlling a sound in accordance with movement of the mobile communication device 200 and thereby in accordance with movement of the functional cover 202 . The instruction may incorporate a sound or audio effect to be forwarded to the loud speaker 204 or may be a control signal for adjusting sounds from the loud speaker 204 . That is, the instructions may relate directly to a sound or audio effect to be presented to a user of the mobile communication device 200 such as a drum sound, Star Wars™ lightsaber sound, or any other sound, or the instructions may relate to qualitative measures of a sound to be presented to the user of the mobile communication device 200 such as volume, loudness, pitch, bas, treble, clang or any combination thereof.
[0035] The audio effects (sounds) may be, for instance, drumming sounds that may be applied to music from a second functional cover attached to the mobile communication device comprising an MP3 player.
[0036] FIG. 2 b , shows a block diagram of a functional cover 202 according to a second embodiment of the present invention. The functional cover 202 comprises an accelerometer 212 generating a movement signal to a local processor or directly to a synthesizer 214 , which synthesizer 214 converts the movement signal into an electrical audio signal, such as described above. The synthesizer 212 communicates the electrical audio signal to an amplifier 218 amplifying the electrical audio signal and communicating the amplified electrical audio signal to the loud speaker 204 generating the audio effect. Hence in these embodiments the functional cover 202 acts as an input device for the synthesizer 214 by assigning attributes to movements in particular directions, which are detected and recorded by the accelerometer 212 . The attributes may be sound frequency, clang, tone, pitch, loudness, volume, bas, treble and any combination thereof.
[0037] In an embodiment the processor used for the sound control and the appurtenant instruction set are internal in the synthesizer 214 .
[0038] In another embodiment the output signal from the synthesizer 214 may be coupled to the connected mobile phones amplifier and loudspeaker.
[0039] In a functional cover 202 according to a third embodiment of the present invention, the functional cover 202 further comprises a memory 216 for storing a bank of electric audio signals defining a plurality of sounds. The memory 216 connects to the synthesizer 214 and communicates specific electric audio signals to the synthesizer 214 in accordance with instructions or commands received from the user interface 208 .
[0040] In an embodiment the processor used for the sound control and the appurtenant instruction set are internal in the synthesizer 214 as well as the sound data base 216 .
[0041] In another embodiment the output signal from the synthesizer 214 may be coupled to the connected mobile phones amplifier and loudspeaker.
[0042] The functional cover 202 thus improves the general user interface of a mobile communication device, namely keypad 208 and display 210 .
[0043] The accelerometer comprises one, two and/or three sensors for measuring movement along a three axes. Hence the accelerometer may provide a two or three dimensional measurement of movement.
[0044] The audio effects may advantageously be combined with gaming operations such as shown in FIG. 3 . FIG. 3 , shows a mobile communication device 300 according to a fourth embodiment of the present invention. The mobile communication device comprises a display 302 for interfacing with an operator of the mobile communication device 300 by for example playing a game shown enlarged as reference numeral 304 . The mobile communication device 300 is connected to a functional cover 306 including a accelerometer, shown as reference numeral 402 in FIG. 4 . The accelerometer 402 provides a movement signal to a processor, shown in FIG. 4 as reference numeral 406 , in the functional cover 306 and the processor interprets the movement signal in accordance with predefined operations. In this example the accelerometer 406 measures the movement of the functional cover so as to generate an instruction 308 for the game 304 interface in combining a cursor with an associated audio effect. In this way the operator of the mobile communication device may by movement of the functional cover 306 control the game 304 as if applying curser keys on a keypad 310 . This effect provides great advantages over prior art, since the operation of the mobile communication device is significantly simplified.
[0045] FIG. 4 , shows a block diagram of a control system 400 of the functional cover 306 comprising an accelerometer 402 . The accelerometer 402 communicates movement data to an analogue to digital (A/D) converter 404 in a processor 406 , such as a micro-controller. The A/D converter 404 receives an analogue movement signal from the accelerometer 402 and converts it to a digital movement signal. The processor 406 retrieves an instruction set from a memory unit 408 , such as an external flash memory, through a high speed data carrying bus (SPI) 410 . The processor 406 utilises the digital movement signal to generate a signal to the mobile communication device in accordance with the instruction set associated with the movement signal. The instruction set may be curser actions combined with sounds or other application type instructions.
[0046] The control system 400 further comprises a terminal 412 for connecting to the mobile communication device 300 . When the functional cover 306 is mounted on the mobile communication device 300 the control system 400 powers up. The terminal 412 , which comprises a plurality of pins, such as 3, 5 or 8 pins, provides a power signal to a regulator 414 for regulating power to the processor 406 . The regulator 414 may be any type of regulator known to a person skilled in the art.
[0047] The terminal 412 further enables communication between the functional cover 306 and the mobile communication device 300 through a level shifting unit 416 shifting the voltage level of the communication received from the mobile communication device 300 to a voltage level compatible with the functional cover 306 . The processor 406 communicates with the mobile communication device 300 through an interface element 418 for establishing communication protocol.
[0048] The mobile communication device may comprise one or more functional covers, hence both the functional covers 202 , 306 may in fact be connected to the same mobile communication device. Further, it should be realized that the communication between the mobile communication device and the functional covers may utilise any protocol and elements known to a person skilled in the art.
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This invention relates to a mobile communication device ( 200 ) having a functional cover ( 202 ) for controlling sound applications by means of measuring motion of said functional cover ( 202 ). In particular, the present invention relates to a functional cover ( 202 ) for a mobile communication device ( 200 ) measuring motion and providing a control signal to the mobile communication device ( 200 ) in accordance herewith.
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